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Research Article
Javier de la Cruz, Juan M. Ramirez* and Luis Leyva
1 Introduction
The energy conversion efficiency of electrical machines is
an important parameter to quantify energy production in
terms of cost. Efficiency depends on the machines physical capacity; that is, it is expected that bigger the
machines, higher the efficiency. However, increasing
physical size of machines implies an increment in the
cost. Therefore, there is a trade-off between rating, cost,
and the reachable physical size.
There is not a standard related to the efficiency of
multi-pole permanent magnet machines. Thus, in this
*Corresponding author: Juan M. Ramirez, Department of Electrical
Engineering, Centro de Investigacion y Estudios Avanzados, Av del
Bosque 1145 Col El Bajio, Zapopan, Jalisco 45019, Mexico, E-mail:
jramirez@gdl.cinvestav.mx
Javier de la Cruz, Department of Electrical Engineering, Cinvestav del
IPN, Zapopan, Jalisco, Mexico, E-mail: jcruz@gdl.cinvestav.mx
Luis Leyva, Department of Electrical Engineering, Cinvestav, Jalisco,
Mexico, E-mail: Luis.Leyva@cts-design.com
THD
h2
V1
Vh2
2 Specifications
Using conventional methods [19] and the previous experience [18, 20], an outer rotor generator for a wind turbine
application is designed. The prototypes specifications
are summarized in Table 1. Notice that the expected
efficiency is 92.7%, which is bigger than that specified
in the NEMA Premium standard [1].
PMSM
(a)
(b)
Figure 1 Outer rotor permanent magnet synchronous machine (PMSM) prototype: (a) testing and (b) coupled to a vertical wind turbine
Figure 2 Induced voltage on a 400 W PMSG two-phase prototype: actual and simulated results
Table 1
P
Nominal power
350 rpm
Poles
30 Structural elements Steel SCM35
Stator slots
72 Magnets
Neodymium N35
Phases
3 Core
Silicon steel, M19
Cogging torque 0.03 N m Efficiency
92.7%
p
a
3 Methodology
l
d
t
Design parameters
Modify design
Estimation of coil
inductance:
Run simulation under
load conditions
Torque and winding power estimation:
and
Table 2 presents the values of the modified physical parameters. Case 1 corresponds to the machine with the original
designed parameters. Cases 2 and 3 correspond to the
modifications on the diameter of the bottom slot, t. Cases
4 and 5 correspond to the modifications on the yoke length,
y. Cases 6 and 7 correspond to the modifications on the
polar arc percentage p. The polar arc percentage is
achieved by modifying the rotors diameter. This modification forces to change the slot depth l for maintaining the
original air gap. Cases 8 and 9 are related to variations on
the teeth width d. Cases 10 and 11 stand for the modifications on the air gap a. This is achieved by changing the
outer diameter of the stator. Cases 12 and 13 correspond to
modifications on the number of electrical wires-per-slot S.
For each modification, change of the wire gauge G to use
the available area-per-slot is required. Case 14 tests the
variation on the enlargement of slot depth l. Cases 15
and 16 correspond to modifications on the skew angle at
the poles p. Finally, cases 1719 find out about the reductions in the pole length i.
Design parameters
Modify design
Estimation of induced voltage:
Yes
No
END
3.5
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
2.5
2
M14
M19
M27
M43
1.5
1
0.5
1
3
4
5
6
Magnetic field intensity (H)
9
10 5
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
0 0
Table 2
Changes?
