Design and Construction of a Permanent Magnet Axial Flux Synchronous Generator

Rogel R. Wallace* Thomas A. Lipo** Luis A. Moran* Juan A. Tapia* ** Electrical & Computer Engg. * Department of Electrical Engg. University of Wisconsin University of Concepcion 1415 Johnson Drive P.O. Box 53-C Madison, WI 53706 - U.S.A. Concepcion - CHILE
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Abstract- This paper presents the design characteristics, special features, and manufacturing aspects of a permanent magnet axial flux synchronous generator. This machine is aimed for applications in the low power low speed range (5 kVA, 500 rpm). A central stator configuration is selected for the construction of the axial flux generator, so that the stator leakage inductance is significantly reduced.
I. INTRODUCTION

Electric generators using axial flus conf$yation were developed almost 150 years ago. However, their applications have always been limited to fractional power due to the construction difficulties, specially the heat dissipation from the armature windings [ 11431. However, compared to traditional machines using radial flus distribution, asial flus generators present the following advantages: i) Better efficiency. ii) They operate with similar magnetic f l u s density in all the magnetic circuit, which translates in a better utilization factor of the magnetic core. Also, the axial flus construction takes advantage of the anysotropic characteristic of the oriented grain silicon iron [?I. iii) Axial f l u configuration allows the construction of compact electric generators with a large number of poles (low rated frequency). So far no significant effort has been done to develop axial flux permanent magnet synchronous generator for operation in micro-generating systems. In this paper, a complete design procedure for such electric machine is developed and the manufacturing aspects for the construction of a 5 kVA 500 rpm, 50 Hz prototype is shown. The innovative aspects of the axial flus synchronous generator presented in this paper are the following: i) The bulk and the lateral covers of the generator are made with a non ferromagnetic alloy. This reduces the stator leakage inductance and the corresponding magnetic losses. A bronze-aluminum material is used (90% copper and 10% aluminum), since this material is more resistant and lighter than the traditional bronze. Also, the bronzealuminum is easier to cast in induction or Morgan furnaces. ii) Preliminary studies have shown that the efficiency improvement of the axial flus generator is around 5%.

Moreover, due to the absence of the increasing speed mechanism, the overall system efficiency of the microgenerating station increases between 20 and 50%. iii) Permanent rare earth magnets (neodymium-ironboron) are used in order to avoid the slip rings to supply the field rotor windings. This allows the construction of shielded and more compact units. n i t s It is important to emphasize that even though small u of axial flus generators have been implemented and reported in the technical literature [l], they are inadequate for industrial applications. The principal problems of such prototypes dealt with the reduced number of poles which results in larger stator windings making impossible the construction of power shielded units. The design of axial f l u s generators with a larger number of poles for applications in micro-generating systems represents a new technological development and design of these machmes.
1 1 . GENERAL DESCRIPTION OF THE GENERATOR

For the construction of the axial f l u s generator a hvo airgap central stator configuration was chosen in order to cancel the longitudinal forces over the rotor pieces. In Fig. 1 the central stator topology of the generator is shown. The permanent magnets are embedded in the rotor lateral pieces mounted on the shaft. A yoke of silicon iron sheets closes the magnetic circuit by the back side of the magnets. The stator is composed by teeth formed by stacks of silicon iron sheets arranged in radial form in which the three-phase

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Figure 1: Topology of the Axial Flus Generator

0-7803-3946-0/97/S10.00 0 1997 IEEE.

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winding is houscd. Thcsc tcctli are fiscd by two bronzc disks in their ends, this gcomctry allows to obtain "opcn" slots with low leakage reactanccs and minimal losses of matcrial at the moment of the pattcrn-making. Morcovcr. a skcwing of the teeth with one slot pitch is considered i n order to avoid the cogging torque. A . Windings The stator windings must fulfill tlic followiiig requirements: Avoid wire crossing spccially in tlic cstcrnal part of tlie end winding. Reach the best copper utilization factor in tlic slots. Obtain a sinusoidal distribution of the nimf i n order to avoid torque pulsqt'ions. -The winding factor has to be high enough so that the rated power of the generator is not reduccd.

whcre: is the distribution factor is tlie pitch factor q = 2 number of slots per phasc and pcr polc q =30" elcctrical degrees corresponding to oiic slot y = 1 coil span in numbcr of slots T =6 polar pitch in numbcr of slots
fl
f2

In tliis case fl = 0.966 and fi = 0.866. Thcse factors were calculatcd for a two layer winding corrcsponding to tlic conventional generator. Finally the winding factor (f3) is givcn by:

Figure 2: Linear reprcscntatioli of the windings The construction of two coricciitric windings as sliowi in Fig. 2 satisfies most of the abovc rcquircmcnts. Tlic i i i m r gcneratcd by the winding can bc csprcsscd by tlic Fouricr series:
nm((x) =
n = 1.3,

