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COMPARISON ON WINDING METHOD FOR ELECTRICAL GENERATOR Chua Ten Hou Bachelor of Engineering (Hons) in Electronics (Telecommunications) 2017

COMPARISON ON WINDING METHOD FOR ELECTRICAL …

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Page 1: COMPARISON ON WINDING METHOD FOR ELECTRICAL …

COMPARISON ON WINDING METHOD FOR ELECTRICAL

GENERATOR

Chua Ten Hou

Bachelor of Engineering (Hons) in Electronics (Telecommunications)

2017

UNIVERSITI MALAYSIA SARAWAK

Grade

Please tick (v)

Final Year Project Report [ZJ Masters D PhD D

DECLARATION OF ORIGINAL WORK

J i J-eThis declaration is made on the day of 2017

Students Declaration

I CtUJ rENt1QU lt~Q~mD from fJCUL1yQfENmNEERNQ hereby decla re that the work entitled COMPMU~ON oN WNPJNGME1BOP fOR ELECrRIGN GENiRA1QR is my original work I have not copied from any other students work or from any other SOurces except where due reference or acknowledgement is made explicitly in the text nor has any part been ~ritten for me by another person

Date submitted CHUA TEN HOU (40938)

Supervisors Declaration

I OJLNGU SZESQlG hereby certifies that the work entitiedCOMPARISONQNWmWNQ METBQP fQR ELEGTRtCMQENERA1QR was prepared by the above named student and was submitted to the FACULTY as a partialfull fulfillment for the conferment of JlACHELQR

QL ENGtNEERJNG ltHQNSl IN ELECTRQNJCS lt1ELECQMM1-JNJCATJONSJ and the aforementioned work to the best of my knowledge is the said students work

lu - G - Date _______ _

(DR NGU SZE SONG) Received for examination by

_ _

I declare that ProjectThesis is classified as (please tick (gti))

o CONFIDENTIAL (Contains confidential iriiormation under the Official Secret Act 1972)

D R ESTRICTED (Contains restricted information as specified by the organisation where

research was done)

IZi O PEN ACCESS

Validation of ProjectThesis

I therefore duly affIrmed with free consent and willingness declare that this said ProjectThesis shall

be placed officially in the Centre for Academic Iriiormation Services with the abiding interest and

rights as follows

bull This ProjectThesis is the sole legal property of Universiti Malaysia Sarawak (UNIMAS)

bull The Centre for Academic Iriiormation Services has the lawful right to make copies for the

purpose of academic and research only and not for other purpose

bull The Centre for Academic Iriiormation Services has the lawful right to digitahse the

content for the Local Content Database

bull The Centre for Academic Iriiormation Services has the lawful right to make copies of the

ProjectThesis for academic exchange between Higher Learning Institute

bull No dispute or any claim shall arise from the student itself neither third party on this ProjectrThesis once it becomes the sole property of UNIMAS

bull This ProjectThesis or any material data and information related to it shall not be

distributed published or disclosed to any party by the student except with UNIMAS

permlSSlOll

()~Student signature ____ --_-_ _ _ _ Supervisor signature __4__--_

(~~bllaquoJJ7 ) ( 10 - b- )

Current Address

2E LORONG 5 JALAN MERDEKA 96000 SIBU SARAWAK

Notes If the ProjectThesis is CONFIDENTIAL or RESTRICTED please attach together as

annexure a letter from the organisation with the period and reasons of confidentiality and

restriction

[The instrument is duly prepared by The Centre for Academic Iniormation Services]

COMPARISON ON WINDING METHOD FOR ELECTRICAL

GENERATOR

CHUA TEN HOU

A dissertation submitted in partial fulfillment

of the requirement for the degree of

Bachelor of Engineering (Hons) in Electronics (Telecommunications)

