Robust hybrid optimization design for axial flux-switching transverse-flux permanent magnet wind generator

This paper presents a robust hybrid optimization approach for a novel axial transverse-flux permanent magnet (TFPM) wind generator designed for direct-drive wind turbines. The generator features permanent magnets embedded in the middle arm of a ƎE-shaped stator core, enabling high torque density and modular manufacturability. To address the challenges of its complex 3D magnetic flux and interdependent parameters, a three-layer multi-objective optimization framework is employed. Taguchi analysis identifies critical design variables, response surface methodology develops accurate regression models, and constrained sensitivity analysis refines the design through targeted 3D finite element evaluations. Experimental validation confirms that the proposed optimization strategy significantly enhances generator performance, including a 64.7 % reduction in total harmonic distortion, a 10.1 % improvement in power factor, and a 66 % decrease in cogging torque. Thermal and structural analyses further demonstrate safe operation and mechanical stability. These results highlight the effectiveness of the proposed method in delivering a reliable, efficient, and compact generator solution for next-generation direct-drive wind energy systems.