Axial-flux permanent magnet machines for micropower generation

This paper reports on the design, fabrication, and testing of an axial-flux permanent magnet electromagnetic generator. The generator comprises a polymer rotor with embedded permanent magnets sandwiched between two silicon stators with electroplated planar coils. Finite element simulations have been carried out using ANSYS to determine the effects on performance of design parameters such as the number of layers in the stator coils, and the rotor-stator gap. The effect of including soft magnetic pole pieces on the stators has also been studied. A prototype device with a diameter of 7.5 mm has been tested, and shown to deliver an output power of 1.1 mW per stator at a rotation speed of 30000 rpm. The generator has been integrated with a microfabricated axial-flow microturbine to produce a compact power conversion device for power generation and flow sensing applications.