Faculty of Engineering

Universiti Malaysia Sarawak

2017

To my beloved family and friends

i

ACKNOWLEDGEMENT

First of all my special thanks gratitude and respect go to my final year projectrsquos

supervisor Dr Ngu Sze Song His endless patience persistent encouragements valuable

guidance and advice throughout this project are highly appreciated His timely

supervision on my project had helped me to accomplish my project in time Special thanks to all my friends and staff of Universiti Malaysia Sarawak that

helped me during my degree study Without their contribution and support I would not

be able to finish my project

Last but not least I would like to thank my parents for their mentally and

physically support not only for finishing this project but also during my whole degree

studies in UNIMAS

ii

ABSTRACT

Permanent Magnet Synchronous Generator (PMSG) is the most favorable

generator in producing the electricity especially in wind turbine industry The PMSG has

a higher efficiency compared to other generators as its excitation field is provided by the

permanent magnet This is an advantage for the generator as it reduces the maintenance

cost of the generator

A suitable winding method for the PMSG can increase the performance of the

generator There are four types of winding methods that are widely used in the generator

which are single layer winding double layer winding concentrated winding and

distributed winding In this thesis the single layer concentrated winding double layer

concentrated winding single layer distributed winding and double layer distributed

winding are simulated in Finite Element Method Magnetics (FEMM) The PMSG is

simulated and analyzed according to different winding methods This analysis is aimed

to compare different type of winding methods in order to enhance the efficiency of the

PMSG

iii

ABSTRAK

Permanent Magnet Synchronous Generator (PMSG) adalah penjana yang paling

baik dalam menghasilkan elektrik terutamanya dalam industri turbin angin PMSG

mempunyai kecekapan yang lebih tinggi berbanding dengan penjana lain disebabkan

medan pengujaannya diperoleh daripada magnet kekal Hal ini merupakan satu kelebihan

untuk generator tersebut kerana ia mengurangkan kos penyelenggaraan penjana

Kaedah penggulungan yang sesuai untuk PMSG boleh meningkatkan prestasi

penjana Terdapat 4 jenis kaedah penggulungan yang digunakan secara meluas dalam

penjana iaitu single layer winding double layer winding concentrated winding dan

distributed winding Dalam tesis ini single layer concentrated winding double layer

concentrated winding single layer distributed winding dan double layer distributed

winding disimulasikan dengan Finite Element Method Magnetics (FEMM) PMSG

disimulasikan dan dianalisiskan mengikut kaedah penggulungan yang berbeza Analisis

