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1, JANUARY 2013
High power machine has become a large market for wind power and ship propulsion electric, among other applications. Since the size
of these machines is much larger than conventional industrial ones, optimum design must be considered in order to reduce the material
cost and increase profitability. In this paper, a simple analytic optimization algorithm is used to maximize the apparent airgap power
transferred under tangential stress constraint. In this approach, close related expressions between the main design variables, operational
restrictions, and external dimensions are derived to build the mathematical structure of the optimization process. To improve the torque
capacity estimation of the designed machine, a correction procedure, based on the previous result, is used to remove the idealizations
considered for the initial design. Close agreement with the finite element analysis results are found with this approach, which is based
on analytical method.
Index Terms—Optimization methods, permanent magnet (PM) generator design, tangential stress, wind power applications.
L
Stator induced voltage. OW maintenance, high reliability and efficiency require-
Frequency. ments for wind power generator tend to use gearless di-
rect drive or semi geared machines. These types of machine are
rms stator current.
characterized by the large dimensions and weight but also with
rms current density. requirement on high efficiency and compactness. Similar situa-
Copper fill factor. tion is found in modern propulsion drive systems for large navy
vessels, where efficiency and compactness is required in large
Carter coefficient. synchronous machines [1], [2]. At this point, it is clear that per-
Lamination stack factor. manent magnet (PM) used on electric machinery offers these
characteristics for a wide range of applications. Optimal ma-
Electrical power waveform factor.
chine design must be oriented to maximize power production
Winding factor. with adequate operational condition for the PMs excitation sys-
Iron losses factor correction. tems based.
In high power applications, such as wind power and ship
Active stack stator length. propulsion, the torque capacity is limited by the ability to re-
Leakage inductance. move the heat from the machine. In order to keep the interior
temperature in a safe range, air or other fluid is forced to flow
Magnetizing inductance. through the active material, to remove the heat created by the
Stator number of phases. losses during the machine operation. Main sources of heat are
copper and iron losses which are closely related with the linear
current density and the airgap magnetic load. The relation be-
tween these two variables per unit of airgap perimeter defines
Manuscript received September 19, 2011; revised November 10, 2011, De-
cember 14, 2011, February 29, 2012, and May 14, 2012; accepted June 25, 2012. the tangential stress and this eventually with the torque pro-
Date of publication July 10, 2012; date of current version December 19, 2012. duction capability of the machine [3], [4]. There are a number
Corresponding author: J. A. Tapia (e-mail: juantapia@udec.cl).
of cooling methods used on high power density machines to
Color versions of one or more of the figures in this paper are available online
at http://ieeexplore.ieee.org. improve performance and security [5]. Therefore, ultimately,
Digital Object Identifier 10.1109/TMAG.2012.2207907 cooling issues have direct relation with this design variable.
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TAPIA et al.: OPTIMAL DESIGN OF LARGE PERMANENT MAGNET SYNCHRONOUS GENERATORS 643
Limiting on its value assures adequate operation of the gener- winding as follows [15], [16]. The expression for the tangential
ator and secure temperature of the materials, particularly PMs. stress is derived using the same quantities.
Optimal machine design should maximize the energy deliv-
ered by the generator which provides revenue for the investor. A. Induced Voltage
It also minimizes material use to reduce cost and to guarantee The induced voltage over one phase of a distributed stator AC
safe operation for the machine. Optimization algorithms are winding can be expressed as
available to improve the electromagnetic (EM) design based on (1)
algebraic relationship, physical quantities, and energy balance;
some of them are strictly mathematical approximation and where voltage peak value is
some are other procedures with more physical meaning. Dif-
ferent techniques with extended and documented results in the (2)
literature give us a chance to be applied on electrical machines
design [6]–[12]. However, proper selection of the procedure For the present case, a sinusoidal airgap flux density is assumed
has to combine simplicity precision and resources consumption with as peak value.
