This paper presents a design process and a detailed multiphysics analysis of an axial-flux permanent-magnet synchronous machine for large-power direct-drive applications. The machine in this paper is 130 kW at 26 r/min with a dual-stator inner-rotor structure. A stator core that is assembled with segmented and prewound teeth is first proposed and applied in a large-power axial-flux permanent-magnet machines (AFPMs). Through this method, the challenges of manufacturing large-diameter AFPMs can be solved. A novel water-cooling system is embedded in the machine to transfer the heat. In addition, the assembling procedure and the manufacture process are also proposed, and a novel distributed follower bearing is used to reduce the deformation and stress of the rotor disk. Finally, based on the multiphysics design, a prototype machine is manufactured and tested. The experiment results match well with the finite-element analysis.
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Li et al. (2019) studied this question.