Impact of Manufacturing and Material Uncertainties in Performance of a Transverse Flux Machine for Aerospace

3-dimensional (3D) flux machines accommodate many design and analysis challenges. Transverse flux machines (TFMs) are mostly useful for low speed, high torque applications but in this research a fault tolerant transverse flux alternator with segmented stator has been prototyped and several important design and manufacturing challenges have been thoroughly investigated as different scenarios. The proposed machine consists of axially separated, 4-single phase to achieve low speed power of 40 Watts at 400 revolutions/minute (rpm). In addition, the machine must achieve several high-speed specifications at 15,000 rpm. It is demonstrated that the proposed TFM could be an alternative to more conventional radial flux machines in aerospace as validated within the paper. However, the necessity of stator segmentation and the use of soft magnetic composites for the proposed 3D flux machine lead to many important design and optimization considerations. Therefore, this paper investigates the manufacturing and material uncertainties in a TFM for an aerospace application. The results indicate that transverse flux alternator might be an option as an aerospace alternator but the peak performance of the prototype machine is still far from the 3D models investigated using finite element electromagnetic simulations.