Design Optimization for Minimizing Cogging Torque

in Axial Flux Permanent Magnet Machines

Ali SAYGIN Ahmet AKSÖZ
Gazi University Gazi University
Faculty of Technology Graduate School of Natural and Applied Sciences
Yenimahalle/ANKARA/TURKEY Beşevler/ANKARA/TURKEY
asaygin@gazi.edu.tr ahmetaksoz@gazi.edu.tr

Abstract—This paper deals with the optimization of a single For minimizing of cogging torque, many design techniques
side Axial Flux Permanent Magnet machine (AFPMM) designs have been applied. They are stator slots skewing, magnet
with respect to cogging torque. Although the AFPMMs run skewing, special magnet designing, using different dimension
generally at high speed and high torque, these machines may run magnets, using extra slots and gears, optimization of magnetic
at lower operational speed for aircraft applications. At lower poles and using fractional windings [1], [3], [4], [6]–[22]. Fig 1
operational speed, the cogging torque is an undesirable effect. describes cogging torque minimization techniques.
Firstly, a reference AFPMM is designed with Finite Element
Methods (FEM) and is analyzed with Finite Element Analysis
(FEA) in Ansoft Maxwell. According to analysis results, it is seen
that the cogging torque of reference model is 6.53% of machines
torque. Secondly, a parametric analysis is realized to find better
stator and rotor height to lower cogging torque. Third, design
parameters of AFPMM are estimated with artificial intelligence
methods for minimum cogging torque under constant output
torque in MATLAB. Finally, all methods are compared and
discussed. The best parameters are modified according to the
optimal results. In this part, different methods of the
optimization problem of the AFPMM are presented.

Keywords—Axial Flux Permanent Magnet Machines, Cogging

Torque, Design Optimization, Finite Element Analysis, Genetic
Algorithm, Grey Wolf Optimizer, Particle Swarm Optimization

I. INTRODUCTION
Moment fluctuates of electrical machines are undesirable
effects on efficiency and working life. These fluctuates consist
of
• Cogging torque,
• PWM current harmonics,
• Nonideal waveform of back EMF, Fig. 1. Cogging Torque Minimization Techniques [1]
• Phase commutation and
Mathematical formulations and modelling of AFPMM
• Fluctuates on DC bar. [1]–[3] machines help to calculate the cogging torque. So 3-D Finite
The most important moment fluctuate is the cogging torque Element Method (FEM) and Finite Element Analysis (FEA)
for the AFPMM. Although the cogging torque at high are used for AFPMM design and analysis to finding the value
operational speeds can be filtered by the inertia of the system, of the cogging torque [2, 6, 7, 11, 13, 20, 22, 24].
the cogging torque at low operational speeds causes
unexpected speed change, vibrations, and acoustic noise [4]. There are many studies about optimization of the magnet
These disturbing factors have a negative effect on the system dimension and shapes with experimental and theoretical
operation. methods, equation calculation and estimations using artificial
intelligence [1–4], [6–22], [24–30]. Also, it is seen in Fig 2.
The cogging torque arises from the interaction of the EMF But just a magnet optimization is inadequate for the best
harmonics consisting of the permanent magnets and the minimization of the cogging torque [10-13].
magnetic conductance harmonics consisting of the stator teeth.
If it is not decreased, it can damage to the shaft and the bearing
[1], [2], [4–16].