to achieve valid and useful results. In [13] and [14], authors
B. Current Expression
address the split ratio or inner to outer ratio optimization for
surface and interior PM motors, using analytical approach. The Since the typical load of a generator is a power electronic con-
torque to rotor volume ratio is maximized under fixed copper verter type (nonlinear load), stator current waveform can be far
losses constrain. Slot area expressions for different design from sinusoidal. Therefore, considering any current waveform,
parameters influence are obtained considering equal iron mag- it is possible to define the current waveform, , factor as
netic loading on the stator yoke and tooth. Results presented (3)
are valid for low power motors where such an assumption is
applicable; however in large PM machines where stator teeth Introducing the linear stator current density expression, ,
are more magnetically stressed than the stator yoke, therefore a the maximum value of the current waveform is
different value for each section of the magnetic circuit must be
considered. This effect will help to increase heating problems, (4)
which is relevant, particularly when permanent magnets are
used for excitation, since their properties are very sensitive to where
the temperature. Selection of the proper iron magnetic loading
has to be part of the design process considering operational (5)
conditions and material properties.
In this paper, an application of a widely know mathematical and finally, the current expression becomes
method is used to optimize the stator machines size based on (6)
maximizing the airgap Apparent Power value under
a maximal tangential stress constrain. This solution provides
the algebraic relationship between physical unknowns (stator C. Airgap Power Expression
dimensions), operational electric and magnetic values and tran- The average apparent power transferred through the airgap
scendental function to optimize (inner to outer diameter ratio). over one period of the power source can be written in terms of
The proposed method was developed for the particularities the instantaneous induced voltage and the current equations as
present on high power PM machines where the mechanical and
thermal issues are more demanding, compared to traditional (7)
low power machines. The algorithm provides the optimal outer
to inner diameter ratio for a given value of the operational
constrain. Using these results, a finite element analysis (FEA) replacing (1) and (6) in (7) results
validation is carried out and a correction procedure is developed
to improve the torque estimation. Hypotheses established for (8)
the ideal conditions to calculate the optimal diameter ratio are
removed to include more realistic situations such as flux leakage The maximum apparent power available to transfer electrome-
chanically from the stator to the rotor (motor operation) or vice
and magnetomotive force drop on the magnetic circuit.
versa (generator operation) is expressed in (8).
Finally a flow chart summarizes the design procedure to achieve
optimal design and electromagnetic torque requirement. D. Tangential Stress
Tangential stress establishes the relation between the total
II. ANALYTICAL RELATIONSHIPS electromagnetic torque developed by the machine per unit of
rotor volume. This merit index has intimate relation with the
In order to establish the analytical relationship between the machine construction, type of excitation source and cooling
electromagnetic variables, stator geometrical dimensions, and method [3]. The linear current density and the magnetic flux
constrain functions, the airgap apparent power expression is de- density (and their angle) define the maximum value achievable
veloped in terms of the induced voltage and current on the stator torque per rotor volume. For regular commercial silicon iron,
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644 IEEE TRANSACTIONS ON MAGNETICS, VOL. 49, NO. 1, JANUARY 2013
(9)
therefore peak linear current density can be written using (5) These last two parameters represent the saturation ratio of
and (10) becomes the stator teeth and stator yoke iron respect of the airgap flux
density. Adequate selection of the iron magnetic load should be
(11) based on operational frequency value and iron magnetic prop-
erties in order to tolerate a reasonable amount of losses. At 50
Consequently, (9) can be rewritten as and 60 Hz machine frequency operation, the author in [16] sug-
gests values for and of 0.55 and 0.62, respectively, for
(12) regular silicon iron. For higher frequencies, there are some sug-
gestions for the magnitude of the flux density in different part
of the magnetic circuit [18] that can be considered.
This last expression relates the linear current density with the
total slot area available. Optimization procedure uses this rela- B. Total Stator Slot Area
tionship to achieve maximum for a given outer machine From the stator geometry depicted in Fig. 1, the following
diameter. At the same time, this index is used to establish a op- two expressions can be written:
erational constraint to the optimization process.