It must bc noticed that tlic winding docs not gcneratc a third harmonic and that the fifth and scvcnth harmonic coiiiponcnts arc small. Thus tlic flus distribution rcsulls aliiiost sinusoidal since tlie dominant rcluctance harmonic gencratcd by the slot (due to tlic salicncy of the stator tccth) is tlie sixth. When tlie reluctance harmonic and the harmonic component gcneratcd by the winding havc tlie same frequency tlie cogging torque increascs. Figurc 2 shows that the coppcr mire ocuppies about 213 the space of the slots which results in an utilization factor cquals to 0.46 for wire with circular cross scction and 0.60 for wirc with squarc cross scction. In convcntional gaicrators tlie winding utili7~tion factor is in tlic range or 0.50 to 0.55 for wircs with circular cross scctioii.
B. Electrwiingnetic Design

c ...b,,sin(nx)

00

(1)

For a masitnum value of mmf(s) equals to 1 tlic Fouricr cocflicients are shown in Table I.
TN3LE I FOURIER COEFFICIENTS OF T11E MMT: I'I<OI)UCEI> l3Y A I'IIASE WINDING

The magnctic circuit corresponding to a pair of poles is fornicd by tlic tccth of tlie stator, two airgaps, four pcrniancnt magncts and two rotor yokes. Tlic dctcrmination of the perniancnt magnct width was done by using traditional clectromagnctic calculations. Also tlic rotating ficld powcr was masimizcd. ~ ~ 4 i i c rcsults h in cqual cross scctions of tcctli and slots .
111. CONI:IGUIIATION OFV I E ANAL FLUS GENERATOR wrrri PERhlANENT h4AGNE'TS

n
1

b .
1.065 ..

n
9 11 13
15

I?,
0 -0.097

n
17 19 21

h,,
0.017 -0.01 5

Figrirc 3 sliows tlic gencral drawing of tlic prolotypc. Tlic principal parts of thc generator arc tlic followings:
1. Bulk of tlic gciicrator 2. Latcral cover 3. Pcrmancnt magncts 4. Rotor yoke 5 . Rolor Iatcral piccc

3 5 7

0
-0.OS7 0.04 1

-0.82

-0
0.046

23

The winding factors for tlic fiind;imcntal coniponcnt o f tlie mmf are dcfined by the following csprcssions:

6 . Bearing 7. Shaft 8. Holding stator disk 9 . Stator tccth IO. Stator holding ring

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Figure 5: Permanent magnet asial flus generator

V. CONCLUSIONS

Fibwe 3: Configuration of the axial flus generator

IV. CONSTRUCTIVE ASPECTS OF THE AXIAL F L m GENERATOR

Figure 4 shows a photograph of the generator stator. The three phase winding is formed by sis sections of molded coils in this way one phase is formed by two sections connected in series. The general connection procedure is "abcabc", which equalizes the leakage inductances.

The paper presented the design characteristics of an axial flus generator with central stator rated 5 kVA, 500 rpm,50 Hz. The escitation system consists of Nd-Fe-B permanent magnets, so a high power density is obtained. Efficiency of the generator is about 96 % and the use of bronze in its construction improves the heat dissipation (the frame was constructed of a non-ferromagnetic alloy due that the internal part of the bulk is close to the end turns of the stator windings). Also the use of bronze presents a good mechanical rigidity and corrosion resistance.
ACKNOWLEDGMENT

The authors would like to acknowledge the financial support from the International Copper Association and from Agency for International Development through the project I.C.A. # 416 and A.I.D. # 11.196. Also the authors would like to thanks the Fondo de Desarrollo Cientifico y Tecnologico "FONDECYT" through the # 1950796 project.
REFERENCES

[I]
[2]

[3]

Figure 4: Stator of the generator with windings The use of permanent magnets allows the shielded construction of the machine. Also reduces its longitudinal size. Figure 5 shows the esternal aspect of the permanent magnet axial flus generator (external diameter: 36 cm, length of the frame: 45 cm)

[4]

[j]

[6]

C.C. Chan., "Axial-field electrical machinesdesign and applications," . Trans. on Energy Conversion, vol. 2, No. 2, pp. 294-300, June 1987. i t h axial flux D. Plat, "Permanent magnet synchronous motor w geometry," IEEE Trans. on Magnetics, vol. 25, No. 4, pp. 3076-3079, July 1989. M.A Rahman. "Analytical models for exterior type pamanmt magnet synchronous motors," IEEE Trans. on Magnetics, vol. 23, Xo. 5 , pp. 3625-3627, Sept. 1987. I. Boldea and S.ANasar , "Permanent-Magnet Linear Altsmaton, Part I: Futidimental Equations," IEEE Trans. on Aerospace ana Electronic Systems, vol. 23, No. 1, pp. 73-78, January 1987. I. Boldea and S.ANasar, "Permanent-Magnet Linear .4lmmtors, Part 11: Design Guidelines," IEEE Trans. on Aerospace and Necrronic Sysrems, vol. AES-23, No. 1, pp. 79-82, January 1987. B. Chalmen, S. Hamed and G. Baines, "Parameters and puformance of a high-field permnnent-magnet synchronous motor f a variablefiequency operation," IEEProceedings, vol. 132, Pt.B, No. 3, pp. 117124, May 1985.

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