Design, Construction and Test of a Permanent-Magnet Prototype Machine for

Wind Energy Applications

R.E.Hanitsch1, M.S.Widyan 2

IInstitute of Energy and Automation Technology, Berlin University of Technology, Einsteinufer 11, D-10587 Berlin,
2

Germany
Electrical and Computer Engineering Department, Hashemite University, Zarqa 13115, Jordan

Abstract- A low-speed radial-flux permanentmagnet (PM) electrical generator with new topology
was designed, optimized, built and tested. The
equivalent magnetic circuit approach together with the
permanent magnet load line method were used as predesign tools. The finite element technique (FET) was
used for detailed characteristics and final adjustments.
The design was carried out with high-energy NdFeB
magnets with flux concentration arrangement. The
topology allows for toroidal (torus) windings placed in
flat slots with short ends, which contributes to higher
efficiency and higher power to weight ratio. The flux
concentration of the permanent magnets is tangential
on the rotor support structure, which can be made
from light nonmagnetic material. The cogging torque
of the machine is estimated using the Flux-MMF
technique together with the help of FET. Good
agreement between theoretical and experimental
results has been achieved. Compared with other
machine types of close power ratings, the developed
prototype machine exhibits relatively high efficiency.

FET [1]. The generator is constructed from two rotors and

one stator. The prototype was built and tested. The design
permits short endwindings, which improves the
performance of the machine by reducing the weight,
increasing the efficiency and reducing the cost of active
material. The difference between the calculated and
measured values was in the range of 7%. A 2.7kW, 18pole, axial-flux air-gap winding prototype machine was
designed, built and tested. Good agreement between
theoretical and experimental results has been indicated [2].
The equivalent magnetic circuit approach together
with the load line method, which represents the permanent
magnet output characteristics, were used as pre-design
tools. The FET is then used to check the electromagnetic
behavior of the machine where final adjustments and
detailed investigations were done. The prototype machine
was built and tested. Compared with other machine types
of close power ratings, a relatively high efficiency has
been achieved.
This paper is organized as follows. The machine
topology is explained in section II. Magnet load line
characteristics and preliminary design are summarized in
section III. Section IV presents the FET analysis.
Experimental investigations and a comparison between the
theoretical and practical results are given in section V.
Finally, some conclusions are drawn in section VI.

I. INTRODUCTION
Recently, a great attention has been paid to the
pollution-free renewable energy sources to be an
alternative source for oil, gas, Uranium and coal sources
that will last no longer than one century. Wind energy is
considered as one of the most important types of
renewable energy sources that has been widely used in
electricity generation. The fact is that the cost of energy
supplied by wind turbines is continuously decreasing.
Nowadays, more than 16,000 MW wind power capacity
has been installed in Germany with a total number of wind
energy systems greater than 15,000 units.
So many generators have been proposed as directdriven wind energy generators with different
configurations, for different purposes and designed using
different approaches. Permanent magnet (PM) machines
can be categorized according to the direction of flux
penetration as radial-flux, axial-flux and transversal-flux
machines. A slotless rare-earth permanent-magnet radialflux wind-energy generator with new topology was
designed and optimized using the finite element technique

II. MACHINE TOPOLOGY

A schematic diagram explaining the machine
topology is shown in Fig. 1. The permanent magnets are in
a flux concentration arrangement and fixed on the rotor
support structure, which consists of nonmagnetic material.
To produce an easy path for the flux penetration, pieces of
soft magnetic material are attached on both poles of the
magnets. The windings are of toroidal (torus) type and
placed in flat slots. To increase the compactness of the
windings, similar flat slots are excavated on the outer
surface of the stator yoke. Due to the short endswindings
higher efficiency, lower overall weight and lower active
material cost can be realized. Slotted stator is chosen to
reduce the effective air gap length. As the air gap length
decreases, the length of the magnets in the direction of
magnetization decreases. As a result, the cost of active
material will largely decrease as it is dominated by the cost

159

Shoit Circuiit Fltux

/
Opeii Cir cuit
\s51

\]
mm

F,X1ttl.

