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Mixed-Pole Hybrid-Excitation Machine

G. Borocci, F. Giulii Capponi, G. De Donato, and F. Caricchi

Abstract This paper presents the concept of a novel HE machines can be classified in different ways. The
hybrid-excitation machine. This machine is of the parallel most widely used system is based on the flux paths of the
excitation type and has rotor poles in which both PMs and excitation sources. If the wound-excitation flux doesnt
wound-excitation co-exist to produce the total no load
magnetomotive force; for this reason it is named mixed-pole pass through the PMs, the machine is said to have a
hybrid-excitation machine. Due to its parallel excitation parallel HE. Examples of parallel HE machines are
nature, the machine has excellent flux linkage regulation found in [1]-[8], [12] and [18]-[26]. A well-known
properties and its use is therefore envisaged for applications drawback in parallel HE machines is the structural
that require wide constant power speed ranges. A very complexity of the machine that usually arises in order to
useful property that stems from this particular topology is guarantee distinct excitation flux paths. Conversely, if
that the designer is able to select the relative contributions
the wound-excitation flux passes through the PMs, the
of PM and wound-excitation flux by simply designing the
relative portions of the PM part and wound-excitation part machine is said to have a series HE. Examples belonging
of the rotor poles. Although both radial flux and axial flux to this group are found in [9]-[21]. A well-known
versions can be designed, this paper concentrates on the drawback in series HE machines is the risk of PM
latter type. A proof-of-concept prototype is designed for a demagnetisation if heavy flux weakening is required.
600-6000 rpm constant power speed range and the Nonetheless, for applications such as the one in [15],
machines performances are analysed with finite element where the excitation winding is only used to compensate
simulations.
the armature reaction voltage drop, the series HE
Index Terms Axial flux, hybrid excitation, finite element machine is a valid alternative. Comparisons between
analysis (FEA), losses, constant power regime. series and parallel HE machines are performed in [12]
and [18]-[20], and show that parallel HE machines have
I. INTRODUCTION superior no-load flux regulation capabilities, due to their
Hybrid-excitation (HE) machines are a broad class of intrinsic flux-shunting nature.
synchronous machines, in which both permanent magnets A second method that is used to classify HE machines
and excitation windings are present, [1]-[2]. Two well- is based on the location of the excitation sources. These
known benefits stem from the combination of both can be placed both on the rotor, [3]-[15] and [26], both
magnetomotive force (mmf) sources. Firstly, by using on the stator, [16]-[21], or the excitation winding on the
excitation windings it is generally easier to regulate the stator and the PMs on the rotor, [22]-[25]. A common
flux compared to a purely permanent magnet (PM) criticism found in the scientific literature, regarding the
machine. This is a very attractive property in a number placement of the excitation winding on the rotor in
of applications, ranging from automotive generators, favour of the placement on the stator, is that this implies
where wide constant power speed ranges up to 10:1 are the use of brushes and rings. However, these undergo
required, to generators in island operation, where a considerably less stress compared to the brushes and
constant terminal voltage is required in all working commutator feeding the armature of dc machines since
conditions. Secondly, the combined use of rare-earth there is no commutation process; proof of this is the
PMs results in lower excitation losses compared to a extremely long lifespan of automotive alternators, which
purely1 wound-field synchronous machine. This is a key usually require a substitution of the brushes only after
property in light load operation, where the efficiency of 200000 km.
HE machines can be comparable to that of PM machines. Most of the HE machines that have been analysed in
From an historical point of view, HE machines have literature are cylindrical-stator machines, both of the
been around since the advent of commercially available radial and transverse flux types, however some axial flux
ferrite magnets in the 1950s and have since been (AF) machines have been proposed too, [22]-[25]. In
proposed in the literature in a variety of topologies. An these AFHE designs, the electrical excitation is fixed to
example of one of the first HE machines is reported in the stator, making it is necessary to use a consequent pole
[3], i.e. a PM claw-pole generator with an auxiliary, structure in order to obtain a parallel HE machine. On
stationary dc coil and ferromagnetic core, positioned at the other hand, in [26] the authors propose a AFHE
one end of the rotor, which shunts part of the PM flux machine which achieves parallel HE without the need of
away from the main armature windings. The dc current consequent poles, since the electrical excitation is
flowing in the stationary coil controls the amount of PM rotating. This machine, shown in fig.1, is of the double-
leakage flux in the machine, allowing both flux rotor single-stator topology, also known as Torus
weakening and strengthening, depending on the direction topology, [27], and ample flux linkage regulation is
of the dc current. demonstrated experimentally. Constructively, the stator
is slotted and core-wound; one of the two rotors carries
All the authors are with the Department of Astronautical, Electrical
and Energetic Engineering, University of Rome La Sapienza, Rome
the PMs, while the other carries the excitation poles.
Italy (e-mail: gabriele.borocci@uniroma1.it, Such layout implies that the rated flux linkage produced
fabio.giuliicapponi@uniroma1.it, giulio.dedonato@uniroma1.it, by the excitation winding is the same as that due the
federico.caricchi@uniroma1.it).
PMs. On the other hand, it can be useful for a designer to
1
978-1-4799-4389-0/14/$31.00 2014 IEEE 2625
a)