ini bertujuan untuk membandingkan kaedah penggulungan yang berbeza bagi

meningkatkan kecekapan PMSG

iv

TABLE OF CONTENTS

Page

Acknowledgement i

Abstract ii

Abstrak iii

Table of Contents iv

List of Tables vii

List of Figures viii

List of Abbreviations xi

Chapter 1 INTRODUCTION 1

11 Overview 1

12 Problem Statement 3

13 Objectives 4

14 Expected Outcomes 4

15 Project Outlines 4

Chapter 2 LITERATURE REVIEW 6

21 Permanent Magnet Alternating Current Machine 6

22 Winding Approaches 9

221 Single Layer Winding 9

222 Double Layer Winding 11

223 Distributed Winding 12

224 Concentrated Winding 13

23 Fundamental PMSM Relationships 14

231 Speed 14

232 Winding Factor 15

233 Electromagnetic Torque 15

24 No Load Operation 16

25 Winding Function Analysis 17

v

26 Magnetomotive Force (MMF) 19

261 Concentrated Full-Pitch Coil 19

262 Distributed Full-Pitch Coil Phase Winding 19

263 Three Phase Full-Pitch (Single-Layer) Winding 20

264 Three Phase Shorted-Pitch Coil (Double-Layer) 20

Winding

27 Inductance 20

28 Reactance 21

281 Synchronous Reactance 21

282 Leakage Reactance 21

29 Losses 22

291 Copper Loss 22

292 Core Loss 22

210 Back-EMF 23

Chapter 3 METHODOLOGY 24

31 Overview 24

32 Work Plan Flow Chart 25

33 Finite Element Method Magnetics 42 27

34 Block Integral 27

35 Lua Programming Language 28

36 Magnetics Preprocessor 29

37 Analysis Processor 30

38 Magnetics Postprocessor 32

Chapter 4 RESULTS AND DISCUSSIONS 34

41 Overview 34

42 Design Specification of PMSG 34

43 The Structure of PMSG 36

44 Winding Patterns 37

441 Single Layer Concentrated Winding 37

442 Double Layer Concentrated Winding 39

443 Single Layer Distributed Winding 41

444 Double Layer Distributed Winding 43

vi

45 Flux Linkage 45

46 Back-EMF 50

47 Air-gap Flux Density 55

48 Cogging Torque 58

49 Copper Loss 61

410 Summary 65

Chapter 5 CONCLUSION AND RECOMMENDATION 66

51 Conclusion 66

52 Recommendation 67

REFERENCES 68

APPENDIX A 71

APPENDIX B 72

APPENDIX C 73

APPENDIX D 74

vii

LIST OF TABLES

Table Page

41 Design Parameter of the PMSG 35

42 Materials of the Generator 35

43 The Current and Flux Linkage of SLCW PMSG 45

44 The Current and Flux Linkage of DLCW PMSG 46

45 The Current and Flux Linkage of SLDW PMSG 47

46 The Current and Flux Linkage of DLDW PMSG 48

47 The Back-EMF of SLCW PMSG 50

48 The Back-EMF of DLCW PMSG 51

49 The Back-EMF of SLDW PMSG 52

410 The Back-EMF of DLDW PMSG 53

411 The Air-gap Flux Density of PMSG for each Winding Patterns 55

412 The Cogging Torque of PMSG for each Winding Patterns 58

413 The Copper Loss of SLCW PMSG 61

414 The Copper Loss of DLCW PMSG 62

415 The Copper Loss of SLDW PMSG 63

416 The Copper Loss of DLDW PMSG 64

viii

LIST OF FIGURES

Figure Page

11 Global Electricity Production of Renewable Energy Share 2015 1

12 Global Capacity of Wind Power in the year 2005-2015 2

21 Axial Flux PMSMrsquos Structure 7

22 Radial Flux PMSMrsquos Structure 7

23 Surface PMSM 8

24 Surface Inset PMSM 8

25 Interior PMSM 8

26 Interior PMSM with Circumferential Orientation 8

27 Schematic Layout for Single Layer Winding 10

28 Winding Diagram with a Single Conductor per Slot 10

29 Winding Diagram with Multiple Conductors per Slot 11

210 Schematic Layout for Double Layer Winding 11

211 Winding Diagram for Double Layer Winding 12

212 Distributed Winding 13

213 FSCW-IPM with Double Layer Winding 13

214 FSCW-IPM with Single Layer Winding 14

215 Phasor Diagram for No Load Motor and Generator Operation for 16

Underexcited Condition respectively

216 Phasor Diagram for No Load Motor and Generator Operation for 16

Overexcited Condition respectively

217 Turns Function Definition 18

31 The Flow Chart of the Project 25

32 Drawing Mode Toolbar 29

33 Grid Manipulation Toolbar 30

34 Toolbar for Analysis Processor 30

35 Mesh for the PMSG Model 31

36 Status of the Model 31

37 Analysis Mode Toolbar 32

ix

38 The Depiction of Model in Point Values Mode 32

39 The Depiction of Model in Contour Mode 33

310 The Depiction of Model in Block Mode 33

41 Part of the Structure of the PMSG Model 36