(17)
III. GEOMETRICAL RELATIONS (18)
In general, for simplicity, the stator windings of low and
medium power electrical machinery are unsorted and allocated therefore the total stator slot area becomes as
by hand or other type of mechanism on the slots. They can
easily be fixed using tooth tip performed during the punching (19)
process. In this manner, stator slots are trapezoidal and teeth are
rectangular. On the other hand, in large machines, windings are where the function is defined by
prefabricated with solid or holed conductors with transposition
and proper insulation. As a result, manufacturing and repair (20)
process is simple and less time consuming. A schematic rep-
resentation of a larger synchronous machine stator lamination with the and constant are
is depicted in Fig. 1, for the present analysis only the active
magnetic portion of the iron is considered. (21)
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TAPIA et al.: OPTIMAL DESIGN OF LARGE PERMANENT MAGNET SYNCHRONOUS GENERATORS 645
C. Function:
With (5), (10), and (19), the expression for the airgap apparent
power, (8), can be expressed as
(23)
(24)
Fig. 2. Optimal diameter ratio for airgap VA for teeth magnetic loading
. Solid line: rectangular slot optimization approach. Dotted line: trape-
zoidal slot optimization approach [16], [17].
Equation (23) states that for given values of current density
and airgap flux density, current and voltage waveforms, number
of pole and operational frequency, the is maximal when
function , defined by (24), is maximal. This equa-
tion is only dependant on the diameter ratio and the iron mag-
netic loading across the magnetic circuit. At this point, max-
imum power is transferred through the airgap for a specified
outer stator diameter and axial active stack length.
In order to evaluate this function, a relation of 0.8125 is used
as a to ratio. This value indicates that stator teeth are ap-
proximately 23% more saturated than the stator yoke, which is a
reasonable approximation for synchronous machines. In Fig. 2,
several functions defined by (24) are plotted in terms of the
inner to outer diameter ratio (solid lines). Additionally,
function [16], [17] for trapezoidal slot geometry is depicted in
the same figure (Fig. 2, dotted line). It is clear that the differ-
ences on the optimum values found using each approach will
reach to dissimilar stator geometry. Optimum values for the
function for the present case are located between 0.6 to
0.67 of the diameter ratio as the parameter varies. These re- Fig. 3. Tangential stress as a function of the diameter ratio with teeth magnetic
loading as a parameter.
sults indicate that the optimum inner diameter is approximately
one half of the outer diameter with deep slots and thin tooth.
stress is limited to a maximum value specified by . Then,
However, this diameter ratio leads in a high value of stator slot
constraint function can be written as
area, resulting in an unacceptable high tangential stress com-
pared with those recommended values [3] for the optimal design
area, as is shown in Fig. 3. Consequently severe heating prob-
lems removal arises, a limit on the tangential stress value must
be imposed to reduce the problem.
D. Constrain Function
Introducing (19) and (20) in (12), the tangential stress equa- (26)
tion, in terms of the diameter ratio expression, becomes
The extended function to be optimized is formulated as (27),
where and are the function and
the constraint function, respectively, expressed by (24) and (26)
(25) and is the Lagrange multiplier:
On Lagrange multiplier formulation, a constrain function,
, must be defined in terms of the maximum value
(27)
allowed for the restricted variable. In this case, tangential
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646 IEEE TRANSACTIONS ON MAGNETICS, VOL. 49, NO. 1, JANUARY 2013
TABLE I
OPTIMAL DESIGN STATOR LAMINATION
Fig. 4. New optimal diameter ratio for airgap VA under tangential stress con-
strain with teeth magnetic loading as a parameter.