Fig. 1. AFHE machine with excitation sources on separate rotors b)


[26]

be able to select the relative contributions of PM and


wound-excitation flux linkage. To that end, this paper
proposes a machine in which both PMs and wound-
excitation are combined in every rotor pole, giving rise to
what is called by the authors a mixed-pole hybrid-
excitation (MPHE) machine. While a radial flux version
of this machine is possible, the main focus in this paper is c)
on the axial flux version. Fig. 2 Flux paths at different excitation current levels: a) positive
rated b) zero c) negative rated
The paper is structured as follows. The machines
structure and its flux linkage regulation properties are
described in section II. The design of a proof-of-concept
machine is presented in section III; static and time
stepped FE simulation results are reported in section IV,
demonstrating the machines electromagnetic properties
together with its performances in the flux-weakening
regime. Finally the main conclusions are reported in
section V.

II. PROPOSED MACHINE TOPOLOGY


The following discussion is valid for both a radial flux
or an axial flux MPHE machine. The proposed topology
is shown in fig.2, where an elementary two pole machine
a)
is shown. The stator carries a standard three phase
winding, with a single slot per pole per phase drawn for
simplicity; each rotor pole comprises two PMs
magnetised in the same direction and a central wound-
excitation pole. In rated or enhanced flux conditions, as
shown in fig.2a, the excitation current magnetises the
wound-excitation pole between two north PMs as a north
pole and the wound-excitation pole between two south
PM pieces as a south pole; in this condition the flux
linkage with the stator winding reaches its rated or
maximum value. In weakened flux conditions, the
excitation current is progressively reduced to zero, as
shown in fig.2b; in this condition the flux linkage with
the stator winding is produced only by the PMs. If it is
necessary to weaken the flux further, the excitation
b)
current magnetises the excitation pole between two north
PMs as a south pole and the excitation pole between two Fig. 3. Two solutions for the MPHE topology: a) radial flux
version b) axial flux version
south PMs as a north pole. In this condition, shown in
fig.2c., it is possible to cancel the fundamental flux By observing the flux paths in fig.2, it is evident that
linkage harmonic. the machine is a parallel HE machine, since the PM flux
paths are distinct from the wound-excitation flux paths.

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This sets this machine apart from other machines TABLE I: RATED VALUES
presented in [5] and [15], which have similar Rated speed 600 rpm
rotorstructures, but are inherently series HE machines.
Rated torque 127 Nm
From a design perspective, the main advantage of the
MPHE topology is that it is straightforward to choose the Rated power 8 kW
amount of PM excitation versus the amount of wound- Constant power speed range 600-6000 rpm
excitation. A useful hybridisation coefficient, based on
the rotor geometry, can be defined as:
wPM
kw = (1)
wPM + wexc

where wPM is the total width of the PM portion of the


pole and wexc is the width of the shoe of the wound-
excitation portion of the pole. This coefficient is equal to
0 for a fully wound-excitation machine and equal to 1 for
a fully PM machine. The above kw is different from the
usual definition, [2], which involves flux linkage:
Fig. 4. Comparison of airgap flux density
PM
k = (2)
PM + exc
where PM is the flux linkage due to the PMs and exc is
the flux linkage due to the wound-excitation. Also in this
case 0 is for a fully wound-excitation machine and 1 is
for a fully PM machine.
Radial and axial flux versions of the MPHE machine
are shown in fig.3. This contribution develops the axial
flux version, as described in the following sections.

