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A novel flat winding topology has been proposed as an alternative to conventional windings with stranded round wires and other bar wound windings. The proposed winding is manufactured from thin conductor sheets by industrial tools such as stamping press, laser cutter, or water jet. As these tools are widely used in the production of electric machines, the flat winding topology can provide ease of manufacturing without significant modification to the production line. Besides, superior current ratings, shortened end windings, and high fill factors are other advantages of flat winding. Its performance is measured by comparison study between flat wired prototype machine and the stranded wired machines with similar ratings presented in the literature. The proposed winding is implemented on an axial flux permanent magnet machine. Analytical modeling is presented, including field modeling, voltage, torque derivations, and loss modeling. Then, experimental verification of a 1.4‐kW and 26‐Nm prototype with copper and aluminum flat windings is presented, and the performances of two are compared.

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With the increased demand for renewable energy resources, the direct-drive wind turbine generators have been studied intensely in the last few decades. One megawatt direct-drive axial flux permanent magnet generator is presented. The novelty in this design is that instead of conventional stranded wires, the windings of the generator are manufactured from a conductor sheet by cutting and bending processes. This creates critical advantages of superior current ratings, ease of manufacturing, and reduced structural mass. An optimization study is conducted with the presented fully analytical model, and the optimum design is compared with the other wind power generators presented in the literature. At the end, a 1 MW, 480 kNm, and 16 tons direct-driven generator is achieved.

Although axial‐flux permanent magnet machines have high torque densities, challenges regarding mass production of stators make them a less appealing choice. Printed circuit board (PCB) axial‐flux machine is a type of machine with a stator that is made of layers of PCB. Given the precise, fast, and cheap mass production capabilities of PCB manufacturers, PCB axial‐flux machines stand as a viable alternative for conventional round‐wire winding machines. In this study, five different winding topologies are compared. Their induced phase voltages and torque are calculated using the developed magnetic scalar potential method and finite element analysis (FEA). Proposed windings are tested on a 16‐pole, 2000‐RPM, double rotor‐single stator axial‐flux permanent magnet synchronous machine. Results showed that the parallel winding had the smallest resistance and loss. Moreover, radial and concentric winding had the highest induced voltage and torque while the radial winding had 20% less phase resistance than concentric. Also, the induced voltage of radial winding had the smallest total harmonic distortion in comparison with other winding types. A novel unequal width parallel winding is proposed and it is compared with parallel winding separately. It is found that by simply increasing the cross‐section area of wave windings, it is possible to decrease copper loss by 17%.