Analysis and Testing of a Tubular Linear IPM Generator for Free Piston Engines Applied to Linear Range Extender Systems

This text involves the analysis and application of the tubular linear generator with interior permanent magnets design for free-piston systems using Ansys-Maxwell.A comparison of the Linear generator, whose primary part (stator) consists of 6-piece silicon steel sheet modules and its solid models including 2D and 3D models, was carried out.Although the solid models have the same motion, the effect of the decrease in packing ratio in the solid model on induced voltage, iron loss, output power, and thrust force has been examined.Additionally, by calculating the voltage constant and force constant, the percentage decreases have been determined.While the results obtained from the 2D and 3D models are quite close, a decrease of approximately 32.39% in the voltage constant and 28.06% in the force constant has been observed due to a 50.28% decrease in the packing ratio.Moreover, the reduction in approximate total mass is 38.18%, as well as the reduction in total approximate cost is 9.6%.Based on the findings from the study, a prototype of the generator has been manufactured, and an unloaded experiment has been conducted through a pneumatic setup.These experiments aim to determine how effective the design is in practical applications.