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Li Li David Dorrell
University of Technology Sydney University of the Witwatersrand
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Abstract — High speed brushless permanent-magnet high speed operations, liquid cooling method is more effective
generators (HSBPMGs) may be the most suitable choice for small than air cooling, but liquid in jackets alone cannot effectively
solar co-generation systems due to a variety of merits. For cool the inner rotor and windings, so self-ventilation may be
instance, they offer substantial reduction in size, and thermally
needed along with liquid cooling. In [14] effective cooling
excellent high-power density, which reduces the running costs with
method is presented and also thermal analysis for different rotor
good performance and reliability. Moreover, high efficiencies i.e.
over 90%, light-weight, low operating temperature, high
types are discussed.
insulation, no brushes/slip rings and almost negligible cogging The design approach demonstrated in this study is elaborated
torque make HSBPMGs ideal for co-generation systems. However, for a particular type of high speed PM machine. Basic machine
because of the very high rotor speed and high stator frequency, the specifications are set to required power of 660kW, required
design of HSBPMG is quite different from designing a speed of 60,000 rpm, and output voltage of 700V. Geometry of
conventional generator with low speed and low frequency. As the the machine is set to 24 stator slots and 2 poles, and 3-phase
speed increases, the losses and temperature go up, and thus careful
machine. The number of slots per pole per phase is q = 2. There
attention is needed while selecting the design parameters and
material for the machine. This paper is aimed to use the basic
are number of options that can be set for the rotor topology in
design process for HSBPMGs running at 60,000rpm, with 6.6kW Motor-CAD, U-shaped magnets are used with circular ducts in
capacity keeping the losses minimum by using an appropriate this design which help to reduce the high temperature and losses.
material and cooling method. Finite element analysis of the Concentrated winding is used to achieve the shortest possible
machine is carried by using Motor-CAD simulation software, and length of the machine; winding is set to double layer overlapping
modeling of a prototype machine is presented. and the number of turns per coil is 8 with 224 conductors per
slot. Magnet material used in this design is 6.5%SiFe, which is
Keywords—high speed brushless permanent magnet generators excellent to reduce the iron losses and has a very good operating
(HSBPMG); Co-generation; Motor-CAD. temperature range. In thermal analysis, water jackets are used in
housing for cooling and windings are set to self-ventilate.
I. INTRODUCTION Electromagnetic and thermal analysis of the machine is carried
In past few years, increasing demand of green energy and to by using Motor-CAD simulation software. Finally, all the results
minimize the dependence on fossil fuels have provide a route to are verified by finite element analysis.
worldwide combination of renewable energy generation. Mainly
there are two main technologies which are mostly focused: - II. DESIGN PROCEDURE
wind and solar. Concentrated solar thermal power (CSP) Designing high speed BPM generator is more
integrated with co-generation system is one of the promising complicated than designing a conventional generator. Because
solutions for distributed power generation as discussed in [1]. In of high frequency and high losses, all the parameters need to be
regions with low transmission capabilities smaller power plants selected carefully.
are better idea than to a large power plant due to their cost
effectiveness. In electrical machines theory, the output power is In this paper 6.6kW/60,000rpm HSBPM generator is
directly proportional to the speed of rotor, higher speed, would designed. In first step, basic requirements of the module need to
lead to higher output power with reduced size. Permanent be decided, secondly selection of rotor and stator is done. Two
magnet machines with high rotor speed operations are the best
common topologies of stator which are mostly used in high
candidates for small co-generation system as they have simple
structure and higher power density as discussed in [2]. speed applications: slotted stator, slotless stator. Slotted stators
Designing high speed brushless permanent magnet (BPM) offer high torque density and high acceleration, selected for the
generator is quite different from designing a conventional design. Radial flux interior permanent magnets (IPM) rotor is
generator. In high speed operations, the frequency and the selected, as it offers low cogging torque and higher peak-to-
temperatures of the rotor are very high which leads to higher peak ripple torque. Selection of material is very critical in high
losses and need careful attention while selecting the design speed BPM generator design. A material which offers low
parameters as discussed in [3]. losses and has capability to stand with higher temperature needs
to be chosen. Selection of pole number, number of slots, number
Different design topologies of high speed BPM generator of phases, number of slots per pole per phase and winding
were presented by the researchers in past few years presented in
layout are very important constraints which affects the overall
[4-6]. Different design features of HSBPMG have been
efficiency of designed generator.
