Halbach Array Motor/Generators A

Novel Generalized Electric Machine

By Bernard T. Merritt, Robert F. Post, Gary R. Dreifuerst, Donald A. Bender;
October 28, 1994; Lawrence Livermore National Laboratory, UCRL-JC-119050
Introduction
For many years Klaus Halbach has been investigating
novel designs for permanent magnet arrays, using ad
vanced analytical approaches and employing a keen in
sight into such systems. One of his motivations for this
research was to nd more ecient means for the utiliza
tion of permanent magnets for use in particle accelera
tors and in the control of particle beams. As a result of
his pioneering work, high power freeelectron laser sys
tems, such as the ones built at the Lawrence Livermore
Laboratory, became feasible, and his arrays have been
incorporated into other particlefocusing systems of
various types. This paper reports another, quite dier
ent, application of Klaus work, in the design of high
power, high eciency, electric generators and motors.
When tested, these motor/generator systems display
some rather remarkable properties. Their success de
rives from the special properties which these arrays,
which we choose to call Halbach arrays, possess.
In August 1979, Klaus Halbach submitted a paper
1
enti
tled Design of Permanent Multipole Magnets with Ori
ented Rare Earth Cobalt Material. In this paper, he
presented a novel method of generating multipole mag
netic elds using nonintuitive geometrical arrange
ments of permanent magnets.
In subsequent publications,
2,3 ,4
he further dened these
concepts. Of particular interest to one of the authors
Richard F. Post was the special magnet array that gen
erated a uniform dipole eld. In 1990 Post proposed the
construction of an electric machine a motor/generator
using a dipole eld based on Klaus Halbachs array of
permanent magnets. He further proposed that such a
system should be employed as an integral part of an
electromechanical battery EMB, i.e., a modular y
wheel system to be used as a device for storing electrical
energy, as an alternative to the electrochemical storage
battery.
This paper reviews Halbachs theory for the generation
of a dipole eld using an array of permanent magnet
bars, presents a simple analysis of a family of novel
ironless electric machines designed using the dipole
Halbach array, and describes the results obtained when
they were tested in the laboratory.
The Dipole Array
Although electric machines can be constructed using
multipole elds based on the techniques introduced by
Klaus Halbach, the dipole eld oers some unique ad
vantages for the construction of a high speed electric
machine. Figure 1 shows an end view of a dipole Halbach
array. Shown in Figure 1a are the directions of magneti
zation of the bars and in Figure 1b, one quadrant of the
computed lines of force produced by the array. Note the
highly uniform eld inside the array, and the near
cancellation of the eld outside the array.
Figure 1a Halbach Array
Halbach Festschrift Symposium, Berkeley, CA; February 3, 1995 1
Figure 1b Halbach Array Field Lines
Except near the ends of the array, or very near its inner
surface, the dipole eld inside a such an array is given by
the expression derived by Halbach:
B
0
= B
r
C
N
ln
r
2
r
1

1
with r1 and r2 indicating the inside and outside radius of
the magnet array, respectively, and Br representing the
remanent eld of the permanent magnet material. If M
is the number of segments in the magnet,
C
N
=
sin
2
M

