Statistical Analysis of Manufacturing Tolerances Effect on Axial-Flux Permanent Magnet Machines Cogging Torque

This work aims to provide a tolerance analysis of a two-stator one-rotor tooth coil winding axial flux permanent magnet (TCW-AFPM) machine with iron-less rotor core. The rotor structure can be subjected to several manufacturing uncertainties because of the absence of ferromagnetic material in the rotor body, which is very time consuming to assess by means of conventional finite element simulations. In this paper, a statistical analysis is carried out using an adapted superposition method in order to evaluate relevant tolerance combinations, determining the impact they have on the cogging torque of a 12-slot 10-pole TCW-AFPM. From the results, it was found that cogging torque of TCW-AFPM is significantly affected by remanence deviation and angular displacement of magnets.