42 The Structure of SLCW PMSG 37

43 SLCW Configuration 38

44 Flux Line and Flux Density of SLCW PMSG 38

45 Vector Plot of SLCW PMSG 38

46 The Structure of DLCW PMSG 39

47 DLCW Configuration 40

48 Flux Line and Flux Density of DLCW PMSG 40

49 Vector Plot of DLCW PMSG 40

410 The Structure of SLDW PMSG 41

411 SLDW Configuration 42

412 Flux Line and Flux Density of SLDW PMSG 42

413 Vector Plot of SLDW PMSG 42

414 The Structure of DLDW PMSG 43

415 DLDW Configuration 44

416 Flux Line and Flux Density of DLDW PMSG 44

417 Vector Plot of DLDW PMSG 44

418 The Flux Linkage of SLCW PMSG 46

419 The Flux Linkage of DLCW PMSG 47

420 The Flux Linkage of SLDW PMSG 48

421 The Flux Linkage of DLDW PMSG 49

422 The Back-EMF of SLCW PMSG 51

423 The Back-EMF of DLCW PMSG 52

424 The Back-EMF of SLDW PMSG 53

425 The Back-EMF of DLDW PMSG 54

426 The Air-gap Flux Density of SLCW PMSG 56

427 The Air-gap Flux Density of DLCW PMSG 56

428 The Air-gap Flux Density of SLDW PMSG 57

429 The Air-gap Flux Density of DLDW PMSG 57

430 The Cogging Torque of SLCW PMSG 59

431 The Cogging Torque of DLCW PMSG 59

x

432 The Cogging Torque of SLDW PMSG 60

433 The Cogging Torque of DLDW PMSG 60

434 The Copper Loss of SLCW PMSG 62

435 The Copper Loss of DLCW PMSG 63

436 The Copper Loss of SLDW PMSG 64

437 The Copper Loss of DLDW PMSG 65

xi

LIST OF ABBREVIATIONS

PM - Permanent Magnet

PMSG - Permanent Magnet Synchronous Generator

FEMM - Finite Element Method Magnetics

PMSM - Permanent Magnet Synchronous Machine

MMF - Magnetomotive Force

FSCW - Fractional-slot Concentrated Winding

IPM - Interior Permanent Magnet

RPM - Revolutions per Minute

EMF - Electromotive Force

SLCW - Single Layer Concentrated Winding

DLCW - Double Layer Concentrated Winding

SLDW - Single Layer Distributed Winding

DLDW - Double Layer Distributed Winding

1

CHAPTER 1

INTRODUCTION

11 Overview

Electricity is one of our essential needs especially in our daily life as most of the

appliances in the home office or even factories depend on electricity to function Almost

all the electricity produced in the world is generated by the electric machine Electricity

exists in nature as a form of lightning It also can be generated from the electrical power

generator Electricity can be produced through various ways such as wind water nuclear

or even combustion of coal and oil Figure 11 below depicts that the wind energy is the

second highest of the renewable energy in the electricity generation which is 37 [1]

Figure 11 Global Electricity Production of Renewable Energy Share 2015 [1]

2

A synchronous machine is an alternating current rotating machine that its speed

is proportional to the frequency of the current in its armature under steady state condition

This means that the magnetic field of the armature currents will rotate at the same

synchronous speed as the permanent magnets (PM) or the field current on the rotor Due

to the characteristic of the synchronous speed the synchronous generator is applied to the

constant speed drive

Figure 12 Global Capacity of Wind Power in the year 2005-2015 [1]

Figure 12 shows that the wind power global capacity had increased continuously

for each year from the year 2005 until 2015 In the year 2015 the global capacity for wind

power had reached 433 Gigawatts [1] This concluded that the demand for the electricity

from wind energy had risen In wind turbine industry permanent magnet synchronous

generator (PMSG) is widely used to produce electricity Permanent magnet is used for

the synchronous generator instead of the coil for excitation field PMSG does not require

slip rings to operate There is no direct current supply that is needed for excitation circuit

Without the need of slip rings PMSG is easier to be constructed and lower maintenance

cost The permanent magnet minimizes the rotor losses and this indirectly improves the

efficiency of the generator

PMSG offers a great privilege due to its stable operation [2] However the

construction fee for PMSG is costly due to its rare earth material permanent magnet