978-1-5090-4489-4/17/$31.00 ©2017 IEEE 324

 d φg
TA = Ni (4)
dθ

1 dR
Tcog = − φg 2 (5)
2 dθ
Here, ∅g is the air-gap flux, dR is the air-gap reluctance and
dθ is the rotor position. As it can be seen, the cogging torque
arise from the interaction of the magnets that produce air-gap
Fig. 2. Magnet Types of Planer AFPMM disk rotor [1]
flux and the stator teeth that is variable with air-gap reluctant.
In this paper, the aim is to minimize the cogging torque of The cogging torque arises from the interaction of the EMF
an AFPMM machine. The single side (single rotor – single harmonics of the permanent magnets and the magnetic
stator) AFPMM is used, because the cogging torque of it is conductance harmonics of the stator teeth. Because of the
lower than other type of AFPMM. Firstly, a reference AFPMM periodical change of air-gap reluctant, the cogging torque
has been designed and analyzed with FEM and FEA in Ansoft changes periodically. Owing to the fact that the cogging torque
Maxwell in the Section II. Secondly, a parametric analysis changes periodically, the cogging torque value can be
based on AFPMM volume and height optimization is realized calculated with Fourier series is expressed as (6).
to decrease the cogging torque in the Section III. Better value
of parameter has been found and applied. Third, parameters of
the AFPMM have been estimated by artificial intelligence ∞
methods for minimum cogging torque in the Section IV and all Tcog ( θm ) = Tk sin ( kN c θm + ϕk ) (6)
methods’ results have been compared. After the comparison, k =1
the AFPMM has been designed using the best parameter in the
Section V. Finally, conclusion discusses the significance of Here, θm is the rotor position, Tk is the amplitude of the k-
presented. th harmonic, φk is the phase angle of the k-th harmonic and Nc
is the least common multiple of rotor pole number and stator
II. AFPMM MACHINES DESIGN AND ANALYSIS slot number. Beside Fourier series, numerical equations are
expressed as follows:
A. Formulation
The cogging torque can be determined by finite element np +1
∞
μM np  Rm 
method, it can be defined by the Fourier series. Torque is a
measure of rotating force. However, the produced torque from
Brl ( θ) =  2 0 n   ...
n =1,3,5… μ r ( np ) 2 − 1  Rs 
the electrical machines is the most important parameter to
analyze. Torque in electrical machines can be described as;
 np +1 2 np 
  Rm   Rm  

( np − 1) + 2   − ( np + 1)   
dWm dθ  sR R
 s
Pm = =T = Tw (1)  2 np 
...
 μ r + 1   Rr   μ r − 1  Rm   Rr   
2 np 2 np
dt dt
 μ 1 −  R   − μ  R  −  R   
In Eq. (1), Pm is the power, dWm is the differential form of  r   s   r  s   m   
energy, dθ is the differential form of mechanical angle, w is the
angular velocity and T is the torque. Torque of a PMSM cos ( npθ)
consists of reluctance torque, alignment torque and cogging (7)
torque. These are expressed as:

T = TR + TA + Tcog (2)  nπα p 

sin  
B   2 
Mn = 2 r αp (8)
 μ0  nπα p
1 dL
TR = i 2 (3) 2
2 dθ

325
 π 2 torque is found of 0.5 mNm for the best height values. In spite
2
φg = αBrl (θm ) ( Rm − Rmi ) (9) of the reduced cogging torque value, it can be reduced more by
p estimations with artificial intelligence methods. Because the
lowest cogging torque is desired in aircraft application.
Where Rm is the magnet outer radius, Rs is the stator outer
IV. ARTIFICIAL INTELLIGENCE METHODS
radius, Rr is the rotor outer radius, p is the number of pole-
pairs., αp is the pole step and α is the average magnetic flux
density coefficient. A. Multi Objective Genetic Algorithm
The Genetic Algorithm is a bio-inspired searching and
B. Reference Model Parameters optimizing algorithm. Generally, it generates high-quality
solutions. For that purpose, genetic algorithm uses operators
A reference model is designed in Ansoft Maxwell and the
such as mutation, crossover and selection. According to a
reference motor parameters are given in Table I.
fitness function and multi objective inputs, this algorithm finds
the best value of the function and the best individual in this
TABLE I. REFERENCE MOTOR PARAMETERS function. If the best results are desired, stop criteria must be
well defined and maximum iteration number must be
Parameter Value
increased. Multiobjective genetic algorithm flow chart is
Number of Poles 8
shown in Fig 3.
Number of Slots 24
Air Gap 1 mm
Number of Phase 3
Slot/Pole/Phase 1
Operational Speed Range ±3000 rpm
Maximum Torque at Nominal Speed 90 mNm
Machines Torque at Nominal Speed 75 mNm
Machines Diameter 222 mm

After analysis of the reference motor, the cogging torque is

found 4.9 mNm. This is 6.53% of the motor torque and it must
be decreased in lower than 5% of the motor torque [1, 2].

