Permanent magnet claw pole machine (PMCPM) is a special kind of transverse flux permanent magnet machine. Compared with other electrical machines, it has the advantages of high torque density and high efficiency for high speed operation. However, because of its complex irregular structure, the manufacturing process using silicon sheets is complicated. Soft magnetic composite material (SMC) is manufactured by powder metallurgy technology, which can produce various shapes of stator core structures, so it is easier to produce various irregular shapes of the stator core. However, the raw SMC material is relatively expensive, and the mechanical strength of SMC is weak. In this paper, a PMCPM with hybrid cores is proposed. With the adoption of hybrid silicon sheet -SMC cores and amorphous alloy -SMC cores, the torque ability of PMCPM can be improved greatly and it can have higher efficiency for more wide operation frequency. Meanwhile, its mechanical strength has been improved and it can be designed for high torque direct drive applications as it is a modular machine. Furthermore, three methods are proposed to reduce the additional eddy current loss which resulted from the employment of hybrid cores in PMCPM.
As permanent magnet claw pole machine (PMCPM) is designed with complex 3D magnetic structure, the 3D finite element method (FEM) is commonly used for its accurate performance analysis. However, using 3D FEM will consume very long time in the initial design stage. Its analysis time can be saved greatly by using the analytical method (AM) or equivalent magnetic circuit method (MCM), however the obtained performance is not accurate and some performance even can’t be obtained if only one of these methods is used. To overcome above constraints, this paper proposes a calculation method that combined analytical and equivalent magnetic circuit method (AMCM) to calculate the main electromagnetic performance of PMCPM quickly. Its calculated results are verified by corresponding results that obtained by using the 3D FEM. It can be seen that the proposed AMCM is effective for calculating the main electromagnetic performance and designing of PMCPM.
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