Design and fabrication of rotor lateral shifting in the axial-flux permanent-magnet generator

International Journal of Electrical and Computer Engineering (IJECE)
Vol. 12, No. 1, February 2022, pp. 141~149
ISSN: 2088-8708, DOI: 10.11591/ijece.v12i1.pp141-149  141
Journal homepage: http://ijece.iaescore.com
Design and fabrication of rotor lateral shifting in the axial-flux
permanent-magnet generator
Nurma Sari1,2
, Gatut Yudoyono1
, Ali Yunus Rohedi1
, Yono Hadi Pramono1
1
Department of Physics, Institut Teknologi Sepuluh Nopember, Surabaya, Indonesia
2
Physics Study Program, University of Lambung Mangkurat, Lampung, Indonesia
Article Info ABSTRACT
Article history:
Received Jan 29, 2021
Revised Jul 16, 2021
Accepted Aug 4, 2021
The development of axial-flux permanent-magnet (AFPM) machines has
become a mature technology. The single-stator double-rotor (SSDR) AFPM
structure has advantages on the compactness and the low up to medium
power applications so the microscale size and low-cost applications are
reachable to be designed. The research main objectives are designing and
manufacturing the lateral shifting from the north poles of the first rotor face
the north poles of the second rotor (NN) to the north poles of the first rotor
face the south poles of the second rotor (NS) categories as well as finding
the best performance of the proposed method and implementing in a low
cost and micro-scale AFPMG. The novel lateral shifting on the one of the
rotors shows performance at 19.20
has the highest efficiency at 88.39%
during lateral shifting from N–N (00
) to N–S (360
) on rotor2.
Keywords:
Axial-flux permanent-magnet
NN
NS
Rotor lateral shifting
Single-stator double-rotor This is an open access article under the CC BY-SA license.
Corresponding Author:
Yono Hadi Pramono
Department of Physics, Institut Teknologi Sepuluh Nopember
Kampus ITS Sukolilo-Surabaya 60111 Indonesia
Email: yonohadipramono@gmail.com; yono@physics.its.ac.id
1. INTRODUCTION
Development of permanent-magnet (PM) generators from magnetic interactions between permanent
magnets, currents, and various magnetic materials are successfully converting rotational mechanical energy
into electrical energy for a wide variety of applications [1]. Compared to other types of magnetic machines,
PM machines have several benefits for miniaturized or microscale applications. The magnetic interactions
governing the machine operation scale independently with size. Power generator electric machinery designs
are being made as compact and light as possible and also considering its size and weight [2]. Moreover, PM
generators advantages are having high-torque and low-speed applications [3]-[7]. PM generators are widely
used as an alternative of non chemical batteries power source research propagates rapidly in recent years and
mainly motivated by the needs of power requirements especially in low-power consumption and applications.
The design of a high-speed 100 W generator suitable for use with a gas turbine was developed by [8] and its
losses caused by the high frequency operation are compensated by optimizing the winding and the stator core
material.
For the last 40 years, as development of axial-flux permanent-magnet (AFPM) machines rapidly and
widely spread research effort and becoming a mature technology [9], also become very attractive due to its
highly-efficient machines for distributed power generation systems [2], [10]. and also due to other benefits
compared to the slotted radial flux configuration such as shorter stack length, high torque density
achievement and high efficiency [11]-[14]. The AFPM machines can be classified into three types which are
single stator single-rotor (SSSR), single-stator double-rotor (SSDR), double-stator single-rotor (DSSR), or
multi-stator multi-rotor (MSMR) [6], [15]. Many research of AFPM machines mainly focuses on in the

