Presentation Title

Design of an Axial Flux Alternator with PCB-Embedded Stator Coils Using Algorithmic Coil Generation and Optimization

Abstract

This paper presents the design of an axial flux permanent magnet machine for applications in low power, low RPM energy harvesting. The design and optimization are executed using 2D finite element analysis (FEA) and script generated coil layouts. Using a feedback system between the coil generating script and the FEA software, machine design parameters and coil layouts for KiCAD were generated for target voltages and RPM. A prototype machine was built to test the effectiveness of the proposed method. The prototype machine is shown to be phase balanced, and produce 1.4 watts of power at 3000 RPM. The machine is shown to have 70% efficiency compared to the simulated results. After initial verification of simulation and algorithm validity a new alternator is being designed which will produce 10 watts at 3000 RPM.

Primary Faculty Mentor Name

Dr. Eva Cosoroaba

Secondary Mentor Name

Dr. James Kay

Faculty/Staff Collaborators

Dr. Eva Cosoroaba (Faculty Advisor), Dr. James Kay (Faculty Advisor)

Status

Undergraduate

Student College

College of Engineering and Mathematical Sciences

Second Student College

College of Engineering and Mathematical Sciences

Program/Major

Electrical Engineering

Second Program/Major

Computer Science

Primary Research Category

Engineering & Physical Sciences

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Design of an Axial Flux Alternator with PCB-Embedded Stator Coils Using Algorithmic Coil Generation and Optimization

This paper presents the design of an axial flux permanent magnet machine for applications in low power, low RPM energy harvesting. The design and optimization are executed using 2D finite element analysis (FEA) and script generated coil layouts. Using a feedback system between the coil generating script and the FEA software, machine design parameters and coil layouts for KiCAD were generated for target voltages and RPM. A prototype machine was built to test the effectiveness of the proposed method. The prototype machine is shown to be phase balanced, and produce 1.4 watts of power at 3000 RPM. The machine is shown to have 70% efficiency compared to the simulated results. After initial verification of simulation and algorithm validity a new alternator is being designed which will produce 10 watts at 3000 RPM.