Development and Design Optimization of a Single-Phase Doubly-Fed Flux-Switching Permanent Magnet Machine

Demand for brushless alternatives to the series universal motors and induction motors in domestic applications and automotive applications is increasing. Among the available candidates, single-phase flux-switching permanent magnet (SP-FSPM) machines have gained attention due to a simpler magnetic structure and control system. However, their torque density remains limited. Therefore, a SP doubly-fed FSPM (SP-DF-FSPM) machine is developed in this paper which features an additional set of armature windings on the rotor. By effectively utilizing the rotor slot area, the proposed SP-DF-FSPM machine enhances electrical loading and torque density while providing inherent fault-tolerant capability, a critical addition compared with conventional SP-FSPM machines. A comprehensive parameter-sensitivity analysis is conducted for a 10-stator-pole/10-rotor-tooth configuration to optimize key geometric parameters for the maximum torque and reliable self-starting operation. The electromagnetic performance of an optimized design is evaluated and compared against a conventional SP-FSPM machine. The results show that the SP-DF-FSPM machine can achieve a 24.75% higher torque output, improved efficiency, and enhanced power factors under the healthy condition. Moreover, the machine can deliver 63.5% and 36.0% torque when operating with only stator and rotor windings, respectively, demonstrating the fault-tolerant capability. Experimental validation via an SP-DF-FSPM prototype shows close agreement with simulation results.