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Design and Optimization of 4.8 kW Permanent Magnet Brush-less Alternator for

Automobile

Article · January 2016

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Sabaresh Gs Nattuthurai Senthilnathan

Indian Institute of Information Technology, Design & Manufacturing, Kancheepuram,… Kongu Engineering College
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 INTERNATIONAL JOURNAL FOR TRENDS IN ENGINEERING &
TECHNOLOGY
VOLUME 14 ISSUE 1 – JUNE 2016 - ISSN: 2349 – 9303
Design and Optimization of 4.8kW Permanent MagNet
Brushless Alternator for Automobile
G. Sabaresh (PG Scholar) Dr. N. Senthilnathan (HOD)
Kongu Engineering College-Perundurai Dept. of EEE Kongu Engineering College-Perundurai Dept. of EEE
nsenthilnathan@gmail.com
sabareshgs@gmail.com

Abstract — This paper presents the optimized design of 4.8kW, 184V at 3600 RPM- Outer rotor permanent magnet brush
less alternator (PMBLA) for recreational vehicles. The finite element analysis is carried out using MagNet 2D/3D FEA- package for fine
tuning the design and performance evaluation of the alternator under no-load and full-load conditions for saturation considerations. The
analysis results demonstrate the effectiveness of proposed machine design methodology

Index Terms — Finite element analysis, Permanent magnets (PMs), Permanent magnet brush less alternator (PMBLAs), Ferrite (Fe),
Neodymium Iron Boron (NdFeB)

—————————— ——————————

1. INTRODUCTION
The recent trend in the automotive field is adding new
features improve the performance in terms of fuel efficiency and also
in comfort of the customers. The power demand in the vehicles
is increasing gradually in terms of kilowatts due to the addition
of several electric systems like air conditioning, automatic parking
system, traction control etc. The development of electronics field has
simultaneously enabled improvement of the performances and
customer satisfactions in the automobile application like cruise-
control, Auto-Parking facilities, air conditioning or GPS. To drive all
these a high power alternator is necessary.
The Permanent magnet brush less machines have more
advantages over other electrical machines such as brushed DC Fig.1. PMBLA with three phase converter.
machines, synchronous machines, induction machines and switched
2. MAGNET – FINITE ELEMENT ANALYSIS (FEA)
reluctance machines. Because the field winding is replaced by TOOL
permanent magnets, these machines exhibit high efficiency in
operation due to electronic commutation. As a result, PMBL The MagNet tool is An electromagnetic field simulation
machines have been increasingly used in small motor drives software, an Electromagnetic field simulation software designed by
for automobiles, recreational vehicles, and aircrafts. Infolytica Corporation. This tool helps to predict the performance of
any electromagnetic or electromechanical devices like Electric
Recent researches in the field of high speed PMBL motors / Generators, Transformers, Actuators, Induction heating’s
machine (around 2000-4500 RPM) for automotive applications and and more in different conditions. It helps to model the machines in both
2D and 3D for to solve static 2D/3D, time harmonics, transient
low speed PMBL machines (around 200-1500 RPM) for wind
2D / 3D (or) transient 2D / 3D with motion analysis and it provides
power generations ,have introduced different types of methods, accurate field results.
algorithm and model types improve the efficiency of the PM machines.
The losses which include copper loss, eddy current loss, hysteresis loss,
3. ALTERNATOR DESIGN
friction and windage losses were taken in to account in these methods
3.1 Topology of alternator
The surface mounted permanent magnet outer rotor
The main objective of this work is to design an configuration is selected for the proposed machine and shown in
efficient three-phase PMBLA supplying 184V, 4.8kW at 3600 Figure.2. Based on various parameters the 16Pole-48Slot double
RPM. The converter topology of alternator is uncontrolled layer distributed winding configuration was selected for proposed
three phase bridge rectifier is shown in Figure.1 This paper PMBLA.
presents the design algorithm of the three phase PMBLA. The Finite The cogging torque in the outer rotor is lesser than inner rotor
element analysis is carried out using Magnet 2D and 3D FEA- package. configuration for the same performance level and it is can further be
minimized by skewing the stator or rotor. It has a lower audible noise
45 due to greater inertia and less cogging makes the machine very
suitable for use in quiet applications.
 INTERNATIONAL JOURNAL FOR TRENDS IN ENGINEERING &
TECHNOLOGY
VOLUME 14 ISSUE 1 – JUNE 2016 - ISSN: 2349 – 9303
The Alternator is designed by using two different types of magnets
Ferrite and NdFeB for different machine dimensions with the same
pole slot combination. The grades of the magnets is shown in
Table 1

S. No Description Fe-Magnet NdFeB-

Magnet
1 Magnetic field density 0.45T 1.1T
2 Coersivity 342KA/mm?^2 769KA/mm?^2
Table 1 Grades of the magnets.