investigated in [7-9]. The potential and limits of HSBPM
machines, selection of magnet, rotor and stator material, rotor
and stator topologies and advantages of using retaining sleeves Finite element analysis (FEA) is done using Motor-CAD.
are illustrated in [10]. Reference [11] presented the design Motor-CAD provides the ability to quickly and easily perform
solution of high speed permanent magnet (PM) machine for a electromagnetic and thermal performance tests on prototype
flywheel application, also rotor losses reduction techniques are designs. Results are matched and verified with calculated
discussed. A high speed PM machine which operates in elevated values. Finally, thermal analysis is done and temperatures are
temperature environments with specification of 23kW, 84krpm calculated. If the results are not verified machine calculated
with a torque density of 50kNm/m3 is discussed in [12]. Different dimensions, rotor and stator structure and selected material
materials for high speed PM machines are discussed in [13]. In would be modified.
2
δ=
ωμ σ Fig 2. Phasor circuit of the machine
Winding Losses winding in air cause losses as well, power Machines are basically sized for rated torque capability
is needed to control the drag resistance of rotor cylinder. rather than power, output torque is proportional to product of
Different gases or fluids are also used in between rotor and rotor volume and shear stress, air-gap shear stress is proportional
stator, so winding losses is a function different operating to the product of air-gap electrical and magnetic loading. Shear
conditions such as temperature, density, the pressure of these stress is calculated as.
fluids/gases and the rotational speed of the shaft. Winding loss τ ∝ K z .Bg
can be estimated by the following equation.
Typically for liquid cooled machines the value of shear stress
= is 10-20Psi, we will use 15Psi for our design. We have discussed
the tip speed previously, with the assumed value of 200m/s. we
can use the following fundamental power equation to find out VIII. FINITE ELEMENT ANALYSIS (FEA)
the stack length and rotor radius.
A. Machine’s geometry and windings
P = 2.π .R.LST .τ .Vtip Geometry of the machine is set as; housing is round, slot
type parallel tooth in stator. Rotor topology is set to u-shaped
We will assume the L/D ratio to be 2.5, air-gap flux density to
inner magnets with circular rotor ducts for ventilation. Stator
be 0.8T, slot height 15mm and slot fill fraction to be 0.5. We can
calculate all design parameters using MATLAB code and given and rotor dimensions in radial view as calculated in matlab. The
in table 2. resulted geometry is shown in fig 1. Winding type is selected as
overlapping; the winding definition is defined by wire size,
The phasor relationship between internal voltages ( ), terminal which is set to be 0.885mm and 0.800mm from the metric table
voltage ( ) and the synchronous voltage drop is used to get the and the material between the liner and lamination is set as air.
terminal voltage and current of the machine as shown below.
= −( . . ) − . .
Once the basic parameters are known in depth analysis is done.
To get a better understanding pre-existing database of the same
kind of machines need to have a look. These data bases are
helpful to choose input parameters. This data can be collected
from several firms including ATE in Germany, Rueland electric
in the USA and E und A in Switzerland given in the appendix,
from all these databases and analysing different machines the
following input parameters are developed. Fig 3. Radial and axial view of the machine
Machine Size:
Machine Diameter = 0.195 m Machine Length = 0.257 m MMF harmonics of the machine are analysed, no odd harmonics
Rotor radius = 0.032 m Active length = 0.160 m are detected in this design which depicts voltage waveform is
symmetric about the centre of the rotor flux. Secondly winding
Slot Avg Width = 8.050 mm Slot Height = 25.000 mm
factor is analysed. Because of the almost sinusoidal counter-
Back Iron Thick = 11.200 mm Tooth Width = 8.050 mm electromotive force (CEMF), the PM machines work very well
Machine Ratings: with distorted stator magneto-motive force (MMF), where the
Power Rating = 660.0 kW Speed = 60000 RPM high winding factor is of highest priority [18]. In figure 5 it can
Va (RMS) = 417 V Current = 527.9 A be seen that winding factor value is 0.96 which is good to
maximise the torque, avoid unbalanced magnetic pull and to
Ea (RMS) = 430 V Arm Resistance = 0.00246 ohm
minimize the rotor losses.
