A high-power, totally enclosed, permanent magnet, axial flux machine for engine integration

With the development of new forms of vehicle drive system and the interest of low fuel consumption, there is an increasing need for compact electrical machines that can be integrated with the IC engine to form compact power units. The paper will describe the design approach, development and testing of slotted totally enclosed permanent magnet axial flux machine and power electronics interface suitable for integration with an IC engine. The machine can be controlled to operate as a motor or generator over a wide speed range. Test results demonstrate that the electrical machine is capable of supplying a continuous rating of 42kW, 200Nm with efficiencies in the excess of 95% and a peak torque of 400 Nm. The combined efficiency of the DC/DC converter and the active rectifier is just over 96%.