Fig.4 - 2D model of NdFeB machine

ItemNo Description
1 Yoke
2 Magnets
3 Coils
4 Stator Core
5 Rotor Table.2 Machine dimensions.
The initial design start-up was with 200mm outer-DIA and
Fig.2 – Surface Mounted outer rotor PMBLA the axial length of 50mm. Subsequently this design is optimized to the
final level by varying the axial length, changing slot area and
3.2 MagNet model shape, tooth width, back iron portion that satisfy the output
requirement, with adequate flux density to avoid saturation and
The initial wire frame design of alternator is drawn in Auto- current density issues to ensure high efficiency of the machine.
CAD software, imported and modelled in MagNet tool. The design has While designing and optimizing the machine size and volume should
several constraints that it should satisfy. Like slot fill factor, be take into account because it plays a major role in the automotive
current density, demagnetization of magnets, cogging torque after the field in terms of cost and also in weight. The Flux density and
selection of poles and slots. The Ferrite and NdFeB MagNet 2D current density values are shown in Table 3 and the Flux density
model are shown in Figure.3 and Figure 4. The dimension details are saturation in tooth and yoke were shown in Figure 5
as shown in Table 1.

Figure 5 Flux density saturation

3.3 ANALYSIS OF ALTERNATOR
The proposed model is analysed in various stages to check the
performances. The types of analysis are
1. Static 2D analysis
Fig.3 - 2D model of Ferrite machine
2. Transient 2D with motion and
`
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 INTERNATIONAL JOURNAL FOR TRENDS IN ENGINEERING &
TECHNOLOGY
3. Static 3D analysis VOLUME 14 ISSUE 1 – JUNE 2016 - ISSN: 2349 – 9303
3.3.1. Static 2D Analysis
A static analysis calculates the magnetic fields created
by magnets. The loss computations cannot be predicted by using
the static analysis.
Initially the static analysis is carried out to check the current
delivering capability of machine. This method is relatively easy
and gives quick results. The machine is model is created. Because the
model exhibits axial symmetry analysis need only be done in two
dimensions. The machine is analysed in two different conditions
under the static 2D.
No-Load analysis and
Load analysis. Fig 6 Flux Linkage between rotor and stator
[1] No-Load analysis
It is carried out for one-pole pair rotational angle and it is
divided in fine steps to get better results.

One pole pair rotational angle =

Where Pole-pair =

The rotational angle (0°– 45°) is divided into fine steps to get
better results.
1. To calculate the phase voltage, Induced
emf, E = (pψ * ω) Where pψ =
,ω=
- N = Speed (in RPM)
– dψ = Change in flux linkages (in Wb)
– dθ = Change in angle (in deg)
- To calculate the line voltage,
The difference between phase voltages is line voltage. VRB
= VR-VB (in Volt)
Where R indicates – R Phase Voltage
B indicates – B Phase Voltage.
Fig 7 Three phase flux linkage
[2] LOAD Analysis
Load analysis is carried for load current of 50A. The
response surface method used for carrying out load analysis gives the
output of flux linkage values at three phase terminals after solving
the problem, for different rotor positions and load current array given
as input. With the help of flux linkage data, the output current
produced by the machine under different speed for the corresponding
regulating voltage is easily calculated by another tool called Claw
Pole Circuit Simulator. The output performance of the machine is
easily identified by plotting the graph of DC output current produced
by the machine for different speed. The output load performance
curve for the alternator is shown in Figure.8

The No-load flux linkage from rotor to stator is shown in

Figure 6 and three phase flux linkage waveform is shown in Figure
7.
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 INTERNATIONAL JOURNAL FOR TRENDS IN ENGINEERING &
TECHNOLOGY
VOLUME 14 ISSUE 1 – JUNE 2016 - ISSN: 2349 – 9303
Fig.8 Load performance Curve
Response Surface Method
In statistics, response surface methodology (RSM) explores
the relationships between several explanatory variables and one or
more response variables. The method was introduced by G. E. P. Box
and K. B. Wilson in 1951.
The main idea of RSM is to use a sequence of designed
experiments to obtain an optimal response. Box and Wilson suggest
using a second-degree polynomial model to do this. They
acknowledge that this model is only an approximation, but its usage is
plenty because such a model is easy to estimate and apply, even when
little is known about the process.
3.3.2. Transient Analysis
The transient analysis is mainly used for loss
computation. The types are
Fig 10. 3D model of Ferrite machine
1. Transient 2D and
2. Transient 2D with motion.
The Transient 2D is similar to Static 2D it gives the
additional information about losses. In Transient 2D with motion the
loss data for specific speed can be obtained. The rotor components are
created as 'Motion components' and the stator winding are
connected with diode bridge rectifier. The battery is connected in the
rectifier end and it acts as an electrical load. Then the machine
is made to run at 3600 RPM loss data has been computed and
load current value was verified. The winding connected with rectifier
and battery is shown in Figure 9.