IF M

Fig. 2. Schematic diagram for the Flux-MMF characteristics of PM

Opell Circuit

Fig. 1.Schematic diagram for the machine configuration

Opefatilig Poiint

of magnets. However, cogging torque occurs as a

consequence of slots.
The technical specifications of the single-phase
prototype machine are:
1kW and 230V at 180rpm.
number of slots=number of pole pairs=20.
NdFeB permanent magnets with a remanent flux
density Br = 1.4 1T, maximum energy product (BH)maX

Noimiial Load

lbtI

DeiIagiietizilig Cliaiacteristics\

cu

/-\

Load Liie

Demwaglnetiziln Etfect

/
of Pliase Cutieit
Fig. 3. Schematic diagram for the B-H characteristics of PM
/

of about 370 kJ/m3 and coercivity force H of about

-700 kAim.

MMF at the terminals of the magnet. It is clear from this

that magnets require two parameters F and b to
characterize them properly. The remanent flux (/5 and the
coercive MMF F depend not only on the material
properties but also on the dimensions of the magnet, and
this makes matters a little more complicated during the
design of the magnetic circuit. The material property
associated with (/5 is the remanent flux density Br, and this
is related to (/ by the equation:

III. MAGNET CHARACTERSTICS AND

PRELIMINARY DESIGN
The characteristics of permanent magnets can be
expressed graphically in terms of the Flux-MMF
relationship at the terminals or pole faces as shown in Fig.
2. This is analogous to the voltage-current relationship of
an electrical source at its terminals. The magnet can be
short circuited by connecting an infinitely permeable
keeper across its poles. This ensures that the MMF across
the terminals is zero and the magnet is operating at the
short circuit point where the maximum amount of flux
is produced. The open circuit condition, on the other hand,
requires that the flux leaving the magnet poles is zero. In
order to achieve this, an external demagnetizing MMF
must be applied to suppress the flux. The external MMF
must exactly balance the internal MMF of the magnet
when the flux emerging from the poles is zero. The
terminal MMF is negative because it opposes the internal
MMF F of the magnet, and is exactly equal to it. F1 is
called the coercive MMF because it is the MMF required
to coerce the magnet to produce zero flux. It directly
expresses the resistance of the magnet to demagnetization.
In normal operation there is no keeper, and the magnet
operates at a flux below O . This is because the MMF drop
across the air gap appears as a negative demagnetizing

/r

BrAM

(1)

where AM is the magnet pole area. The material property

associated with F is the coercive magnetizing force of
coercivity H , and this is related to F by the equation

(2)
FC = HCLM
where LM is the length of the magnet in the direction of
magnetization.
From these equations, it is clear that if the vertical
axis of Fig. 2 is scaled by I/AM and the horizontal axis by
/ILM, the result will be a relationship between BM and
HM, the flux density and magnetic strength of the magnet,
respectively. These in turn are related to the magnetic flux
Om and the MMF drop FM at the operating point:
tM =BMAM

160

and

FM

HMLM

(3)

The graph of BM VS. HM is shown in Fig. 3, and

this is, in fact, the second quadrant of the B-H loop or
hysteresis loop of the magnetic material. The magnet's
operating point generally moves reversibly up and down
on the straight part of the characteristics shown in Fig. 3.
This characteristic is called the demagnetizing
characteristic. The unit of the horizontal axis is A/m while
of the vertical axis is T. So, the slope of the demagnetizing
characteristic equals to the relative recoil permeability ,u.
Hard permanent magnets have relative recoil permeability
in the range 1.05-1.15, close to that of air.
It has already been seen that the air gap applies a
static demagnetizing field to the magnet, causing it to
operate below its remanent flux density. With no current in
the phase windings, the operating point is typically at the
point labeled Open-Circuit Operating Point in Fig. 3, with
BM of the order of (0.7-0.95) Br The line from the origin
'o' to the Open-Circuit Operating Point is called the load
line [3].
Most of the machine dimensions are preliminarily
calculated using the equivalent magnetic circuit approach.
The FET is then used to check the details of the
electromagnetic design and some small modifications in
terms of few millimeters are done. The length of the
magnets in the direction of magnetization, air gap length
and the slot opening are selected based on the FET
analysis of the magnetic circuit.
The basic design equation of the machine is that
of the rms value of the fundamental component of the
induced voltage Erm:
(4)
Erms = 4.44NfBM hM LStk fLKG
where N is the total number of turns, f is the frequency
of the induced voltage, BM is permanent magnet flux
density, hM is the height of PM, L5tk is the active or stack
length of the machine and fLKG is the leakage flux
coefficient, which is the ratio between the linkage flux and
the total flux provided by the magnets. In this topology,
fLKG is relatively high. A value of 0.85 is acceptable for
initial design purposes.