III. PARAMETRIC ANALYSIS OF AFPMM MACHINES

Parameters of AFPMM are defined in parametric analysis
of Ansoft Maxwell. Also, Fig. 4 illustrates the cogging torque
values at different values of stator and rotor height. The
reluctance value changes by rotor and stator height. In addition,
the best stator height of 86 mm and the best rotor height of Fig. 3. Multiobjective Genetic Algorithm
6 mm are found. As it is shown in Fig 4, the minimum cogging

Fig. 4. The Cogging Torque Values at Different Values of Stator and Rotor Height

326

B. Particle Swarm Optimization
Particle swarm optimization flow chart is given in Fig 5.
Using the particle's position and velocity, local best known
position can be found by means of each particle's movement.
As the local best positions are compared, the best global
positions can be found.
Fig. 5. Particle Swarm Optimization
Fig. 7. Comparison of All Methods’ Cogging Torque According to Rotor Angle (Electrical Degree)
327
C. Grey Wolf Optimizer
Grey wolf optimizer is a hybrid method. This method relies
on hunting of grey wolves in the nature. Wolves’ leadership
hierarchy is orderly alfa, beta, delta and omega. The main steps
of wolves’ hunting are searching prey, encircling prey and
attacking prey when the best position is found. According to
this steps, grey wolf optimizer has been supplied better solution
than particle swarm optimization, gravitational search
algorithm, differential evolution algorithm and evaluation
programming algorithm [23]. 2D position vectors and their
possible next locations are given Fig 6.
Fig. 6. 2D position vectors and their possible next locations. [23]
Using these three algorithms for estimation, new
parameters of AFPMM are found and are applied on reference
motor in Ansoft Maxwell. Results are shown in Fig 7.
 IV. COMPARISON AND DISCUSS And lastly, the B vector of 1/8 AFPMM motor is shown
Motor torque is 75 mNm at nominal speed. When in Fig. 10.
parametric analysis is applied in Maxwell, the minimum
cogging torque is found 0.5507 mNm. Despite this cogging
torque value, better cogging torque values are found by
MOGA, PSO and GWO in Matlab. New results are given in
Table 2. The comparison results describe that the best cogging
torque is obtained by GWO.

TABLE II. COMPARISON OF METHODS

Method Cogging Torque(mNm)

The Reference Motor 4.9
Parametric Results 0.5507
MOGA 0.4787
PSO 0.3435
GWO 0.2877
Fig. 10. B Vector of 1/8 AFPMM motor
V. LAST DESIGN AND ANALYSIS RESULTS
After the comparison, the best cogging torque is obtained Figures show that founded new parameters have been
by GWO. So the best parameters of AFPMM are found for the chanced stator outer radius and inner radius, rotor inner radius
best cogging torque. Using the best parameters of AFPMM, a and outer radius, rotor and stator height, magnet thickness,
last design is modelled. It is illustrated in Fig 8 magnet length, magnet angle, stator teeth and stator teeth
depth. Thus, the best design is found according to the minimum
cogging torque by changing parameters of AFPMM motor.

Fig. 8. Last Design in Ansoft Maxwell
At the same time, Mag_B of 1/8 AFPMM motor is
illustrated in Fig 9.
VI. CONCLUSION
This paper describes the design optimization procedure of
the single side AFPMM using parametric analysis, MOGA,
PSO and GWO with the objective of minimizing cogging
torque. The proposed approach is useful in the initial design
stage of the machine to determine optimal structure of
AFPMM. Although the cogging torque of the reference model
is 4.9 mNm (6.53%), the cogging torque of last design is
0.28877 mNm (0.3836%). Thus, it is described that using
artificial intelligence methods for FEM and FEA of AFPMM is
quite important. Especially, GWO has supplied the best results
that is the hybrid method. So desired AFPMM can be modelled
in detail.
Although last design is better than previous ones, producing
this motor is very difficult due to sensitive machining and high
producing costs. The constant power, constant motor torque
and constant operational speed are protected, but stored energy
in rotating parts and maximum motor torque is decreased based
on decreased air-gap reluctant and air-gap flux. Also, a new
AFPMM motor design study can be realized for maximum
efficiency and minimum cogging torque.

ACKNOWLEDGMENT
The authors would like to thank Gazi University and Assoc.
Prof. Dr. Mahir DURSUN for his contributions. He allowed to
use his Ansoft MAXWELL program. Also, the study was
supported by TUBITAK 2211-A.

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