III. MPHE MACHINE DESIGN


The design of a proof-of-concept AF MPHE machine
is described in this section. In order to demonstrate the
performances, a typical automotive constant power speed Fig. 5. Mixed pole hybrid excitation pole
range from 600 rpm to 6000 rpm has been chosen. Table
in order to reduced the permeance harmonics at the
I shows the selected rated values of the prototype. The
airgap, [29].
design of the machine is carried out by first performing
The rotor discs are made of Armco pure iron;
the design of an equivalent PM machine, [27], and
experience suggests a pole-arc to pole-pitch ratio equal to
subsequently substituting the PM rotors with the mixed-
0.8. NdFeB magnets are used. A PM thickness equal to
pole rotors.
3 mm and an air-gap equal to 1 mm are chosen. Static
The key design choices are discussed in the following.
FE simulations are performed to evaluate the flux density
The inner diameter of the active parts is set to 200 mm
at the air-gap and the resulting distribution, in red, is
and the outer diameter is set to 296 mm. This implies a
shown in fig.4. An average value of about 0.6 T over the
ratio between the two equal to 0.676, which is in the
pole pitch can be seen, which results in an average value
range that allows to obtain maximum torque density for
of about 0.75 T over the pole-arc. Based on this result,
AF machines. Due to the wide CPSR, the pole pairs have
an equivalent mixed pole rotor is designed. Since this is
been set equal to 4, so that the electric frequency is equal
a proof-of-concept machine, no optimisation is carried
the 40-400 Hz range.
out on the selection of the hybridisation coefficient as
The stator, is a spirally wound, index-punched, toroid
defined in (2). It is decided to select a kw equal to 0.5,
made of M250-35A electrical steel lamination. An
i.e. half of the pole arc is made of PMs and half is made
integral-slot, core-wound winding has been chosen; the
of wound-excitation. In order to facilitate the
available stator periphery, due to the relatively low
construction of such an unusual rotor, it is decided to use
number of poles, allows to select an integer number of
an SMC shoe that covers the pole body and the wound-
slots per pole per phase (q) equal to 3. Thus, the
excitation coils. In this way, the excitation slots and pole
distribution factor Kd is equal to 0.9598. The choice of
body can be easily machined on the iron rotor and the
the number of turns per phase is based on the voltage and
excitation coils can then be simply wound around the
current requirements of the converters available in the
pole bodies. Once the excitation winding is in place,
laboratory; 7 turns per coil and 168 series turns per
each SMC shoe can be placed above the corresponding
phase result in a 37 A rms rated current and a 71 V rms
pole body and coil by either gluing or bolting it onto the
rated phase back-emf, similar to the ratings of previously
pole body. Fig. 5 shows a close-up of the mixed-pole
designed AFPM machines, [28]. The slots are closed
rotor. The amount of excitation mmf that is required to
with soft magnetic composite (SMC) wedges with gaps
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obtain the same average flux density at the air-gap is
initially calculated with classical analytical formulas and
subsequently verified by FE simulations. Slight
modifications on the shape of the shoe and on the aspect
ratio of the rotor slots are made in order to reduce
excessive local saturation in the pole body and shoe at
rated excitation. Fig.4 also shows, in blue, the flux
density distribution at the air-gap for the MPHE machine
with an excitation mmf equal to 775 A turns; it can be
seen that the average value is equivalent to that of the PM
machine, proving that the two solutions are equivalent Fig. 6. Flux linkage regulation characteristic
from an electromagnetic point of view.
The final design parameters are shown in table II.
TABLE II: DESIGN PARAMETERS OF THE AF MPHE PROTOTYPE
Number of pole pairs 4

Rated current 38 Arms

Rated phase back-emf 72 V rms

Number of slots 72

Outer active radius 148 mm

Inner active radius 100 mm

Stator yoke thickness 40 mm

Slot width 6 mm a)
Slot height 13 mm

Conductor size 5x1 mm

Turns per coil 7

Series turns per phase 168

Stator slot fill factor 0.7

SMC wedge thickness 2.5 mm

Wedge gap width 1 mm

Magnet average width 19.4 mm

Magnet thickness 3 mm

Mechanical air-gap 1 mm b)

Total axial length 64 mm

Total rotor thickness 30 mm

Pole body height 14.2 mm

Pole shoe height 5.9 mm

Rotor slot 14.2 x 9.7 mm

Rotor slot fill factor 0.8

IV. MPHE MACHINE PERFORMANCE ANALYSIS


2D, average radius, static FE simulations have been
performed in order to evaluate the no load properties of c)
the machine. The wound-excitation mmf has been varied Fig. 7 FEA field maps: a) rated positive excitation mmf b) zero
between 800 A turns and -800 A turns and the resulting excitation mmf c) rated negative excitation mmf
flux linkage regulation characteristic is shown in fig.6, than that of the wound excitation. In fact, while kw = 0.5
where the peak of the fundamental harmonic of the flux due to the rotor design, it turns out that k = 0.365, i.e.
linkage is plotted against the wound-excitation mmf. It only 36.5 % of the rated flux linkage is due to the PMs.
can be seen that for values less than -400 A turns, the Fig.6 also shows that in order to fully cancel the
flux linkage is inverted. This means that the fundamental flux linkage, the rated negative excitation
contribution of the PMs to the total flux linkage is less mmf is only around 50% of the rated positive excitation