(a)

f-

(b)
Fig. 4. Hux lines distribution (a) no load and (b) full load
8

'P.'
ilD
.l

J.

z
(LI
,f) 9
x

-E.
PI,

.-j

Angle (Degree)

Fig. 5. No load air gap flux density distribution

When the rotor rotates, the co-energy of the PMs varies

accordingly as the magnetic circuit of the stator seen by
the PMs varies with the rotor position. It causes vibration
and might prevent the starting of the rotor. It should be
estimated and minimized. The cogging torque of the
developed prototype is estimated by the Flux-MMF
diagram technique together with the help of the FET [4].
Mathematically, the cogging torque T6g is defined as:

Iv. FET ANALYSIS

For final adjustments, a FET analysis is carried
out. The machine is modeled by three pole pitches for both
the rotor and stator. Actually, all sharp points of the stator
are smoothed by curving. Because otherwise, the high flux
concentration of the PMs might saturate them. Fig. 4 (a)
and (b) show the flux lines distribution at no load and full
load, respectively. The no load air gap flux density
distribution is shown in Fig. 5.
Slotted PM machines suffer from cogging torque.

Tcog

aw (i,a)l

i=const.

(5)

where W' is the co-energy of the PMs, a is the rotor

position and i is the stator current.

161

The machine is modeled by one pole pitch for

both the stator and rotor. The air gap of the machine is
divided into two parts. The first one is attached to the
stator and the second one moves with the rotor. The rotor
has the option of changing its position incrementally. The
co-energy of the PMs is calculated using the FET itself at
every incremental rotor position for the first half pole pitch
at no load. The co-energy of the second half pole pitch has
been concluded as the mirror image of the first half. The
closest polynomial representing the co-energy variation of
the PMs with respect to the rotor position is found. The
cogging torque is then estimated by differentiating the
resulted co-energy polynomial function. Fig. 6 shows the
flux lines distribution at different rotor positions. The coenergy of the PMs for one pole pitch obtained by the FET
and the corresponding cogging torque are shown in Fig. 7.
It can be concluded that the maximum value of the
cogging torque is about 2.3% of the rated torque of the
machine and occurs at a rotor angle of about 2.0
mechanical degrees.

shows the waveform of the no load induced voltage at a

speed of 180rpm with counter clockwise (CCW) rotor
rotation. The no load air gap flux density is shown in Fig.
5. As can be seen, both waveforms are close to each other.
The no load input power to the machine
represents the iron losses in the stator yoke and teeth,
windage and friction losses and the driving power of the
rotor. Fig. 10 shows the no load input power to the
machine as function of rotor speed and Fig. 11 shows the
corresponding driving torque.
B. Load Characteristics

As the load varies, the stator current varies. The

terminal voltage of the generator varies accordingly as the
voltage drop across the stator resistance and inductance
varies. Fig. 12 shows the terminal voltage of the machine
as function of stator current at rotor speeds of 180 and
250rpm with pure resistive load. The voltage variation in
case of 250rpm is higher as the stator reactance increases
with frequency (speed).
The efficiency of the machine as function of
speed with pure constant resistive load of 110.5 Q is
shown in Fig. 13. The generator has an efficiency of about
83.7% at a speed of 254rpm. Additionally, it can be
concluded that the efficiency of the machine increases with
speed. The efficiency as function of stator current at two
different speeds of 250 and 180rpm is shown in Fig. 14.
The efficiency of the machine at a stator current of about
4A and a speed of 250rpm (1270W) is about 84.6% and
the maximum efficiency at a speed of 180rpm is about
83.2% and occurs at a stator current of about 2.15A
(512W). The efficiency of the developed machine is
compared with that of the already existing electrical
machines of close power ratings in Fig. 15 [1], [5] and [6].
It can be concluded that the proposed machine topology
provides relatively better efficiency.