Fig 11. 3D model of NdFeB machine

The machine is modelled for one-pole pair with
appropriate 'Boundary conditions' in order to reduce time. The grey
section in the model that represents as 'Boundary conditions' its
periodicity of 450 and it applied electrically to full machine. The
machines were modelled for actual axial distance is shown in
Figure 12 and Figure 13

Fig 9 Three phase winding with diode bridge rectifier and

Battery.

3.3.3 Static 3D Analysis

This Static 3D is used to verify the results obtained from
the above analysis and it is the final verification of results. In this the
machine is modelled like the actual machine and the Static 2D
procedure is followed to analysis. The 3D model of Fe and NdFeB
machine is shown in Figure.10 and Figure 11.

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 INTERNATIONAL JOURNAL FOR TRENDS IN ENGINEERING &
TECHNOLOGY
VOLUME
Fig 12 Actual axial length 14 ISSUE 1 – JUNE
of Ferrite machine 2016and- ISSN:
organization in making2349 – 9303
necessary arrangements for successfully
developing the machine designed

References
[1] J. R. Hendershot and T. J. E. Miller, Design of Brushless
Permanent Magnet Motors. Oxford, U.K.: Magna Physics Publishing
and Clarendon Press, 1994.
[2] M. Comanescu, A. Keyhani, and Min Dai, "Design and Analysis
of42V Permanent-Magnet Generator for Automotive Applications,"
IEEE Transaction on Energy Conversion, vol. 18, no.1, March 2003.
[3] E. Spooner and A. Williamson, "Direct-coupled, permanent
magnet generators for wind turbine applications," IEE Proceeding of
Electric Power Applications, 1996, vol. 143, no. 1, pp. 1-8.
[4] B. H. Bae, and S.K. Sul, “Practical design criteria of interior
permanent magnet synchronous motor for 42V integrated starter-
generator,” Electric Machines and Drives Conference. IEMDC’03,
Vol. 2, No., pp. 656- 662, 1-4 June 2003.
[5] MIT/Industry Consortium on Advanced Automotive
Fig 13 Actual axial length of NdFeB machine Electrical/Electronic Components and systems, “Discussion with
IV SHORT CIRCUIT ANALYSIS AND COGGING. Automotive OEMs about Typical Future Vehicle Requirements,”
1996
The machine winding terminals are shorted and the
[6] Edward Carl Francis Lovelace, “Optimization of a Magnetically
maximum short circuit current is calculated. That current is fed in to Saturable Interior Permanent-Magnet Synchronous Machine Drive,”
the winding and the machine rotates for one pole pair angle. The Doctoral dissertation at MIT Jun/2000
demagnetization properties of the magnets were studied. These
[7] B. Stumberger, G. Stumberger, D. Dolinar, etc., “Evaluation
properties should take into account while modelling the PM
of saturation and cross-magnetization effects in interior permanent-
machines because the magnets plays a vital role in the operation magnet synchronous motor,” IEEE Trans. Ind. Appl., Vol. 39, No. 5,
The Cogging Torque is minimised by using Sept./Oct. 2003.
Skewing [8] J. Y. Lee, S. H. Lee, G. H. Lee, and J. P. Hong, “Determination of
Technique. parameters considering magnetic Non linearity in an interior
permanent magnet synchronous motor,” IEEE Trans. Magn., Vol. 42,
V RESULTS AND DISCUSSIONS No. 4, Apr. 2006.
[9] J. Chen, C. Nayar and L. Xu, "Design and finite-element
S. analysis of an outer rotor permanent-magnet generator for directly-
Description Ferrite NdFeB Units
No
No-Load voltage coupled wind turbine applications," Proceedings of the IEEE Trans. on
1 440 446 V
(@ 3600 RPM) Magnetics, vol. 36, no. 5, September 2000, pp. 3802-3809.
Load current
2 28.15 31 A [10] S. A. Papathanassiou, A. G. Kladas and M. P. Papadopoulos,
( For 184 V , 3600 RPM)
"Direct coupled permanent magnet wind turbine design
Output power
3 5.15 5.6 kW considerations," Proceedings of the European Wind Energy
( For 184 V , 3600 RPM)
Conference (EWEC'99), Nice, France, 1999
The above table shows that the proposed design meets the
AUTHOR PROFILE:
requirement. The machine that designed and optimized in FEA
G. Sabaresh is currently pursuing masters degree program in power electronics
software is being developed practically for testing and verifying the and drives in Kongu Engineering College, Perundurai, Tamil nadu, India, PH-
results and performance as already achieved through simulation. +91 96553 98553. E-mail: sabareshgs@gmail.com

ACKNOWLEDGMENT
The corresponding author hereby expresses deep gratitude to
Lucas-TVS Ltd. & its G. Vigneshwaran (Development Engineer-
Advanced Engineering department- Lucas-TVS Ltd) for his constant
guidance and support to carry out this project in their prestigious
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