International Journal of Power Electronics and Drive Systems (IJPEDS)

Vol. 12, No. 1, Mar 2021, pp. 51~58

ISSN: 2088-8694, DOI: 10.11591/ijpeds.v12.i1.pp51-58  51

Design and analysis of double stator HE-FSM for aircraft

applications

Hassan Ali1, Erwan Sulaiman2, Mahyuzie Jenal3, Irfan Ali4, Laili Iwani Jusoh5, Zarafi Ahmad6,
Mohd Firdaus7
1,2,3,4,5,6ResearchCentre for Applied Electromagnetics, Universiti Tun Hussein Onn Malaysia, Batu Pahat, Malaysia
7Center for Roboticts & Industrial Automation, Fakulti Kejuruteraan Elektrik, University Teknikal Malaysia Melaka,
urian Tunggal, Malaysia

Article Info ABSTRACT

Article history: The main objective of aerospace industry is to produce all electric aircraft
(AEA) equipped by electrical devices in coming developments. Electrical
Received Aug 26, 2020 machines that provide higher torque densities are gaining more interest for
Revised Jan 14, 2021 researchers to obtain sustainable direct-drive electrical propulsion system for
Accepted Jan 26, 2021 aircraft applications. In addition to lesser weight and higher torque density, a
machine should be “fault tolerant” to applied in aerospace applications. A
novel machine for high starting torque, identified as flux switching machine
Keywords: (FSM) was established over the last decade. FSMs comprise all effective
sources on stator including robust rotor structure. These machines exhibited
Aircraft higher “torque-to-weight ratios” and reliability. Nonetheless, the challenge of
Double stator developing a machine suitable for aircraft applications goes far beyond
Flux switching electromagnetic design and much deeper into the field of mechanical systems
Hybrid excitation than traditional ones. Thus, a new double stator (DS) hybrid excitation (HE)
Segmented rotor FSM design employing segmented rotor is proposed and analyzed in this
research work. The suggested design for DS HE-FSM comprises of six field
excitation coils (FECs) and six permanent magnets (PMs) as their excitation
sources. In this research, investigation of DS HE-FSM is accomplished with
respect to flux linkage, back EMF, cogging torque and torque analysis based
on 2D FEA.
This is an open access article under the CC BY-SA license.

Corresponding Author:
Hassan Ali
Research Center for Applied Electromagnetics
Institute of Integrated Engineering
Universiti Tun Hussien Onn Malaysia, 86400 Parit Raja, Batu Pahat Johor, Malaysia
Email: [email protected]

1. INTRODUCTION
The Integration of electrical power to “drive aircraft systems and sub-systems previously propelled by
hydraulic, pneumatic, and mechanical structures is now becoming an attractive segment in the aviation
industry. Advancements in the power electronics sectors provide the innovations to improve the effectiveness
and protection of operation. The aviation industry operators undergo a long-term transformation from
mechanical, hydraulic, and pneumatic power systems to worldwide optimized electrical systems [1]-[3].
Electric motor drives are capable of transferring electrical power to various systems, like drive actuators,
pumps, compressors as well as other subsystems at various speeds, combined with progressive electronics and
control approaches [4]. Electrical drives are able to offer improvements in overall performance, while reducing
weight and meeting reliability requirements at low cost. The main objective for the aviation industry is to
accomplish the all-electric aircraft (AEA), converting all power systems to electric” power [5]. Moreover,