 ISSN: 2088-8708
Int J Elec & Comp Eng, Vol. 12, No. 1, February 2022: 141-149
142
aspects of construction, features, electromagnetic and thermal modelling, simulation, analysis, design,
materials, and manufacturing [16]. Another research are focusing on the effect back iron on the efficiency of
the generator [17] and the testing of the airgap value [18]. The structure with two rotors and one stator
(SSDR AFPM) machine introduced by Profumo et al. is one of the promising solution for both induction and
synchronous machines due to the two rotors can rotate at different speeds, therefore the motor is able to act as
a mechanical differential. Moreover, the AFPM motor with two rotors is highly compacted form [19]. The
SSDR AFPM structure has advantages on high power density, the rotation of fans around the stators winding
is working as a cooling fan for the windings and also applied from the low up to medium power applications
[15], [20].
TORUS development and arrangement of axial modern machines by [21]-[23] made simpler
toroidal winding and allowing the windings moves along the stator to achieve spatial windings automatically.
Commonly there are two categories of SSDR AFPM machine based on the flux directions inside the
machine, the NN type TORUS [15], [24], [25] and the NS type TORUS [15], [26] which are showing the
north poles of the first rotor face the north poles of the second rotor and the north poles of the first rotor face
the south poles of the second rotor respectively. Meanwhile, Omrani et al. [27] studied that independent
bearing and axis of double sided disc type permanent magnetic motor are able to rotate two different loads at
equal velocities without encountering stability problems and will lead increasing the usages of the motor.
With advantages of PM generators [1] and compactness of SSDR type of AFPM [19], the
microscale size applications are possibly designed. In this research, our main objectives are designing and
manufacturing the lateral shifting from NN to NS categories as well as finding the best performance of the
proposed method and implementing in a low cost and microscale axial-flux permanent-magnet generator
(AFPMG). We designed and fabricated the AFPMG consist of one stator between two rotors (SSDR type) to
generate high efficient AFPM generator. Performance analysis is presented to show the reach of our research
in this particular design. The objective of this paper is to design and implement a high performance of SSDR
AFPM. To this purpose, we have introduced a novel rotor lateral shifting to one of the two rotors to improve
the efficiency of the state-of-the-art NN and NS categories in the SSDR types. Specifically, we have:
a. Composed independent rotor lateral shifting from N–N (0o
) to N–S (36o
) on rotor2.
b. Introduced a novel approach for the rotor best position at 19.2o
with the highest efficiency at 88.39%
during lateral shifting method.
c. Provided a compact and a low cost of SSDR AFPM generator with high efficiency.
2. RESEARCH METHOD
The design of the SSDR type of AFPM generator consists of the components and materials as
shown in Table 1. Rotor and its permanent magnet are parts of the AFPM generator and structured by turns
of the different poles in the circular form. Rotor plates material made from aluminium and the thikness is
0.3 cm. We designed rotors with diameter 25 cm and made from Neodymium material in the form of circular
(with diameter 5 cm and width 1 cm). An angle 36° for each magnet was symmetrically arranged with poles
oppositely to bring N-S-N-S shifting. This arrangement implies rotor magnetism varied from N-N (0°) to
N-S (36°). Figures 1(a) and 1(b) shows the rotor design and its implementation.
The stator desain as shown on the Table 1 which are consisted of 12 coils with diameter is 20 mm,
outer coils diameter is 75 mm, outer coils width is 60 mm, and the number of coils turns are 1000. The stator
design was marked with certain combination as to make it easier during the electrical circuit to generate three
phase electrical source. The design and its implementation can be clearly seen in the Figures 2(a) and 2(b).
Table 1. The design of the DSSR type of AFPM
Components Features
Coils diameter (mm) 20
Outer coils diameter (mm) 75
Outer coils width (mm) 60
Phase 3
Number of coils turns 1000
Number of coils 12
Wire diameter (mm) 0.7
Magnet type Neodymium (Nd2Fe14B)
Magnet shape Circular
Number of magnets 20
Magnets diameter (mm) 50
Magnets thickness (mm) 10
Core type Axial
Air gap between rotor and stator (mm) 1.5

Int J Elec & Comp Eng ISSN: 2088-8708 
Design and fabrication of rotor lateral shifting in … (Nurma Sari)
143
(a) (b)
Figure 1. Rotor with permanent-magnets attached, (a) design, (b) its implementation
(a) (b)
Figure 2. Stator with coils attached, (a) design, (b) its implementation
The magnetic flux (φm) calculation in which measuring the total magnetic field (B) that passes
through a given surface area (A). The formula of the magnetic flux as (1):
𝜑𝑚 = 𝐵 𝐴 (1)
Meanwhile, the number of the magnetic flux at which the normal component of field lines passing through a
given surface area, thus the magnetic flux formula become:
𝜑𝑚 = 𝐵. 𝑛
̂𝐴 (2)
𝜑𝑚 = 𝐵 𝐴 cos 𝜃 (3)
where 𝑛
̂ is the normal component and θ is the angle between the magnetic field lines and the normal
(perpendicular) to the surface area. However, there is back emf that existed during running motor due to the
consisting of a coil turning in the magnetic field and opposing the voltage powering and driving the motor
[28].
The angle of each coil is 30o
and classified in three different marked with series connections
generating one phase each. With R1 = R2 = R3, amplitude and the phase (output sinusoidal voltages are 120o
)
are identically same see in Figure 3. The windings combination on the coil and electric circuit equivalent to
generate three phase machine of the marked Figure 2 can be clearly seen on Figure 3.

