A Novel High-Order-Harmonic Winding Design Method for Vernier Reluctance Machine with DC Coils across Two Stator Teeth

Vernier reluctance machine with DC field coils in stator is a competitive rare-earth-free design for variable-speed industrial applications due to its robust structure and controllable excitation, while its torque density is relatively disadvantageous. To address this issue, this paper proposes a new armature winding design method for VRM with DC field coils across two stator teeth. The key is to break the traditional winding design principle based on the flux modulation effect of fundamental DC field harmonic, and instead, reconstruct a novel harmonic winding to enhance the utilization factor of the modulated high-order DC field harmonics. By this means, the torque density can be improved by 75.6% compared to the existing poor counterpart. In this paper, the machine structure and operation principle are introduced, with emphasis on the high-order DC field harmonics distribution rule and its influence on the armature winding design. By finite element design and optimization, a comparative study is performed to evaluate the machine performance using two different winding configurations with variable slot pole combinations. A prototype is fabricated and tested, and the results agree well with finite element analysis, which verifies the feasibility and advantages of the proposed winding design method.