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52  ISSN: 2088-8694

mechanically actuators have significantly replaced hydraulic actuators with electronic servo valve control. The
"more electric" advancement has permitted decrease in mechanical components and hydraulic power supply
systems to be more simplified. Such as, electric machine fuel pumps were recognized in place of hydraulic
pumps to offer advantages of system efficiency, and speed control flexibility [6], [7].
Significant improvements can be acquired by “presenting multi-phase machines to enhance the
reliability of motor drives for MEA. These machines are typically represented as machines with more than
three phases, this number being presumed to be the critical threshold in situation of a single-phase fault.
Reporting suggestions for multi-phase motors powered by multi-phase electronic converters can be found in
literature, in which both the motor and the drive are required to meet extreme fault tolerant requirements [8],
[9]. By providing solutions for potential failures, a fault-tolerant system can realize goals of reliability
deprived of resorting to un-optimized redundancy or over-sizing [10]. Engine generators, flight surface
actuators, flap actuators, engine fuel pumps, and landing gear nose wheel”steering systems are main regions to
be condsider for safety drives in aircraft [11].
Recently, for top performance applications like within the aerospace, and electric vehicles, “flux
switching machines” (FSM) using PMs have presented high torque densities besides “fault tolerance” abilities
[12]-[14]. FSMs contain active sources flux within the stationary part of the “motor with the benefit of sturdy
rotor assembly, which is helpful to be used for higher speed applications. Where the flux control is maintained
by DC excitation” coil. FSMs are divided three main types such as “permanent magnet (PM) FSM”, “field
excitation (FE) FSM”, and “hybrid excitation (HE) FSM”. Active flux producing sources in case of “PM-
FSM” and “FE-FSM” are PMs and “field excitation (FE) coil” respectively. While in case of “HE-FSM” PMs
and FE Coils are combined to generate the flux [15], [16].
“PM-FSMs” are becoming common in different applications due to the technologically advanced
high-performance rare earth magnetic products, varying “from electric and hybrid electric cars, renewable
energy systems like wind power turbines, electric aircraft, industrial drives, automation” to household
appliances [17], [18].
Moreover, “PM machines” have certain limitations, such as higher cost of “rare earth” materials,
comparatively low flux weakening, unchanging flux, demagnetization and restricted operating
temperature [19]. Hence, the machines which are completely free from PMs got attention of the researchers.
FE-FSM was suggested and evaluated using “double stator” in [20], [21]. Though, this causes high “copper
losses”, as both the armature and field coils are mounted individually on both stators. Besides, it also
compromises the torque and efficiency because of low flux strength [22].
Consequently, the idea of HE machines have been proposed to incorporate the advantages PM and
DC excitations. HE machines are effective applicants for varying speeds applications e.g. electric cars, aircraft
and wind power generation [23]-[25]. HE machine models are diversified, as two sources of excitation are
being assembled efficiently. In the last twenty years a wide variety of promising designs have been studied and
developed. Even so, these structures are needed to be further improvement due to flux cancellations issues
between certain PM flux and FE flux.
Therefore, the new structure of DS HE-FSM with segmented rotor has been proposed and examined
in this paper. PM and FE are being used as main and secondary excitation in the proposed system and generate
“parallel hybrid excitation” to prevent “flux cancellations” and the influences of demagnetization. In addition,
the coil test is performed to legitimize the motor's operating principles, as well as the non-load and load
conditions performance is also observed based on the 2-D FEA.

2. PARAMETR SPECIFICAIONS AND DESIGN METHODOLOGY OF PROPOSED DS HE-FSM

The design specification and parameters of a proposed (DS) HE-FSM using segmental rotor are
itemized in Table 1. The maximum limit of both “armature current density (Ja)” and “FEC current density
(Je)” is 15 A/mm2. Whereas, the weight of PM is fixed as 1kg. The proposed machine consists of 6 PMs
situated only at internal stator tips, together “with 6 FECs uniformly distributed in the midst of each outer
stator teeth. Armature windings and FECs are mounted on the outer stator. Figure 1 presents a cross-sectional
view of proposed DS HE-FSM with a segmented rotor. The flux linkage in the armature coil has one periodic
cycle for motor rotation through 1/10 of a revolution and so the frequency of back EMF in the armature coil is
ten times the mechanical” rotation.
The design specifications are basically classified into two parts, including those referring to the
stators and the rotor. On the stator, it is subdivided into three clusters which are the shape of the FEC slot, the
shape of the armature slot and the PM in (inner stator).