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TAPIA et al.: OPTIMAL DESIGN OF LARGE PERMANENT MAGNET SYNCHRONOUS GENERATORS 647
TABLE II
FEA INPUT DESIGN DATA
where and are the flux intensity on the teeth and stator
yoke, respectively, calculated from the BH iron characteristic
(Appendix A). For this particular evaluation, stator and rotor
yoke depth are considered to be equal. Electromagnetic torque
obtained from the optimized design (considering the restricted
tangential stress value imposed to the design procedure) is cal-
culated using FEA. This result is depicted in Fig. 8. At the same
time, torque calculated by (29) is also presented in this figure
exhibiting a proportional dependence with the tangential stress.
As is indicated, these two torque values came from the same
tangential stress. Significant differences between the ideal case
(29) and FEA are found as the tangential stress increases, which
leads to a poor torque estimation based on (29).
Several factors not considered on the ideal case torque calcu-
lation represented in (29) are the main source of this difference.
Fig. 7. Optimal stator design lamination for constant airgap diameter. Airgap
diameter constant at 1562 mm.
Detailed discussion about these non-ideal conditions are pre-
sented in the next section.
A. Optimal Design and Finite Element Evaluation B. Ideal and Non-Idealities Issues on Torque Production
Using the optimization algorithm, a set of machine stators is For the ideal case, Fig. 9(a), torque is the resultant effect of
designed for different tangential stress values considering stator a continuous superficial sinusoidal current distribution, inter-
inner diameter as a design input. In general, in a situation when acting with an equally sinusoidal airgap flux distribution and
there is no restriction on space, airgap diameter is considered as the shift angle between them . This entire phenomenon takes
a design data which leads, using this procedure, to determine the place in a smooth, continuous, and homogeneous airgap surface
outer diameter with the optimal diameter ratio defined by (28). and infinity permeable stator and rotor iron [19]. The optimal
Under this circumstance, output torque is proportional to the torque production occurs when both distributions are in phase
tangential stress as expressed in (29) for a given stack length [3]: . The corresponding phasor diagrams that represent
these ideal conditions are presented in Fig. 10(a) and (b), re-
(29) spectively. With this, there are not leakage flux and mmf drops
along the magnetic circuit and all the current components con-
In Table II, design variables are listed for the optimal design tribute to torque production, and terminal voltage corresponds
to calculate the machine dimensions for the FEA solution. to the airgap voltage, induced from the resultant flux.
The resultant stator lamination geometries achieved from this From the same equation and (2) and (4), it can be easily
approach are depicted in Fig. 7. It is clear that, as the tangential demonstrated that electromagnetic torque for the ideal case is
stress increases, more slot area is required to allocate higher given by (31) [see (30) at the bottom of the next page]:
stator current; therefore slots become deeper and deeper (rising
(31)
in Fig. 1), and since the iron magnetic loading is the same in
each evaluation, teeth have the same airgap width ( in Fig. 1).
and the torque angle from Fig. 10(b)
Magnet geometry is determined in order to establish an airgap
flux density value taking into account the BH curve and
(32)
magnetic loading of the iron. PM height is calculated by (31),
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648 IEEE TRANSACTIONS ON MAGNETICS, VOL. 49, NO. 1, JANUARY 2013
(36)
(37)
Fig. 9. 80 kPa optimal design. a) Fields distributions for torque production on
the airgap: ideal case. b) Non-ideal magnet and stator current allocation. For the non-ideal case , the slotted stator surface is in-
cluded by the Carter coefficient; at the same time, the increment
of the magnetic circuit reluctance due to the mmf drop effect
along the magnetic circuit and the nonlinear BH characteristic
of the magnetic steel can be reflected as an additional airgap
length on top of the physical one:
(38)
(30)
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TAPIA et al.: OPTIMAL DESIGN OF LARGE PERMANENT MAGNET SYNCHRONOUS GENERATORS 649
TABLE III
BH CURVE
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650 IEEE TRANSACTIONS ON MAGNETICS, VOL. 49, NO. 1, JANUARY 2013
Authorized licensed use limited to: ULAKBIM UASL - Balikesir University. Downloaded on May 21,2021 at 21:02:16 UTC from IEEE Xplore. Restrictions apply.