 ISSN: 2088-8708
144
The AFPM Generator was designed with lateral shifting on the one of the rotor and then
investigating the highest efficiency of the machine as shown in Figure 4. We designed double rotor and the
one stator in between as it has higher efficiency compared to single rotor [29]. Both rotors and stator are
coreless and connected in the same axis so technically easier to manufacture [30]. The rotor lateral shifting
was observed from 0o
to 36o
matching the angle between both magnets curve length. The efficiency was
calculated by the load of δ connected to three phase generator output. Total power output was measured from
the current and voltage of δ. Meanwhile, total power input measurement was gotten from the motor rotation
powered by direct current (DC) power supply.
Figure 3. Three phase machine generated by Figure 2 marked configuration and the electric circuit equivalent
Figure 4. Schematic design of the lateral shifting of α (between two rotors)
We test our approach by connecting AFPM generator (G) prototype to electronic circuit and
measuring the current (A) and the voltage (V) as shown in Figure 5. By measuring current and voltage, power
out can be calculated and then compared to the generator for calculating efficiency of the generator.
Implementation of the circuit can be clearly seen on Figure 6. Power out calculation was taken from the
generator resistance, current, the load resistance and its voltage:
Pout = I2
Rg + Vout I (4)
where Pout is power consumption, I is the flowing current in the circuit, Rg is the generator resistance and Vout
is the output voltage taken from the load. Eficiency of proposed AFPMG should be calculated as (5),
( ) 100%
out in
P P
 = 
(5)

145
where the input power Pin is determined from the input voltage and current on DC motor as a generator drive.
Total mechanical losses in this case will not be discussed, because they are included in the measured output
power. We only consider how much input is supplied and how much power is generated to get the value of
efficiency.
Figure 5. Electronic circuit with load for testing power efficiency
Figure 6. Implementation of the circuit from Figure 5
3. RESULTS AND DISCUSSION
Figure 7 shows the sinusoidal wave form that attached to the oscilloscope during experiment as
shown in Figure 6. The three phase angles are 120o
each. It is also indicating that the system is working well.
Figures 8(a) dan 8(b) are both in the symmetrical condition with θ=0 applied in (3). In Figure 8(a), there are
no field lines passing through the surface; however, there are small magnetic flux from both sides of the
rotors and reducing back emf, resulting small power output due to small V and I. This reduced back emf
implicates voltage frees up to push the motor to operate at higher output speeds so the RPM is reaching
maximum due to reducing resistance from the back emf since no magnetic fields in between both rotors.
Meanwhile, Figure 8(b) is having highest magnetic flux since all field lines passing through the given surface
but the back emf is also fully emerged, limiting its rotation (RPM is decreasing) and resulting power output is
higher than on the Figure 8(a).
The measured efficiency and RPM of the rotor lateral shifting show that during the first structure
which are α=0o
or N-S-N-S for rotor1 and N-S-N-S for rotor2 on the pole condition is 20.21% due to flux
from the same magnet polar will be annihilated each other and implied to only small flux change inducted
emf on the coil in Figure 8(a). Small emf detected on the back and torque become lighter that made RPM
around 1300 and finally only small amount of power consumed. Meanwhile, during the second structure
which are α=36o
or N-S-N-S for rotor1 and S-N-S-N for rotor2, all flux from both magnets induct emf on the
coil in Figure 8(b). It has higher efficiency which is 68,19%. However, this conditions made RPM speed is
decreasing since larger emf detected on the back and torque become heavier and larger power consumed.