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Table 1. Design parameters and restrictons of DS Outer stator

HE-FSM FE Coils
DS HE-FSM with
Items
segmented rotor
Armature
Diameter of outer stator (mm) 273
coils
Diameter of inner stator (mm) 131
Number of rotor segments 10
Tooth width of outer stator
11
(mm)
Outer stator back iron length
20
(mm)
Air gap length (mm) 0.5 PMs
Armature coil slot area of Inner stator
526
(mm2)
FEC slot area (mm2) 526 Rotor segments
FEC number of turns per slot 10
Armature coil number of turns
10
per slot
Segment span (degree) 30°
Figure 1. Initial design of proposed DS HE FSM with
segmental rotor

3. PERFORMANCE ANALYSIS OF DS HE FSSM

Performances of proposed DS HE-FSM are analyzed on the basis of 2D-FEA using JMAG designer.
The material used for PM is “NEOMAX-35AH” while “electro-magnetic steel (35H210)” is used for the cores
of rotors and stators. The slot area of the “armature coil (Sa)” provides maximum amount of armature coil
turns (Na), while, the boundaries of “armature current density Ja” is set to 15 Arms/mm2. Equally, the
maximum “field current density Je” is set to 15 A/mm2.

3.1. Flux linkage at diffrent sources

The results of suggested “DS HE-FSM with segmented rotor” at open circuit including flux linkage,
back-EMF, and cogging torque are initially evaluated. Flux linkage is an examination to affirm the “magnetic
flux”, produced through the combination of “PMs and FECs”. The flux linkage of proposed machine is
investigated and compared at different excitations sources such as PM only, FEC only and at HE conditions as
shown in Figure 2. From the figure, it can be seen that the machine draws lowest flux linkage when only FE
sources is active (without PMs).
The determined flux linkage is generated as both the excitations are used at hybrid condition where
the flux linkage achieved is almost 0.0345 Wb. It also verifies that the flux linkages from both sources are
combined properly and hybrid excitation is successfully achieved. Whereas, in case of “only PM excitation”,
the amount of flux density obtained is approximately 0.025 Wb.

Figure 2. Flux linkage at various conditions PM only, FEC only and HE

3.2. Cogging torque examination of DE HE-FSM

At first, the behavior of the cogging torque for presented DS HE-FSM has been evaluated being
shown in Figure 3 at no load circumstance. That can be seen from figure that cogging torque at “PM only” is
about 5.57 Nm peak to peak. Although the “maximum field current density” of 15 A/mm2 is inserted into field
Design and analysis of double stator HE-FSM for aircraft applications (Hassan Ali)
54  ISSN: 2088-8694

coil in the case of FE only. In the case of “FE only” the value of cogging torque is increased due to high
current in the FE coil, which can cause fluctuations and ambient sounds in the motor.
On the other side, while machine is under no load circumstances, the cogging torque is dropped, and
a reasonable value of about 12 Nm “peak to peak” has been generated. Though, the obtained value of “cogging
torque” of the initial design is high compared to “in case of PM only”. The initial structure of the new “DS
HE-FSM” affirms that the performance of proposed motor will be uniform at higher speeds with fewer
vibrations and noises.

Figure 3. Cogging torque of proposed DS HE FSM with segmental rotor

3.3. Induced EMF of proposed DS HE-FSM

Figure 4 demonstrate induced EMF of suggested DS HE-FSM at open circuit condition with speed of
500 rpm. The magnitude of induced voltage produced from PM only is around 26.5 V, with a certain distortion
in the sinusoidal waveform as shown in Figure 4. Nevertheless, "FE only" generates lesser induced voltage
than PM, although there is some distortion in the waveform. Although the magnitude of induced EMF is
increased to nearly 35 V by combining both sources (PM and FE) due to field-strengthening effect. Whereas, it
can be seen in the figure that the variation has also been decreased and validates that the suggested DS HE-
FSM motor operates seamlessly under safe region.