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Fig. 8. Airgap flux density for rated positive, zero and rated a)
negative excitation mmf

mmf. Thus, excitation losses at high speeds, where


strong flux weakening is required, are expected to be
very low.Fig.7 shows the no load field maps; the rotor is
positioned on the top part of each figure, while the stator
is on the lower part. Fig.7a shows the map for rated
positive wound-excitation. It can be seen that the pole
body is strongly saturated, with local flux density values
reaching 1.7-1.8 T. Fig.7b shows the map for zero
wound-excitation; fig.7c for rated negative wound-
excitation. The parallel nature of the hybrid-excitation is b)
easily seen by observing the paths of the flux lines in Fig. 9. P.u. q-axis and d-axis inductances
figs. 7a and 7b.
Fig.8 shows the flux density distribution in the air-gap
for the three different excitation mmfs used for the field
maps in fig.7. It can be seen how the contribution of the
wound-excitation to the air-gap flux density changes with
the excitation mmf; in particular, when the excitation
mmf is negative, the pole body becomes, de-facto, a pole
with opposite polarity of that of the adjacent PMs, as
anticipated in section II. This behaviour results in a non
negligible third harmonic component of the air-gap flux
density which is responsible for high speed iron losses in
Fig. 10. Output power regulation between 600 and 6000 rpm
the stator, as will be shown shortly.
D-axis and q-axis inductances have also been 0.8% with respect to the excitation torque component,
calculated by performing static FE simulations with when the current is 4 out of phase from the q-axis.
different values of stator current. In these simulations, Time-stepped FE simulations have been performed to
the wound-excitation mmf is set to its positive rated evaluate the machine when working as a generator on a
value. Fig.9a shows the p.u. q-axis inductance as a purely resistive load. Simulations have been performed
function of a purely q-axis current; it can be seen that the at 600, 1200, 3000 and 6000 rpm. The wound-excitation
inductance is relatively insensitive to the current mmf has been regulated in order to obtain approximately
amplitude since the q-axis flux path has a large constant power operation over the entire range. Fig. 10
electromagnetic air-gap. On the other hand, fig.9b shows shows the output power as a function of rotor speed, with
the p.u. d-axis inductance as a function of a purely the various levels of wound-excitation mmf that are
demagnetizing d-axis current. Here a very strong required. Constant power operation is demonstrated
dependence with the current can be noticed, due to the throughout the entire speed range. Fig.11 shows how the
facth that the d-axis flux path passes through the wound- magnetic and excitation losses in the machine are
excitation pole body. When the d-axis current is small, subdivided. These losses are calculated directly by the
the wound-excitation mmf saturates the pole body, commercial FE software that was used, by means of a
resulting in a low value of the inductance. As the d-axis proprietary algorithm. Fig.11a shows the induced losses
current increases, it drives the pole body out of saturation in the rotors, divided among the rotor back iron, the SMC
and causes an increase in the d-axis inductance. shoes and the PMs. Permeance and armature reaction
Unfortunately, a significant saliency is seen only for harmonics are the cause of these losses, which are quite
large values of demagnetizing d-axis current (greater than high at 6000 rpm. These results suggest that the use of a
0.5 p.u.) so the reluctance torque component cannot be laminated rotor is mandatory. This would almost
used to increase the electromagnetic torque significantly completely eliminate the induced losses in the back iron,
above the value of the excitation torque component. As reducing the losses to around 200 W at 6000 rpm.
proof of this, FE simulations in rated conditions have Fig.11b shows the induced losses in the stator,
shown that the maximum torque increases only by about subdivided between the SMC wedges and the laminated

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machine is capable of a 10:1 CPSR. Loss analysis has
shown that in order to improve the efficiency of the
machine at high speeds it is necessary to choose a thinner
stator lamination and use laminated electric steel instead
of pure iron in the rotors. A prototype of the machine is
in the process of being built.