2
M

2
giving CN = 0.90 for M = 8 and CN = 0.97 for M = 16.
These equations are derived in reference 2.
When Equations 1 and 2 are compared with a com
puter code using the correct remanent eld of the mag
nets, the code results agree within a percent or two of
the analytical result. Arrays constructed using the high
eld material, NdFeB, have measured elds that are
found to be within a few percent of the predicted values.
Figure 2 is a eld plot of a dipole eld constructed using
an eight segment Halbach array. The permanent mag
nets used for this dipole were ceramic; the eld values
measured are uniform to about three percent. The val
ues for the eld strength are those measured inside the
Halbach array cylinder; the eld decreases somewhat
near the ends of the magnet array. See references for a
detailed discussion and calculation of this decrease.
.97
-1.2
1.17
-1.01
1.67
-.82
1.55
-1.28
.36
-1.68
.78
-1.7
1.10
-1.06
2.23
2.26
2.23
2.1 2.2 2.2 2.2
Figure 2 Halbach Array Measured Field Values
Construction of the Generalized
Motor/Generator
The design of a motor/generator using a dipole Halbach
array is simplicity itself. Furthermore, since there are no
iron laminations used in the design the theoretical pre
diction of the properties of such motor / generators is
equally simple.
In order to construct a motor/generator, all that is re
quired is to insert a single or multiphase winding down
the axis of the dipole eld and provide relative motion
between the eld and the windings. Relative rotation
then generates an EMF in the winding that is linearly
related to the product of the rotation speed and the
amount of ux intercepted by the winding. In the case
of a generator, the work performed in sustaining the
relative motion between the windings and the eld is
transformed directly into ac electrical energy that ows
out of the machine. Conversely, ac electrical energy
owing into the winding, if at the proper frequency and
phase, is transformed into mechanical work that causes
a relative motion between the windings and the eld. At
this point it is important to note that only a relative
motion between the windings and the eld is required;
electric machines having either the windings or the Hal
bach array in motion could be constructed. There are
advantages to each type depending upon the application.
Halbach Festschrift Symposium, Berkeley, CA; February 3, 1995 2
A
B C
A
B C
Halbach Magnet Segments
Winding Barrier
Litz Wire Windings
Figure 3 Halbach Array with Three Phase Winding
Figure 3 shows a three phase winding inserted into the
Halbach array eld. Single phase or higher phase num
ber machines can also be constructed. This paper con
centrates on the three phase machine in which the di
pole Halbach array surrounding the winding is rotating.
This conguration has been employed by us in the ap
plication for which it was rst proposed, electrome
chanical batteries ywheel energy storage modules.
In order to calculate the induced EMF, consider rst the
simple case of a single turn winding. Assume for the
moment that the winding is stationary and that the
Halbach eld, due to the relative motion, is given by
B t ( ) = B
0
cos t ( ) 3
Owing to the linearity of the system the induced EMF is
given exactly by
V t ( ) =
d
dt
4
where is simply given by the product of the dipole
magnetic eld strength and the area, A, intercepted by
the windings with a small correction, usually of order 10
to 20 percent, depending on the relative length of the
windings and the magnets for the fallo of the eld
strength near the ends of the magnet array.
This expression then reduces to
V t ( ) = B
0
Asin t ( ) 5
where A is the area of the winding, i.e., its length multi
plied by its transverse width, and is the rotational ve
locity in radians per second.
For the case of multiple turns per winding, the voltage
becomes
V t ( ) = KNB
0
sin wt ( ) 6
where N is the number of turns and K is a geometric
constant, close to unity, that accounts for the fact that
the winding now has some physical width that spans an
arc along the circumference of the cylinder upon which
the windings are attached. This constant is readily calcu
lated; it accounts for the relative decrease in magnetic
eld since a particular turn is no longer exactly aligned
with the reference direction for the magnetic eld. For
such a turn, the correction factor is equal to cos ,
where is the angle between the reference for the mag
netic eld, usually zero, and the angle at which a par
ticular turn resides. For a distributed winding with angu
lar spread i.e. its two sides intercept a fraction 2/2
of the circumference, upon performing the average over
this spread the factor K is given by the following expres
sion:
K =
2sin / 2 ( )

7
If = 30, for example, K = 0.989.
V
EMF
BNA
= Speed
B = Field
N = Turns
A = Area of one turn
Figure 4 Equivalent Circuit for Electric Machine,
per Phase Basis
Figure 4 is a schematic of the electric machine. It is to
be interpreted on a per phase basis for machines having
multiple phases. Note that this representation contains
only linear elements, and also note that the value of
magnetic eld Bo, that is to be used in calculating the
induced voltage, is that of the Halbach array. In this
ironless system, and for all feasible values of the winding
currents, there is no back reaction between the stator
windings and the inducing magnetic eld. There is, of
course, an eect of the winding inductance on the out
put voltage as well as the usual resistive drop. However,
since the system is ironless, inductances are low, and
Halbach Festschrift Symposium, Berkeley, CA; February 3, 1995 3
with good design, the resistive drops are also low. As will
be shown, not only is the power output very high, but
the eciency is also typically much higher than that of
an ironcore machine of comparable physical size.
The equations for torque are also straightforward. Con
sider again the case of a single turn winding and only
one phase. The vector force on a conductor is given by
F = 2I LxB ( ) 8
where I is the current in the conductor, L is the vector
path along the conductor and B is the vector magnetic
eld. The torque is then
T = r xF 9
where r is the radius.
For a single turn rectangular winding with longitudinal
length L, in a dipole eld, the magnitude of the peak
torque becomes
T = 2rLIB
0
10
and for the multiple turn case, the peak torque becomes
T = 2rLIB
0
KN 11
where K is the geometric factor as before and N is the
number of turns.
Owing to the complete linearity of this ironless system
these simple equations form an adequate basis for the
design of motor/generator systems employing a dipole
Halbach array. We will later discuss the circuitrelated
factors that must be employed in order to calculate the
output power and the eciency of such generators.
Again, as noted, the absence of iron in the magnetic
circuit means that only simple aircore inductances and
winding resistances must be taken into account to calcu
late these quantities.
P =
V
0
2
R
L
1
1+
R
o
R
L

