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Design and Construction of Axial Flux Permanent

Magnet Generator for Wind Turbine Generated


DC Voltage at Rated Power 1500 W
P. Wannakarn, T. Tanmaneeprasert, N. Rugthaicharoencheep, IEEE, Member, and S. Nedphograw
Department of Electrical Engineering, Faculty of Engineering,
Rajamangala University of Technology Phra Nakhon,
Bangkok, 10800, Thailand.
e-mail: w.poonsri@hotmail.com, t.thanarat@hotmail.com, nattachote@ieee.org and supawudn_p_g@hotmail.com

AbstractThis paper presents a design of permanent magnet
machines (PM), such as the permanent magnet axial flux
generator for wind turbine generated direct current voltage
base on performance requirements. However recent developments
in rare earth permanent magnet materials and power electronic
devices has awakened interest in alternative generator topologies
that can be used to produce direct voltage from wind energy
using rectifier circuit convert alternating current to direct
current. In preliminary tests the input mechanical energy to
drive the rotor of the propose generator. This paper propose a
generator which can change mechanical energy into electrical
energy with the generator that contains bar magnets move
relative generated flux magnetic offset winding coils in stator
component. The results show that the direct current output
power versus rotor speed of generator in various applications.
These benefits present the axial flux permanent magnet
generator with generated direct voltage at rated power 1500 W.
Keywords-permanent magnet; axial flux; wind turbine
I. INTRODUCTION
Small wind turbines are economically attractive alternatives
to conventional sources of energy. They can be used in water
pumping battery charging, radio stations, boats or power
generation [1]-[2]. Using permanent magnet generators for
small wind turbines is very common. Usually an alternating
current generator with many poles operates between 10-100
Hz [3]. The generators is directly driven by the wind turbine
generated alternating current [4]-[6]. PM machines are
increasingly becoming dominant machines with the cost
competitiveness of high energy permanent magnets. These
machines offer many unique features. They are usually more
efficient because of the fact that field excitation losses are
eliminated resulting in significant rotor loss reduction [7].
Axial flux machines are formed by a rotor disc carrying
magnets that produce an axial flux and a stator disc containing
the phase windings. Many variations in this basic are possible
including single-side [8], double-side [9], torus [10] -[11], and
multi-disc designs [12]. This paper focuses on the two-rotor,
and one stator topology, where a single stator is placed
between two permanent magnet (PM) rotor discs, as shown in
Fig 1. This figure shows a view looking inward radially [13].



Figure 1. Two-rotor and one stator topology of axial flux magnet generator

In this paper presents the design and construction of the
axial flux permanent magnet generator produce direct current
from wind energy at wind velocity below 24 m/s using
rectifier circuit convert alternating current to direct current at
rated power 1500 W.

II. THEORY FOR PM GENERTOR DESIGN
A. Wind turbine characteristics
The aerodynamic power generated by the wind turbine [14]
can be derived in equation (1).

3
0.5
p
p AC V = (1)
where is the density of air, A is the swept area of the blade,
Cp is the performance coefficient and V is the wind speed.

The velocity to pull shaft of wind turbine can be derived in
equation (2).

60

2
o
V
n
R

= (2)
978-1-4577-0365-2/11/$26.00 2011 IEEE 763
Where n is the rotor speed of wind turbine, is the
acceleration of end blade, V
o
is the wind speed to turn blade, R
is the width of end blade
The acceleration of end blade can be derived in equation
(3).
80 / b = (3)

where b is the number of blade
B. The induce electromotive force of winding in generator
The induce electromotive force of a concentrated winding
per phase can be determined in equation (4).

1
4.44
f w ph
E k fN

= (4)

where k
w
is the fundamental winding coefficient, is the
fundamental frequency, N
ph
is the number turn winding of
stator coils per phase and 1 is the fundamental flux per pole.
The fundamental flux per pole can be determined in
equation (5).

1
. A B

= (5)

where A is the cross section of pole and B is the maximum flux
linking coil.
C. Full bridge rectifier
The average value of the output voltage of the full bridge
rectifier[15] can be determined in equation (6)

2
2
s
d
V V

= (6)
where V
d
is the average value of the output voltage and V
s
is
the rms value of the input voltage.

III. DESIGN AND CONSTRUCTION
Machine design is synthetic knowledge application of
machine theory and manufacturing experience. Many
parameters and dimensions will influence the design results.
Based on the discussion and analysis in the previous section,
the design procedure is calculated, which can be used to
design the double rotor disc and one stator disc of axial flux
permanent magnet generator.
A. Design
Table 1 show the parameter from the design results of wind
generators, which are the double rotor disc and one stator disc
of the axial flux permanent magnet generator for wind turbine
generated direct current voltage at rated power 1150 watts for
wind velocity below 24 m/s.


