Integrated design for a high speed permanent magnet axial flux generator

The generator under investigation is a single phase with an output of 20 kVA at 60 krpm. It has a modular structure, that facilitates multistage and multiphase arrangement, making it easy to extent to a 3-phase generator with three fold output. The half cross section of the generator is shown with the back-iron assembly (only one rotor disc is shown for clarity). In the current work, the selection of material and the profiling of the geometry of the back-iron, are considered to be the key parameters for optimization. The essence of the proposed design methodology rests on the development of an efficient ANSYS-based 3D finite element model of the generator that facilitates iterative magnetic performance predication and mechanical stress analysis.