_
,

1
]
1
2
+
uL
0
R
L

1
]
1
2

Watts/phase 12
If the rms output voltage of each of the 3phase wind
ings is V0, the winding inductance is Lo, and its resis
tance is Ro, then the output power of each phase into a
resistive load with resistance RL is given by the equa
tion:
The eciency is then given by the expression:
=
R
L
R
0
+ R
L
13
Advantages
A fundamental advantage of a machine of this type has
already been mentioned. That is, the fact that the ma
chine can be constructed without the use of magnetic
material other than the permanent magnets. There is no
need for laminations or back iron. This has two major
advantages. First the conventional core loss and eddy
current loss in the laminations or back iron does not
exist. The only loss in the machine will be losses in the
windings. The second advantage is since there is no back
iron or laminations required, the machine is inherently
lightweight.
The uniform eld also results in several important ad
vantages. Since the eld is truly uniform, the machine
design is no longer constrained by the airgap size. This
oers the opportunity to solve other system issues. For
example, in the modular EMB application, it allows a
vacuum barrier to be placed between the windings and
the Halbach array without appreciable degradation of
machine performance.
The eld uniformity of the dipole Halbach array has
another, very important result for the extraction of very
high peak powers over short time scales. Conventional
generators employing narrow gaps and iron laminations
have a problem that is not encountered here. In such
systems, where the drag torque caused by the power is a
function of the gap spacing, there can exist a strong ten
dency to drive the rotating system into socalled whirl
instability. Contrast this with our situation. Since the
eld is uniform, the torque is not a function of the dis
placement of the windings relative to the eld the
windings only know that they are in a uniform rotating
eld, origin unknown. Thus the potential, from this
source, for whirl instability does not exist.
As mentioned earlier, the major loss mechanism in this
type of machine is the losses in the windings. These
losses can be minimized by increasing the amount of
copper in the windings. There is a tradeo between the
eciency of the machine and the size of the winding.
There is also a potential loss due to eddy currents in the
conductors; since the eld is always present, eddy cur
rents will be induced in the conductors due to the rela
tive motion between the windings and the eld. This
latter loss is easily controlled to low levels, i.e. a few
watts, by the use of Litz wire.
Halbach Festschrift Symposium, Berkeley, CA; February 3, 1995 4
Motor Types
Halbach array electric machines could be constructed in
a conventional manner, whereby the Halbach array is
stationary and the windings rotate within the array. As
we have mentioned for use in our modular EMBs, the
Halbach array machine has been constructed inside
out, with the windings stationary and the magnet array
rotating around the windings. There are advantages to
both types of construction; specic applications drive
the choice.
In a conventional machine conguration, the Halbach
array machine would look physically much like a dc ma
chine; that is, the armature is on the rotor and the eld
is stationary. Such a machine could be operated as either
a dc or ac device. If one uses slip rings to bring out the
windings, the machine could be characterized as an ac
machine. However, if now an electronic commutation
circuit is added, the Halbach array machine can be char
acterized as a dc machine. If one desired, one could use
a mechanical commutator as well.
The inherent advantage of this construction technique
is that the inertia of the rotor is dominated solely by the
mass of the windings since there are no laminations re
quired. One can therefor envision the construction of a
very high speed low inertia machine.
If the machine is congured, as we have done, in an
insideout geometry, the windings are stationary and
readily accessible. Again, the machine can be character
ized as either an ac or dc machine. The primary advan
tage of the insideout construction is that it is readily
adapted to evacuated systems such as in our EMB since
there is no need for slip rings.
Our specic application, the EMB
As noted earlier, the impetus for the development of
this new type of electric machine was our application to
modular electromechanical batteries.
5,6,7
The EMB bat
tery consists of a highspeed ywheel with an integral
motor / generator suspended on magnetic bearings and
in an evacuated housing. For practical use, a set of power