Figure 4. Induced EMF against rotor position

3.4. Flux distribution and flux density at full load

Magnetic flux distribution and flux density of suggested “DS HE-FSM” are examined at full load
conditions for sources of excitations. The flux distribution of proposed “DS HE-FSM” are shown in Figure 5.
Figure 5(a) displays the flux distribution at “field current density of 15 A/mm2” besides “armature current

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Int J Pow Elec & Dri Syst ISSN: 2088-8694  55

density of 15 Arms/mm2”. It can be seen from figure that flux density at full load is 2.53 T, whereas, above
2.53T, flux get “saturated which can be seen at the tips of the teeth of outer stator in red” circles. Besides,
Figure 5(b) demonstrates the flux distribution” when “PM only” excitation is utilized at full load, realizing
smooth distribution around the cores of machine and achieving the “maximum flux density of 2.60 T”.
Whereas in case of Figure 5(c), in which “PM and FE” excitations are united to produce magnetic flux linkage.
From Figure 5(c), the overall magnetic flux can be seen circulated almost 100% over the core of machine, due
to the PMs, which are positioned on the surface of inner stator whereas around the outer stator almost 90% of
“magnetic flux” is dispersed with 10% empty core caused by flux saturation at the tips of stator tooth and
occurrence of leakage. Furthermore, from Figure 5(c), it is obvious that maximum and minimum flux density
attained in “DS HE-FSM” are 2.9 T and 3.6 E-05 T respectively. This investigation affirms that the “DS HE-
FSM” competence enough to create high levels of flux densities to reach highest essential torque for aircraft
applications at various speed ranges.

Saturation Saturation Magnetic Flux density

Empty space
Empty space

(a) FE source only (b) PM source only

Magnetic flux density

(c) Both sources (HE)

Figure 5. Magnetic flux density at different excitation sources

4. TORQUE INVESTIGATION AT DIFFERENT CURRENT DENSITIES

The torque investigation of proposed DS HE-FSM is conducted by inserting variable values of
armature current densities from 3 Arms/mm2 to 15 Arms/mm2 at various loads. Henceforward, at maximum
field current density of 15 A/mm2, the value of torque has been observed at various “armature current densities
(Ja)” such as at 3 Arms/mm2, 6 Arms/mm2, 9 Arms/mm2, 12 Arms/mm2 and 15 Arms/mm2. As a source of
flux, PM produces consistent flux and thus the current density of the field is varied to evaluate the output
torque at various loads. Figure 6 demonstrates the result of torque at various current densities under various
currents in the armature. As from figure, it is shown that as the field current density raises, the amount of
torque grows. Therefore, the flux generated from "PMs and FECs" is appropriately combined at high densities.
This favors that the machine being proposed is able to generate higher torque at full load. From figure it seems
to be clear that at a maximum "armature current density of 15 Arms/mm2", the maximum torque attained is
about 160Nm. In addition, the torque plot suggests that DS HE-FSM still tends to withstand the more fluxes
while avoiding any saturation and cancellations between "PM and FEC" fluxes as shown in Figure 7. Electric
motors for aircraft applications require high torques, especially at lower altitudes and lower speeds, hence,
performances of DS HE-FSM are prominent to be applied for such applications.

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Figure 6. Average torque of DS HE-FSM with segmented rotor

5. TORQUE AND POWER CHARACTERISTICS WITH RESPECT TO SPEED OF INITIAL

DESIGN
Figure 7 demonstrates the torque and power characteristics of the “DS HESFM”. From figure, the
graph of torque and power of the proposed design is presented in blue and orange lines respectively. Where, it
is obvious from the figure that proposed “DS HE-FSM” has attained the maximum torque almost 160 Nm
which is continued till the base speed of 3750 rpm. Besides, the value of torque performance is reduced
gradually and reaches till 10Nm at speed of around 16,000 rpm.

Figure 7. Torque and power vs speed chrachteristics of DS HE-FSM

Moreover, the initial design has attained maximum power of around 70 kW at speed of 6000 rpm.
Nevertheless, with rise of speed, the value of power is slowly reduced until 48 kW at maximum speed. This
slowly reduction in power is due to core and eddy current losses on the outer stator. As a conclusion, the
proposed design of “DS HE-FSM” has realized adequate outcomes of maximum torque at high speed ranges.
It also confirms that proposed “DS HE-FSM” can be the favorite solution for aircraft applications where high
torque at high speeds is essential requirement.