VI. REFERENCES
[1] J.F. Gieras, PM synchronous generators with hybrid excitation
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hybrid-excitation machine. Based on the novel layout of [16] R.L. Owen, Z.Q. Zhu, and G.W. Jewel Hybrid-excited flux-
the rotor, a new hybridisation coefficient has been switching permanent-magnet machines with iron flux bridges,
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[17] J.T. Chen, Z.Q. Zhu, S. Iwasaki, and R.P. Deodhar A novel
rotor. The design of axial flux version of this machine
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a negligible reluctance torque in rated excitation mmf [19] Y. Wang, and Z. Deng, Hybrid excitation topologies and control
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system IEEE Trans. Ind. Electron., vol. 59, no. 12, pp 4601- current research interests include digital control of brushless drives and
4616, Dec. 2012. analysis and design of permanent magnet machines.
[20] B. Gaussens, E. Hoang, M. Lcrivain, P. Manf, and M. Gabsi A Prof. De Donato is a member of the IEEE Industry Applications and the
hybrid-excited flux-switching machine for high-speed DC- IEEE Industrial Electronics Societies.
alternator applications, IEEE Trans. Ind. Electron., vol. 61, no. 6, Federico Caricchi received the M.S. and Ph.D. degrees in electrical
pp 2976-2989, Jun. 2014. engineering from the University of Rome La Sapienza, Rome, Italy,
[21] X. Liu, C. Wang, and A. Zeng Operation principle and topology in 1988 and 1994, respectively.
structures of axial flux-switching hybrid excitation synchronous From 1991 to 2010 he was with the Department of Electrical
machine, in Proc. of IEEE ICEMS 2011, Aug. 2011, pp 1-7. Engineering, University of Rome La Sapienza, serving as Head of the
[22] J.S. Hsu, Direct control of air-gap flux in permanent-magnet Department from 2007 to 2010. Since 2010, he has been with the
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361-365, Dec. 2000. Full Professor. He is author or co-author of more than 100 technical
[23] F. Liang, and J.M. Miller, Permanent magnet electric machine published papers and more than 10 national and international patents.
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with flux control, US Patent No. 6373162, 2002.
electric machines, power electronic equipment, and permanent-magnet
[24] N.L. Brown, and L. Haydock, New brushless synchronous motor drives.
alternator IEE Proc.-Elecr. Power Appl., vol. 150, no. 6, pp 629- Prof. Caricchi is a member of the Italian Association of Electrical and
635, Nov. 2003. Electronic Engineers, the Italian Association for Naval Techniques, and
[25] M. Aydin, S. Huang, and T.A. Lipo, Design, analysis and control the IEEE Industry Applications Society.
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Axial-flux hybrid-excitation synchronous machine: analysis,
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magnetic wedges in axial flux permanent magnet machines,
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Sep./Oct.. 2013.

VII. BIOGRAPHIES

Gabriele Borocci was born in Rome, Italy, in 1987. He received the


B.S and M.S. degrees in Electrical Engineering in 2009 and 2012,
respectively, from the University of Rome La Sapienza, Rome, Italy.
Currently he's pursuing a Ph.D. degree in Electrical Engineering at the
same university. His research interests include advanced control of
electrical drives, power electronics and optimisation of electrical drives
for energy savings.
Mr. Borocci is a Member of the IEEE Industry Applications Society.

Fabio Giulii Capponi received the M.S. and Ph.D. degrees in electrical
engineering from the University of Rome La Sapienza, Rome, Italy,
in 1994 and 1998, respectively.
From 1996 to 2010, he was with the Department of Electrical
Engineering, University of Rome La Sapienza, and, since 2010, he
has been with the Department of Astronautical, Electrical and Energetic
Engineering as an Assistant Professor. During 2003 and 2004, he was a
Visiting Scholar at the Wisconsin Electrical Machines and Power
Electronics Consortium (WEMPEC), University of Wisconsin,
Madison. He is author or co-author of more than 60 technical published
papers. His current research interests include permanent magnet motor
drives and digital control systems design for unconventional power
converter topologies.
Prof. Giulii Capponi is a member of the IEEE Industry Applications,
the IEEE Industrial Electronics and the IEEE Power Electronics
Societies. He is currently serving as an Associate Editor for the IEEE
Transactions on Industry Applications.

Giulio De Donato was born in Cork, Ireland, in 1978. He received the


M.S. and Ph.D degrees in electrical engineering from the University of
Rome La Sapienza, Rome, Italy, in 2003 and 2007, respectively.
He was a Research Associate with the Department of Electrical
Engineering, University of Rome La Sapienza, from 2007 to 2008;
from 2008 to 2010 he was an Assistant Professor with the same
Department and, since 2010, he has held the same position with the
Department of Astronautical, Electrical and Energetic Engineering. His

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