electronics is coupled to this module. The ywheel and
its motor/generator is a means for energy storage and
extraction; the power electronics conditions electrical
energy, both for adding energy to and extracting energy
from the ywheel. Since the goal is to mimic a battery,
the input/output voltage to the power electronics is
typically dc, although acbased systems can also be con
templated, using socalled cycloconverters, or the
multiphase devices called matrix converters. A sketch
of the electromechanical battery is given in Figure 5.
Figure 5 Electromechanical Battery
As can be seen in Figure 5, the Halbach array machine is
an integral part of the ywheel construction. The array
of magnets is designed into the rotor; the mass of the
magnets is used advantageously to keep the composite
material in compression. The advantages listed above are
also utilized in this design. The outer diameter of the
stator windings are typically a centimeter smaller than
the inner diameter of the Halbach array magnets. In this
space, a thin vacuum barrier is placed, still allowing for a
substantial clearance between the array and the barrier.
This clearance simplies the design of the bearing/ sus
pension system, which need not constrain the radial dis
placements of the rotor assembly to the fractionofa
millimeter tolerances that would be required in a con
ventional ironcore machine.
We conclude this section with a summary of the design
parameters of one of the modular EMBs that we have
constructed.
Halbach Festschrift Symposium, Berkeley, CA; February 3, 1995 5
Table 1
Electromechanical Battery Parameters
Useful energy
100 to 50 speed
0.6 KWhr
Maximum speed 84,000 rpm
Peak power 50 kW
Open circuit voltage 151 Vrms/phase,
max speed
Halbach array length 18 cm
Halbach array outer diameter 10.5 cm
Halbach array inner diameter 7 cm
Windings turns/phase 6
Conductor size 1700 strand,
#40 Litz
Inductance per phase 7.4 microhenries
Resistance per phase 10.8 milliohms
Using these data and equations 12 and 13 we can cal
culate the power output and the eciency of this gen
erator. We assume that the power from each of the three
phases is summed independently in calculating the out
put power, and we ignore the eddy current losses in the
Litz wire it is of order one or two Watts. In the table
below the power and eciency. are calculated as a func
tion of the load resistance the same for each of the
three phases and at full speed 84,000 RPM. As will be
seen at or below the design power the eciencies are
very high.
Table 2 Generator Efciency
Versus Output Power
R
L
(ohms) Power
(kW)
Efciency
3.0 23 99.64
2.5 27 99.57
2.0 34 99.46
1.5 45 99.29
1.0 66 98.93
Drive Circuitry
Although the Halbach array machine can be operated as
either an ac or dc machine, there are advantages to op
erate it as a dc machine. The primary advantage is that
the drive circuitry can use a simple 1200 gating wave
forms. Normally, in an ac machine, elaborate PWM
techniques are used to generate sinusoidal waveforms in
order to minimize harmonics that can cause losses in the
laminations. Since the Halbach array machine does not
have laminations this is no longer of concern. The re
sulting drive can then be greatly simplied, since in this
case a simple rectangular wave is very nearly as ecient
in driving the rotor as would be a pure sine wave.
Halbach Motor Buck Regulator Electronic Commutator
Figure 6 Simplied Schematic of Spin-up Circuit
In our specic application, energy is transferred into and
out of the ywheel on a routine basis. In order to add
energy to the ywheel, the power electronics treat the
Halbach array machine as an electronically commutated
dc motor, as the voltage is raised across the motor, the
speed of the motor increases. A schematic of the power
electronics for spinup is given in Figure 6. The elec
tronic commutation is provided by six IGBTs connected
to the three phases of the machine. The dc voltage to
Halbach Festschrift Symposium, Berkeley, CA; February 3, 1995 6
the commutating bridge is controlled by the buck
regulator formed by one IGBT, an inductor, and diode.
The IGBTs in the commutation bridge also serve as an
overcurrent protection scheme. The lower IGBT in
each leg can be pulse width modulated to control the
current in the windings. The switching frequency for
this modulation is about 20 kHz, while the electronic
commutation needs to accommodate frequencies up to
1400 Hz to achieve 84,000 RPM operation. This pro
tection is not for the windings but for the power semi
conductors.
Halbach Motor Boost Regulator Diode Bridge
Figure 7 Simplied Schematic of
Energy Extraction Circuit
A schematic for extraction of power from the ywheel is