V. EXPERIMENTAL INVESTIGATION
A. No Load Characteristics

The prototype machine was built and tested as a

variable low-speed generator at different loading
conditions. As the rotor speed increases, the induced
voltage of the machine increases. Fig. 8 shows the
calculated and measured no-load induced voltages of the
machine at different rotor speeds. The good agreement
between the theoretical and practical results can be noted.
Additionally, it can be concluded that the relation between
the induced voltage and the speed is linear with a linearity
constant of about 1.39 V/rpm.
The waveform of the no load induced voltage
should follow that of the no load air gap flux density. Fig.9

7 \

L_

(a)

7~~~~~~~~
L-f-: -~7-

(b)

(c)

-~

Fig. 6. Hux lines distribution at no load with, (a) U, (b) 3, (c) 6 and (d) 9 mechanical degrees rotor rotational angles.

162

(d)

(a)

140

1; 139.5

O co-energy of the PMS

7th polynomial

139

>1138-

a13
1385

a, 137.5

a,g

137
136.5

0.05

0.15

0.1

0.2

0.25

0.3

0.35

0.2

0.25

0.3

0.35

(b)

3
2

~61

(D
-0

.s

-1

O -2
0

0.05

0.1

0.15

Rotational Angle (Rad)

Fig. 7. (a) Co-energy of the PMs for one pole pitch and (b) the corresponding cogging torque

ICl 1ut

100 -_

Calculated_1_1

90

-_

'Measured
0

2
Cc
>)
Q.

0
zo

Speed (rpm)

Speed (rpm)

Fig. 10. No load input power as function of speed

Fig. 8. No load voltage as function of speed

z- 3.(

ST3.1
0
c) 3.,

-j0 2.,

Speed (rpm)

Fig. 11. No load driving torque as function of speed

Fig. 9. Waveform of the no load induced voltage with CCW rotation

163

Developed Prototype
Double Rotor
PM Machines

250rpm
o0

,O

-X

Z-S 50
0

.C

Electronic Commutated
DC PM Machines

DC PM
Machines

.a

2E

40

DC PM
Machines
1

'IT, AC Machines

I.

10
Stator Current (A)

Power (W)

Fig. 12. Terminal voltage as function of stator current with pure resistive
load at speeds of 250 and 180rpm

Fig. 15. Efficiency of the developed prototype machine compared with

that of different electrical machine types of close power ratings

The windings are of toroidal (torus) type, placed in flat

slots and with short ends. A soft magnetic material is
attached on both sides of the PMs, which provides an easy
path for the flux penetration. The prototype machine was
tested as a variable low-speed generator. Good agreement
between practical and predicted theoretical results has been
achieved. Compared with other electrical machines of
close power ratings, the prototype machine exhibits
relatively high efficiency. The efficiency of the machine is
about 84.6% at an output power of 1270W and a rotational
speed of 250rpm.

Speed (rpm)

Fig. 13. Efficiency

as

function of speed with pure resistive load of

REFERENCES

iio.sQ

[1] G. Korouji, "Design, construction and test study of a

wind energy generator with dual permanent magnet
excitation," Ph.D. dissertation, Berlin University of
Technology, Berlin, Germany, 2004 (in German).
[2] M. Stiebler and 0. Okla, "A permanent-magnet toroid
wind generator," in Proc. of the International
Conference on Electrical Machines, ICEM'92,
Manchester, U.K., 1992, Vol. 3, pp.1043-1047.
[3] J. Hendershot and T. Miller, Design of brushless
permanent-magnet motors. Oxford, Clarendon Press,
1994, Chapter 4, pp.4-6.
[4] J. R. Deodhar, D. A. Staton, T. M. Jahns, and T. J.
Miller, "Prediction of cogging torque using the fluxMMF diagram technique," IEEE Trans. Ind.
Applications, vol. 32, no. 3, pp. 569-576, May/June
1996.
[5] J.M.D. Coey, Rare-Earth Iron Permanent Magnets.
Oxford, Clarendon Press, 1996, pp. 494.
[6] J. Chang, "Theoretical and experimental study of an
electronic commutated DC motor with double cylinder
rotor," Ph.D. dissertation, Berlin University of
Technology, Berlin, Germany, 1984 (in German).

250rpm

--=

82

76

74

/ /

II

1.5

Fig. 14. Efficiency

as

2.5

Stator Current (A)

3.5

function of stator current at 250 and 180rpm

VI. CONCLUSIONS
A low-speed rare-earth PM electrical machine
with new topology was designed, optimized, constructed
and tested. The PMs are fixed on the rotor support
structure, which must not consist of soft magnetic material.

164