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An axial flux permanent magnet single-rotor generator has good potential in various applications that require high efficiency, prolonged service life, as well as low mass and dimensions. However, the effect of cogging torque diminishes generator efficiency and flexibility of functionality. The effect of cogging torque arises because of a small air gap between the stator teeth and the rotor. In this article, we suggest that shifting the opposite teeth of the stator to the optimal angle can reduce the effect of cogging torque. A special axial flux permanent magnet generator is developed to choose the optimal disposition of the permanent magnet and stator teeth in the frame. The impact of the optimal angle on the cogging torque, output power, and generator efficiency is investigated. This analytical study with experimental testing proves that the optimal angle between opposite teeth can significantly decrease cogging torque and improve output power and efficiency. The results show that cogging torque decreases significantly (4-5 times) at an optimal angle of 7.5° as compared with that of other angles, although magnetic flux and output power decline slightly but efficiency increases.

The Effects of Cogging Torque Reduction in Axial Flux Machines