TABLE I. DESIGN PARAMETERS CALCULATED
Axial Flux Permanent Magnet Generator 1150 W atts
Parameter Value
Width of end blade 900 mm
Number of blade 3 blades
Current density in the conductor 4 A/mm
2
Bridge rectifiers 35A- 700V per phase
Maximum output current 10 A
Copper conductors S.W.G. 16
Number of coils of stator 10 turns
Number turn winding of stator coils
per phase
370 turns
Number turn winding of stator coils
per coil
185 turns

Number of poles 12 poles
Cross section of pole 0.018 m
2

Maximum flux density of linking coil 0.5 T
Wind speed to turn blade 24 m/s
Rotor speed of shaft of the generator 1,300 rpm
Induce electromotive force 230 V

B. Construction
In moving part are the rotor sets, consist of number 12
poles fix to the rotor disc with rotating part and stator sets are
fixed. It consist of number 10 coils and wire 185 turns per
coil with mix resin shown in Figure 5 to heat transfer get out.
1) Stator sets
In this part the design and construction shown in Figure 2
with number of coils is 10 sets and connected end wire of any
coils concentrated type and series connected two coils include
to one phase circuit with alternating circuits total equal five
phases through the rectifier circuits produce direct voltage for
the application to used next and the circuit connected shown in
Figure 3 and Figure 4 shown the stators of axial flux permanent
magnet generator to mixed resin.



Figure 2. Coils of stator of axial flux permanent magnet generator
764

+

Figure 3. Coil connections of stator of axial flux permanent magnet generator

Figure 4. Stators of axial flux permanent magnet generator to mixed resin
2) Rotor sets
In this part the design and construction shown in Figure 5
with number 12 poles and angle per each equal 30 degree.

Figure 5. Rotors of axial flux permanent magnet generator
The assembly of axial flux magnet generator shown in
Figure 6. The prototype of axial flux magnet generator shown
in Figure 7 and prototype of wind generator shown in Figure 8.

Figure 6. Assembly of axial flux permanent magnet generator


Figure 7. Prototype of axial flux permanent magnet generator

Figure 8. Prototype of wind generator
IV. TEST RESULTS
Testing of axial flux permanent magnet generator shown in
Figure 9 with the generator operating into the resistive load. In
these test all two of the generator coils per phase were
connected in series. The data from no-load and on-load test
shown in Table 2.

765

Figure 9. Testing of axial flux permanent magnet generator

TABLE 2
RESULTS NO-LOAD AND ON-LOAD TEST

Nr(rpm)
No-load On-load
Vout(V) Vout(V) Iout(A) Pout(W)
0 0 0 0 0
200 37.29 36.10 1.66 60
300 58.61 53.10 2.16 115
400 71.88 68.70 2.77 190
500 86.85 85.20 3.40 290
600 105.05 100.70 4.07 410
700 117.50 115.80 4.75 550
800 139.83 130.60 5.44 710
900 150.81 145.30 5.95 865
1000 160.25 158.90 6.48 1030
1100 176.41 170.00 6.94 1180
1200 188.08 183.40 7.58 1390
1300 210.05 189.00 7.94 1500

The output voltage a while on-load test when the variation
speed rotor shown in Figure 10 and the output power of axial
flux permanent magnet generator when the variation rotor
speed shown in Figure 11.
0
50
100
150
200
0 200 400 600 800 1000 1200 1400
Rotor speed (RPM)
D
C
.

O
u
t
p
u
t

v
o
l
t
a
g
e

(
V
)

Figure 10. DC output voltage No-load test versus rotor speed
of generator
0
200
400
600
800
1000
1200
1400
1600
0 200 400 600 800 1000 1200 1400
Rotor speed (RPM)
P
o
w
e
r

o
u
t
p
u
t

(
W
)
Figure 11. DC output power versus rotor speed of generator
V. CONCLUSION
This paper has shown axial flux permanent magnet
generator for wind turbine. In preliminary tests feed the input
mechanical energy to drive the rotor of the propose generator
which can change mechanical energy into electrical energy.
The results show that the direct current output voltage versus
rotor speed and output power versus rotor speed of generator in
various applications. The rotor speed at 1000 rpm produce
direct current voltage is equal to 189.0 V , output current is
equal to 7.94 A and power output is equal to 1500 W when
connected to resistive load.
ACKNOWLEDGMENT
The authors would like to express his gratitude to
Electrical Machine Laboratory, Faculty of Engineering,
Rajamangala University of Technology Phra Nakhon,
Thailand, for support of experimental of axial flux permanent
magnet generator.
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