Synch Reactance = 0.194 ohm Synch Induct = 0.015 mH
Stator Cur Den = 1049.3 A/cm2 Tip Speed = 201 m/s
Efficiency = 0.993 Power Factor = 1.000
Phases = 3 Frequency = 2000.0 Hz
Stator Parameters:
Number of Slots = 24 Num Arm Turns = 8
Breadth Factor = 0.966 Pitch Factor = 0.966
Tooth Flux Den = 1.14 T Back Iron = 0.81 T
Slots/pole/phase = 2.00
Rotor Parameters:
Magnet Height = 25.00 mm Magnet Angle = 50.0 degm Fig 4. Winding factor of the machine
Air gap = 4.00 mm Pole Pairs = 2
Magnet Remanence = 1.20 T Air Gap Bg = 0.57 T B. Electromagnetic analysis of the machine
Magnet Factor = 1.203 Skew Factor = 0.995 Electromagnetic model is solved and results are analyzed
Machine Losses: and compared. Output current and terminal voltage is shown in
Core Loss = 1.5 kW Armature Loss = 2.1 kW the following figures.
Windage Loss = 1.3 kW Rotor Loss = TBD kW
The terminal voltage waveform is close to sinusoidal, although
Machine Weights: some torque ripples can be observed because of harmonic
Core =14.06 kg Shaft = 3.96 kg contents of line-line voltage and skew effect in air-gap flux
Magnet = 2.30 kg Armature = 9.98 kg density, it shows a good agreement between analytical and FEA
Services = 4.55 kg Total = 34.85 kg
result.
Table 2. Detailed sizing parameters of the machine
armature winding, another cause of these losses may the skin
effect resulting from the same source conductors.
Fig 5. Output current In on-load flux distribution, it can be verified that machine is
highly saturated, the value of flux density is about 2.2T as can
be seen in the figure below. It confirms that the dimensions of
tooth width and stator yoke are good. Losses are also within the
calculated range.
C. Thermal analysis
Compared with common permanent magnet (PM) machine,
the high-speed PM machine has smaller size and larger power
density. However, owing to high-speed high frequency and
Fig 6. Terminal Voltage small volume, the PM rotor is more easily to become overheated
so that irreversible demagnetization of the PM is induced.
Cogging torque harmonic spectrum is analysed, it can be seen Traditional cooling methods of machine directly cool the
that the dominant harmonics are 48, 96 and then 144 which are machine stator; the temperature rise of rotor is reduced through
well below 1 % of the rated torque. Although cogging torque is heat exchange among stator, air gap and rotor. Owing to rapid
very low still there is a possibility to reduce cogging torque by temperature rise of high speed PM machine rotor, the method
changing width of stator slot opening and to skew stator slot. of indirect cooling rotor does not effectively protect PM rotor
from overheating[19].
Open circuit losses are analysed as well, we can verify that the
losses in rotor and stator teeth are well below within the
calculated range. Higher losses can be observed in stator yoke Fig 9. Steady state temperatures
due to some harmonics present in current going through the
The predicted average winding temperature is 112 °C. The slots and tooth coil winding is modeled to get comprehensive
predicted magnet temperature is 107 °C. These values are below and cost-effective manufacturing keeping the electromagnetic
the initial estimated values of temperatures. losses as low as possible. 6.5% SiFe is selected as a rotor and
stator material as it offers lowest losses. Losses are kept
minimized by using air-gap length, tooth tip optimization and
D. Slot FEA
wedge geometry. FEA is done by using motor-CAD and all the
In motor-CAD calibration can be done by the conduction heat results show good accord with calculated values. Presented
transfer in the stator slot. Figure shows the result with topology is suitable to use in small co-generation system on
minimum, average and maximum winding temperature of high speed application, this design is able to get design targets,
105°C, 107°C, and 112°C respectively. We can verify that there comprehensive, cost effective and low electromagnetic losses.
is a relatively good match of temperatures in the slot with
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