Rotor Pole Optimization of Novel Axial-Flux Brushless Doubly Fed Reluctance Machine for Torque Enhancement

This paper presents an optimal design of the rotor pole in a novel axial-flux brushless doubly fed reluctance machine (AF-BDFRM), which features higher torque and power density than its counterpart radial-flux BDFRM. The rotor span and rotor overhang lengths were the optimized parameters, with the goals of improving torque density and improving the quality of the output power, i.e., reducing the torque ripple. The optimal design process was applied to obtain the optimized shape for maximizing torque density while minimizing torque ripple in a 16 kW machine. Then, the optimal design results were verified by means of the transient 3-D finite-element analysis. Furthermore, the results of the optimally designed rotor pole were compared with those of a previously developed diamond shape. Finally, a sample prototype of one HP was selected for testing, considering the manufacturing cost and available testing facilities to verify the proper working of the novel AF-BDFRM.