Sanjida PDF

Design of Low Speed Axial Flux Permanent
Magnet Generators for Marine Current

Application
Sanjida Moury
Supervised by
Dr. Tariq Iqbal
Faculty of Engineering and Applied Science

Memorial University of Newfoundland
St. Johns, NL, A1B 3X5, Canada
October 16, 2009 1
Presentation at a glance
Objective
Background
Design challenges
First prototype
Minimization of Cogging Torque TORUS Configuration
TORUS configuration
Alternating Pole Arc
Magnet Shifting
Fractional Number of Slots Per Pole
Generator design
Rotor
Stator
Stator winding
Prototyped Generator
Test Result
Mechanical Parameter test
Electrical parameter test
System model
2
Cont.
Second prototype
Generator Design
Rotor
Stator
Stator winding
Test Result
System model
Comparison between two prototype
Conclusion
Future work
Acknowledgement
3
Objective
To extract few watts electrical power from the
sea-floor ocean current.
To design a generator suitable for under water

application.
To design a direct driven generator by

eliminating step-up gearbox.
To design permanent magnet generators as a

low speed energy converter.
4
Background
Permanent Magnet Generator (PMG)
Figure 1(a): Radial Flux PMG Figure 1(b):Axial Flux PMG
5
Background (Cont.)
Axial Flux PMG
Figure 2:Different types of AFPMG
6
Background (Cont.)
AFPM disc-type motor structures
Figure 3: (a) slotless TORUS, (b) slottedTORUS,

(c) slotless AFIR, and (d) slotted AFIR machines.
7
Design Challenges
No of pole
1
Tmax Ls = Lm + L
Ls
1 120 f
Lm n=
p2 p
Size
Material
Air gap
8
First Prototype
Figure 4: Designed generator
9
Minimization of Cogging Torque
Torque Components
1. Torque Ripple
2. Cogging Torque
3. Pulsating Torque
Minimization technique
1. Reducing the amplitude of each
portion
2. Shifting the relative phase of the
different components
10
Minimization of Cogging Torque (Cont.)
TORUS Configuration
(a) (b)
Figure 5: TORUS Topology (a) NN type and (b) NS type
11
Alternating Pole Arc
Figure 6(a): Same magnet Figure 6(b): Different magnet

pole arc Pole arc
12
Magnet Shifting
Fractional Number of Slots Per Pole
Figure 7: Axial view of Rotor

Figure 8: Two dimensional view
With Shifted magnet
of shifted magnet
13
Generator Design
Rotor
Magnetic material- NdFeB
Number of pole- 100 Large gap
Large magnet
Steel ring
Small gap
Small magnet
Figure 9: Full and sectional view of Rotor

14
Generator Design (Cont.)
Stator
Slotted stator is build with ferrite E-cores.
(a) (b)
Figure 10: (a) E-core (b) Stator
15
Generator Design (Cont.)
Stator Winding
Number of turns
E max 2 Ns
E rms = = N f max
2 2 N ph
max = Amagn Bmax

lm
B max = Br
(lm + )
16
Generator Design (Stator Winding) Cont
Figure 11: Prototyped stator

17
Generator Design (Stator Winding) Cont
Figure 12: Stator winding
18
Figure 13: prototyped generator

19
Test result
mr 2
r J =
2
Rotor
m
F
Figure 14: Initial torque Measurement
20
Test result (cont.)
Generator
Multimeter
Oscilloscope
Load
Prime mover
Figure 15: Test setup
21
Test result (Electrical parameter test) cont.
Figure 16: Open Circuit voltage characteristic
22
Each graph shows the

variation of generated
power with rotational
speed. The different
graphs are for different
load (2-20 ohm).
Figure 17: Output Characteristic
23
The graph shows the

variation of load voltage
with load current as load
varies from 0-20 ohm.
The different graphs are
for different frequencies.
Figure 18:Load current and voltage characteristic
24

power with load. The
different graphs are for
different frequencies.
Figure 19: Load characteristic

25
Resultant wave form after

The voltage wave form for connecting the both sides
the both sides of the stator of the stator in series
Figure 20: Voltage wave form
26
System model
Internal resistance, Rg, [ohm] 1.8
Internal inductance, Lg [H] 216.7
Machine constant, m 0.071
No load loss. Rnull [ohm] 0.003f2+0.0116f-0.1458
Inertia, Jm [Kg-m2] o.96
Initial torque, To [N-m] 14.5
Open Circuit voltage at 72 rpm [volt] 5.18
Load for maximum power point 1.8

Figure 21: System model [ohm]
27
Conclusion
Output Power is 3.5 watt at 72 rpm.
Open circuit voltage is 5.2 volt at
designed speed.
Generating current is high due to
thicker wire.
Cogging torque is minimized.
Large in size
More frictional loss
28
Second Prototype
Figure 22: Designed generator

29
Generator design
PCB stator
Figure 23: Designed topology of second prototype
30
Generator design (cont.)
Rotor
Figure 24: Rotor
31
Generator design (Rotor )cont.
Figure 24: Rotor
32
Stator
Figure 25: 4 layer PCB Stator