 ISSN: 2088-8708
146
Figure 7. The three sinusoidal wave form produced by the three-phase voltage of the generator
(a) (b)
Figure 8. Flux produced by permanent magnets, (a) first structure, (b) second structure
Figure 9 (which is the proposed structure) shows asymmetrical condition with θ≠0 and the back
EMF is partially passing through the given surface area (back emf is not in the maximum condition). This
condition makes smaller torque generated but the number of field lines is as same as before resulting higher
efficiency. During lateral shifting position at α=19.2o
, the flux induction to the coils is similar to the flux at
α=36o
and we found that the significant difference is the decreasing of back emf. As shown in Figure 9, the
back emf always perpendicular to the coil so it gave small contributions to both rotor braking and resulting to
the smaller power consumption with 864 RPM.
Figure 10 shows efficiency and RPM responses during rotor rotation from α=0o
to α=36o
. The
reduced back emf shows the maximum RPM as shown in Figure 8(a) and than the speed keep decreasing as
the back emf is emerging until the back EMF is also fully emerged in Figure 8(b), limiting the rotation and
RPM is minimum. In general, the trend of the RPM as shown in Figure 10 is decreasing during the rotation
(the lateral shifting). Meanwhile, the efficiency of the proposed AFPMG was varied depend on the lateral
shifting procedure and showing rotor lateral shifting performance at 19.2o
reach its peak at 88.39%.

147
Figure 9. Flux magnet at αo
(proposed structure)
Figure 10. Efficiency (red line) and RPM (black line) responses due to rotor lateral shifting on the rotor2 from
0o
to 36o
4. CONCLUSION
In conclusion, we have proposed a novel rotor lateral shifting to one of the two rotors to improve the
efficiency of the state-of-the-art NN and NS categories in the SSDR types. Our independent rotor2 lateral
shifting approach are shifted from N-N(0o
) to N-S (36o
). Our approach resulted performance at 19.2o
with the
best efficiency at 88.39% during lateral shifting. It is has been manufactured a compact and a low cost of
SSDR AFPM generator with high efficiency. In the future, we would like to implement our approach with a
new shape design of the coil to increase the flux and the power generator as well as maintain its efficiency.

 ISSN: 2088-8708
148
ACKNOWLEDGEMENTS
Nurma Sari is supported by Doctoral Scholarship for Lecturer of Indonesian Endowment Fund for
Education (BUDI-DN of LPDP Indonesia).
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BIOGRAPHIES OF AUTHORS
Nurma Sari received the Bachelor's degree in Physics (1996) from University
of Diponegoro (UNDIP) and a masters degree in Physics (2007) specializing in waveguide
antenna from Institut Teknologi Sepuluh Nopember (ITS). She is currently reading for a Dr
degree at Institut Teknologi Sepuluh Nopember (ITS), Indonesia, funded by BUDI-DN
LPDP Indonesia. Her interdisciplinary research interests focus on applying electromagnetics,
applying optics and waveguide antenna. She can be contacted at email:
nurmasari01@ulm.ac.id.
Gatut Yudoyono received the Bachelor's degree in Physics (1988) from
Universitas Airlangga (UNAIR), Master Engineering degrees from Optoelectronics and
Laser Applications (OEAL) Indonesia University (UI) in 1997 and PhD degree in physics
(2017) from Institut Teknologi Sepuluh Nopember specializing in optical materials,
especially titania material. His interdisciplinary research interests focus on optics and
photonics, laser applications, optical sensing, solar cells and optical communications. He can
be contacted at email: gyudoyono@physics.its.ac.id.
Ali Yunus Rohedi received the Bachelor's degree from Department of Physics,
Institut Teknologi Sepuluh Nopember (ITS) Surabaya in 1991, and Master Engineering
degrees from Optoelectronics and Laser Applications (OEAL) Indonesia University (UI) in
1997 respectively. Since 1992, he have been working at Department of Physics, Institut
Teknologi Sepuluh Nopember (ITS) in Surabaya. His current research of interest include
optical and microwave communications, nonlinear optical phenomena, and developing
“smart technique” for solving Problems of Mathematics. He can be contacted at email:
rohedi@physics.its.ac.id.
Yono Hadi Pramono received the Bachelor's degree in physics (optoelectronics
and applied electromagnetics) from Institut Teknologi Sepuluh Nopember (ITS), Surabaya,
Indonesia, in 1991. Since April 1991 he has been a Research Associate of the Department of
Physics (Optoelectronics). Institut Teknologi Sepuluh Nopember (ITS), Surabaya, Indonesia.
He received M. Eng. degree in Electrical and Electronic Engineering from Osaka Prefecture
University, Osaka, Japan, in 1997. From April 1997 to March 2000, he has studying
microwave engineering, optical-wave transmission line and integrated optics under Ph.D.
program in the Department of Electrical and Electronic System, Osaka Prefecture University,
Osaka, Japan. He can be contacted at email: yonohadipramono@gmail.com.

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