S2
<
5.98
5.98
5.98
7.00
5.00
5.98
5.98
5.98
5.98
5.98
5.98
5.98
5.98
5.98
5.98
5.98
5.98
5.98
5.98
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.0
2.0
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
26.6
26.6
26.6
26.6
26.6
29.9
23.9
26.6
26.6
26.6
26.6
26.6
26.6
28.4
26.6
26.6
26.6
26.6
26.6
1.70
1.70
1.70
1.70
1.70
1.70
1.70
1.85
2.00
1.70
1.70
1.70
1.70
1.70
1.70
1.70
1.70
1.70
1.70
4.0
3.6
4.4
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
9.5
6.3
3.2
p %
Core
55
55
55
55
55
50
60
55
55
55
55
55
55
55
55
55
55
55
55
33
33
33
33
33
33
33
33
33
33
33
29
37
33
33
33
33
33
33
14
14
14
14
14
14
14
14
14
14
14
13
15
14
14
14
14
14
14
0
0
0
0
0
0
0
0
0
0
0
0
0
0
3
6
0
0
0
104
5
4.5
M14
M19
M27
M43
Reluctance (H1)
3.5
3
2.5
2
1.5
1
0.5
0
1.4
1.5
1.6
1.7
1.8
Magnetic flux density (B)
1.9
6,000
5,500
Output
100 rpm
150 rpm
200 rpm
250 rpm
300 rpm
350 rpm
5,000
4,500
4,000
3,500
3,000
2,500
2,000
1,500
1,000
500
0
0
100
150
200
250
Angular velocity (rpm)
300
350
3.5 VTHD
M14
M19
M27
M43
0.1
VTHD (%)
0.08
0.06
0.04
0.02
0
9 10 11 12 13 14 15 16 17 18 19
Case of study
2.2
2.1
2
Saturation M14
1.9
1.8
M14
M19
M27
M43
1.7
1.6
1.5
1
3
4
5
Magnetic field intensity (H)
7
104
130
Case 1
Case 17
Case 18
Case 19
Voltage (V)
90
50
10
30
70
110
0
0.004
0.008
Time (s)
0.01
0.016
Figure 16 Output voltage waveforms for cases 1 and 1719 decreasing the pole length (steel M14)
torque has an increment of 33% with respect to the cogging torque [24]. The cogging torque of a typical 5 kW
commercial machines ranges between 2 N m and 3 N m
[2426]. Figure 19 shows the cogging torque for all case
studies in Table 2.
The cogging torque increases from four to five times
for the following modifications:
Polar arc percentage reduction from 55% to 50%.
Air gap reduction from 1.5 mm to 1.0 mm.
Slot depth increase from 26.6 mm to 28.4 mm.
On the other hand, increasing the air gap from 1.5 mm to
2.0 mm, the cogging torque decreases about 50%. The
cogging torque gradually decreases when a skew angle in
the magnetic poles is applied.
Making a correlation of the results of the last sections, it is possible to claim that,
it is not appropriate to reduce the pole length (cases
1719) to reduce the VTHD because the output power
will decrease until 58%.
10
12
10
Case 7 M14
8
6
4
2
0
9
11
13
Harmonic order
(a)
15
17
19
10
0.8
Case 18 M14
0.6
0.4
0.2
0
1
9
11
13
Harmonic order
(b)
15
17
19
Figure 18 (a) Harmonics of voltage with steel type M14, case 7 and (b) harmonics of voltage with steel type M14, case 2
0.4
M14
M19
M27
M43
0.35
Torque (N m)
0.3
0.25
0.2
0.15
0.1
0.05
0
9 10 11 12 13 14 15 16 17 18 19
Case of studies
4 Conclusions
The aim of this research was to find some practical rules
to improve designs of outer rotor PMSMs, to reach an
11
12
Nomenclature
p
i
a
s
t
y
l
d
S
Vn
FEA
B
N
I
A
f
H
p
FFT
t
cp
Cw
R
G
<
L
VTHD
PMSG
References
1. WEQ. Energy efficient programs. Available at: http://www.Weg.
Net/Green/_Files/Energy-Efficiency-Global-Directives_-_Presen
tation.Pdf, August 2013.
2. Ducar IM, Ion CP. Design of a PMSG for micro hydro power
plants, international conference on optimization of electrical
and electronic equipment (OPTIM). Brasov, Romania, 2426
May 2012.
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