33
Stator Winding
Figure 26: Stator Winding Pattern Figure 27: Stator winding
34
Generator design (Stator winding) cont.
Figure 28: A single winding with dimension (in Inches)
35
Prototyped generator
Figure 29: Prototyped Generator
36
Test Result
Stress and strain test
Figure 30: Stress strain test result
37
Test Result (Cont)
Mechanical parameter test
N1= No (1-e t1/BJ )
Figure 31: Friction loss test result
38
Test Result (Cont)
Figure 32: Test setup
39
Test Result (Electrical parameter test) Cont.
Figure 33: Open Circuit voltage characteristic
40

power with rotational
speed. The different
graphs are for different
load (2-20 ohm).
Figure 34: Output Characteristic
41
The graph shows the

variation of load voltage
with load current as load
varies from 0-20 ohm.
The different graphs are
for different frequencies.
Figure 35:Load current and voltage characteristic

42

power with load. The
different graphs are for
different frequencies
Figure 36: Load characteristic
43
Figure 37: Voltage wave form
44
System parameter
Internal resistance, Rg, [ohm] 4.4
Internal inductance, Lg [H] 66.2

Machine constant, m 0.078
No load loss. Rnull [ohm] 0.0003f2+0.0066f-0.1107
Inertia, Jm [Kg-m2] 0.213

Friction, Bm 0.3
Initial torque, To [N-m] 0
Open Circuit voltage at 72 rpm [volt] 5.6
Load for maximum power point [ohm] 4.5
45
Conclusion
Small in size
No cogging
Less friction
Zero initial torque
Higher voltage, 5.6 volt at 72 rpm.
Less current and power (1.8 watt)
46
Comparison between two prototype
Size
Output
Torque
Manufacturing process
47
Conclusion
Two prototypes are built and tested.
First Prototype
New cogging torque minimization technique
More power
Larger size
Higher current
Lower voltage
Second prototype
PCB stator
Smaller size
Higher voltage
Lower current and power
48
Future Work
Air gap reduction
Material choice
Smaller E-core
More layer PCB
Optimization
49
Acknowledgement
Dr. Tariq Iqbal

Seaformatics group
Atlantic Innovation Funds
(www.acoa.ca)
Memorial University of Newfoundland
All of my friends and family
50
THANKS
?
Questions
51
Magnet properties
52
RENSHAPE 440 material properties
53
Properties of AWG 20
54
Rotor Yoke (mild steel C-1020) data
55
FR-4 data
56
Generator design parameters
57
Generator design parameters
58

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Design of Low Speed Axial Flux Permanent

Magnet Generators for Marine Current

Faculty of Engineering and Applied Science

To design a generator suitable for under water

To design a direct driven generator by

To design permanent magnet generators as a

Figure 1(a): Radial Flux PMG Figure 1(b):Axial Flux PMG

Figure 2:Different types of AFPMG

Figure 3: (a) slotless TORUS, (b) slottedTORUS,

Figure 4: Designed generator

Figure 5: TORUS Topology (a) NN type and (b) NS type

Alternating Pole Arc

Figure 6(a): Same magnet Figure 6(b): Different magnet

Figure 7: Axial view of Rotor

Figure 9: Full and sectional view of Rotor

Figure 10: (a) E-core (b) Stator

max = Amagn Bmax

Figure 11: Prototyped stator

Figure 12: Stator winding

Figure 13: prototyped generator

Figure 14: Initial torque Measurement

Figure 15: Test setup

Figure 16: Open Circuit voltage characteristic

Each graph shows the

Figure 17: Output Characteristic

The graph shows the

Figure 18:Load current and voltage characteristic

Each graph shows the

Figure 19: Load characteristic

Resultant wave form after

Figure 20: Voltage wave form

Internal inductance, Lg [H] 216.7

Machine constant, m 0.071

No load loss. Rnull [ohm] 0.003f2+0.0116f-0.1458

Inertia, Jm [Kg-m2] o.96

Initial torque, To [N-m] 14.5

Open Circuit voltage at 72 rpm [volt] 5.18

Load for maximum power point 1.8

Figure 22: Designed generator

Figure 23: Designed topology of second prototype

Figure 24: Rotor

Figure 24: Rotor

Figure 25: 4 layer PCB Stator

Figure 26: Stator Winding Pattern Figure 27: Stator winding

Figure 28: A single winding with dimension (in Inches)

Figure 29: Prototyped Generator

Figure 30: Stress strain test result

N1= No (1-e t1/BJ )

Figure 31: Friction loss test result

Figure 32: Test setup

Figure 33: Open Circuit voltage characteristic

Each graph shows the

Figure 34: Output Characteristic

The graph shows the

Figure 35:Load current and voltage characteristic

Each graph shows the

Figure 36: Load characteristic

Figure 37: Voltage wave form

Internal inductance, Lg [H] 66.2