given in Figure 7. The three phases of the windings are
connected to a six pulse diode bridge to convert the ac
waveforms to dc. Since the speed changes a factor of
two while energy is being extracted, the dc voltage will
also decrease by a factor of two. To accommodate this
change in dc bus voltage, a boost regulator is added.
The boost circuit provides for a constant output voltage
by changing the IGBT duty cycle.
Halbach Motor Buck/Boost Regulator Electronic Commutator
Figure 8 Simplied Schematic of
Electromechanical Battery
Since IGBTs are normally packaged with an antiparallel
diode, the spinup and extraction circuit can be com
bined to one as shown in Figure 8. This circuit works
best when the energy is added to the ywheel on the
same time scale as it is extracted. Figure 8 is an example
of circuit that creates a true electromechanical battery;
the ywheelpower electronics system mimics a dc bat
tery. For those applications where energy compression is
important, that is, the energy is added/extracted on a
much longer time scale than it is extracted/added, there
is a cost advantage to separate the spinup and extrac
tion functions in order to minimize the cost of the
power semiconductors.
Performance
Although the ywheel system has not yet been operated
at full speed, the fundamental characteristics of the
Halbach array electric machine have been veried.
AC Operation
Figure 9a is a typical open circuit voltage waveform; the
purity of the sinusoid is given in Figure 9b which shows
that the highest amplitude harmonic is less than a factor
of 300 than the fundamental i.e., more than 50 decibels
lower.
0.447
0.357
0.268
0.178
0.089
0
-.0.089
-0.178
-0.268
-0.357
-0.447
Figure 9a Open Circuit Voltage
3.16 x 10
-1
1.00 x 10
-1
3.16 x 10
-2
1.00 x 10
-2
3.16 x 10
-3
1.00 x 10
-3
3.16 x 10
-4
1.00 x 10
-4
3.16 x 10
-5
100 Hz 0.0 Hz
Figure 9b Open Circuit Voltage Harmonics
Extraction of High Power
Using the ywheel with an integral Halbach array ma
chine, over 50 kW of power into a load that was not
impedancematched for maximum power in about one
second bursts have been successfully extracted. During
this high peak power, the machine did not exhibit any
indications of whirl instability. To perform this extrac
tion, the windings were connected to a six pulse diode
bridge that was then switched into a resistive load. Fig
ure 10 shows typical bridge voltage and current during
Halbach Festschrift Symposium, Berkeley, CA; February 3, 1995 7
extraction. The peak power that has been extracted to
date was 65 kW for about one second.
Voltage, 50V/div
Current, 98A/div
Figure 10 Bridge Current and Voltage During Extraction
DC Operation
The ywheel with an integral Halbach array machine
has been routinely operated at 40,000 RPM. During the
spinup, a single phase version of the power electronics
as shown in Figure 6 was used. Figure 11 is a plot of
speed versus dc bus voltage. The dc bus voltage is always
slightly higher than the emf to ensure power ow into
the motor during spinup. This operation is typical of a
dc motor with constant excitation.
250
200
150
100
50
0
0 200 400 600 800 1000 1200 1400
DC Bus
Peak EMF
Speed (Hz)
V
o
l
t
a
g
e
Figure 11 Flywheel Speed versus DC Bus Voltage Graph
Publishing History
This work was performed under the auspices of the U.S.
Department of Energy by Lawrence Livermore National
Laboratory under contract No. W7405ENG48.
Reformatted and color illustrations added by Mark
Duncan on July 2009.
References
Halbach Festschrift Symposium, Berkeley, CA; February 3, 1995 8
1
Klaus Halbach; Design of Permanent Multipole Mag
nets with Oriented Rare Earth Cobalt Material, Nu
clear Instruments and Methods, 169, pp. 110, 1980.
2
Klaus Halbach; Physical and Optical Properties of
Rare Earth Cobalt Magnets, Nuclear Instruments and
Methods, 187, pp. 109117, 1981.
3
Klaus Halbach; Perturbation Eects in Segmented
Rare Earth Cobalt Multipole Magnets, Nuclear In
struments and Methods, 198, pp. 213215, 1982.
4
Klaus Halbach; Specialty Magnets, Lawrence Berkeley
Laboratory, LBL21945, 1986. AIP 1985 Conference
Proceedings, U.S. Summer School on High Energy Parti
cle Accelerators.
5
Robert F. Post, T. Kenneth Fowler, and Stephen F.
Post; A High Eciency Electromechanical Battery,
Lawrence Livermore National Laboratory, UCRLJC
110861, 1992.
6
Robert F. Post, D. E. Baldwin, Donald A. Bender and
T. Kenneth Fowler; Electromechanical Battery Research
and Development ant the Lawrence Livermore National
Laboratory, Lawrence Livermore National Laboratory,
UCRLJC113905, 1993.
7
Robert F. Post, Donald A. Bender and Bernard T. Mer
ritt; Electromechanical Battery Program at the Law
rence Livermore National Laboratory, IECEC, Mon
terey, CA, August 1994.