6. CONCLUSION
This paper presents the design analysis and examination of DS HE-FSM. The investigated design
includes two stators within a segmental rotor. Using JMAG designer, performance evaluation of presented
design is examined based on 2D-FEA. The preliminary results of proposed design determines that the design
has produced acceptable values of flux output, smoother flux lines and high torque output. In addition to this,
back EMF, cogging torque, and flux distribution and flux lines have also been tested and confirmed that the
proposed machine would work on safe mood with satisfactory outcomes. The expected study of magnetic flux
and torque demonstrated that the suggested “DS HE-FSM” does have the potential to be further enhanced that
can be used for various applications in the aircraft.

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Int J Pow Elec & Dri Syst ISSN: 2088-8694  57

ACKNOWLEDGEMENTS
This research work is sponsored by “Research and Management center” University Tun Hussein Onn
Malaysia (UTHM), under research fund E15501.

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BIOGRAPHIES OF AUTHORS

Hassan A. Soomro was born in Nawabshah, Sindh, Pakistan, on May 01, 1985. He received his
B.E and M.E degrees in Electrical Engineering from Quaid-e-Awam University of Engineering
Science and Technology Nawabshah, Pakistan in 2008 and University Tun Hussein Onn
Malaysia (UTHM) in 2016 respectively. He has been with UTHM from April 2014 as Graduate
Assistant researcher. “Currently, He is doing PhD in Department of Electrical Power
Engineering, UTHM. His research interests include design and optimizations HE-FSM with”
segmental rotor structure.

Erwan Bin Sulaiman “was born in Johor, Malaysia, on August 31, 1978. He received his B.E
and M.E degrees in Electrical Engineering from University of Malaya in 2001 and University
Tun Hussein Onn Malaysia (UTHM) in 2004 respectively. He received Doctorate Degree in
Electrical Engineering from Nagoya Institute of Technology (NIT), Japan in 2012. He is
currently Associate Professor at Department of Electrical Power Engineering, UTHM. His
research interests include design optimizations of Flux Switching Machines.

Mahyuzie Jenal “got his birth in Johor, Malaysia, on December 4, 1977. He got his B.E and
M.E degrees in Electrical Engineering from Universiti Teknologi Malaysia in 2000 and
Universiti Tun Hussein Onn Malaysia (UTHM) in 2009. He has completed his PhD from
Universiti Tun Hussein Onn Malaysia (UTHM) in 2020. He has been with UTHM from June
2003 as instructor and selected as a lecturer in” 2009. His research interest is electric machine
design especially in permanent magnet flux switching machine.

Irfan Ali Soomro is a researcher. He received bachelor’s degree in “Electrical Engineering from
Quaid-e-Awam University of Engineering, Science and Technology, Nawabshah” Sindh,
Pakistan. Currently he is a full-time researcher at Universiti Tun Hussein Onn Malaysia
(UTHM). Currently, he is pursuing his research in electrical power engineering at the same
university consecutively. His research interest includes design of flux switching motor.

Laili Iwani binti Jusoh “was born in Besut, Terengganu, Malaysia, on August 2, 1987. She
achieved her B.E degree in Electrical Engineering form University of Tun Hussein Onn
Malaysia in 2010. After that, she obtained Master in Technical Vocational and Education from
UTHM in 2014. Currently, she is pursuing Ph.D at UTHM. Her research targets are mainly
related to single and three phase permanent magnet flux switching machines for light electric”
vehicles.

Mohd Zarafi Bin Ahmad “received his BE degree in electrical engineering from University
Technology Mara in 2003 and ME degree in electrical engineering from University Technology
Malaysia in 2006. He has been a lecturer at University Tun Hussein Onn Malaysia since 2006
where he received his Ph. D in 2017. His research interests include electric machine design” and
drive control.

Mohd Firdaus Mohd Ab “Halim graduated from Universiti Tenaga Nasional in Bachelor of
Electrical Engineering. He finished Master Degree of EEIT at University of Applied Science
Rosenheim, Germany. Currently he is a full-time researcher at Universiti Teknikal Malaysia
Melaka, Fakulti Teknologi Kejuruteraan. His reseach mainly focus in Energy Efficiency,
Renewable Energy and Electrical Vehicle. Currently he is full time studying Doctor Of
Philosophy In Electrical Engineering in Universiti Tun Hussein Onn (UTHM)”

Int J Pow Elec & Dri Syst, Vol. 12, No. 1, March 2021 : 51 – 58