Design of a new axial flux permanent magnet generator for hybrid electric vehicles

This paper discusses the development of a new axial flux permanent magnet generator that was specially designed to achieve simple robust construction with a low weight-to-power ratio, high efficiency and a controlled output voltage and frequency over a wide range of speeds. By using a set of standard components and changing only a few key design parameters, a whole series of generators can be designed with various system parameters (power, efficiency, weight). A model based on analytical and finite element calculations is presented together with the test results of a mono-phase prototype that was built. Based on the calculation model, various machines were designed for application in electric vehicles. The effects of different system parameters such as efficiency, weight-to-power ratio and dimensions of the machine were evaluated for a series hybrid electric van that was built at Vito.