3

Despite the high cost of the permanent magnet the PMSG is widely used in the concern

of the environmental conservation The air-gap magnetic flux density also increased with

the use of permanent magnet PMSG has a smaller volume and lower density The

permanent magnet can be positioned inside the rotor or even mounted on the rotorrsquos

surface The maximum efficiency can be achieved by minimizing the air-gap between

rotor and stator

There are various ways for coils to be wound in the stator of the generator Each

of the forms has its own drawbacks and advantages The main purpose of varying the

forms of the coil distribution is to produce three balanced sinusoidal voltages with a little

harmonic voltage and current for three phase machine In other words the output power

is maximized and the losses are minimized with different patterns of coil distribution The

number of slots at the stator can be varied which will affect the manner of the coil

connection and hence different winding patterns can be formed

12 Problem Statement

The PMSG is a part of the wind turbine system Nowadays as the demand for the

electrical energy had increased rapidly around the world the efficiency for the PMSG is

seeking more attention from the researcher With an attempt to increase the performance

of the PMSG the world non-renewable energy consumption can be reduced and the

global warming issue can be minimized or even rectified Moreover the global economy

will also be improved and this will eventually enhance the quality living of life

Furthermore a better performance of PMSG can surely aid in the prevention of climate

change All these advantages come with the energy efficiency Hence various design on

the PMSG had been researched to increase the power output and reduce the losses of the

generator

There is no doubt that the PMSG is well known for its high efficiency and long

lasting performance which can be used in wind turbine However there are various ways

to enhance the performance of the PMSG One of the factors that determine the efficiency

of the PMSG is the winding method In this thesis the winding patterns that are compared

are single layer concentrated winding (SLCW) double layer concentrated winding

(DLCW) single layer distributed winding (SLDW) and double layer distributed winding

(DLDW) In order to improve the efficiency of the PMSG the most suitable winding

pattern has to be chosen

4

13 Objectives

The objectives of this project are

To study and investigate the winding methods for PMSG

To determine the efficiency of PMSG for each type of the windings

To compare the winding methods for the PMSG

To perform analytical analysis and simulation by using Finite Element

Method Magnetics (FEMM) to maximize the efficiency of the PMSG

14 Expected Outcomes

In this project the expected outcomes are listed below

The winding methods of the stator for the PMSG are studied and compared

The simulation of the PMSG is done by using FEMM software

The efficiency of each of the winding methods is analyzed and compared

The winding method that yields the highest performance of the PMSG is

determined

15 Project Outlines

This project contains five chapters These chapters comprised of Introduction

Literature Review Methodology Result and Discussion and Conclusion and

Recommendation These chapters are arranged from Chapter 1 to Chapter 5 respectively

Chapter 1 provides a brief introduction to the electricity generation together with

a short review on the PMSG the problem statement and objectives of this project The

expected outcomes at the end of the project are also included in this chapter

Chapter 2 reviews and compiles all the studies and research that are related to the

project The topologies for the PMSG different winding methods of the stator parameter

that determine the efficiency of the PMSG and analysis approach are discussed in this

chapter

Chapter 3 discusses the methodology that is needed to carry out the project In this

chapter the PMSG model that is used in this project is presented and explained The

5

terminology and the analytical approach by using the FEMM software are depicted in this

section

Chapter 4 computes the performance of the PMSG either through mathematical

calculation or via the 2 dimension simulation of the FEMM The parameters that affect

the efficiency of PMSG is evaluated All the graphical results and the magnetic field maps

are delineated in this chapter

Chapter 5 concludes all the results of the project and summarize the outcomes

The recommendations after carrying out this project are discussed in this chapter Any

limitation of this project is included too

6

CHAPTER 2

LITERATURE REVIEW

21 Permanent Magnet Alternating Current Machine

The Permanent Magnet Synchronous Machine (PMSM) can be divided into two

categories which are axial field and radial field For axial field topology the flux is

moving parallel to the rotor shaft whereas the flux is moving along the machinersquos radius

for the radial field topology [3] The permanent magnet can be placed at a various position

on the rotor The pro and cons of the axial field and radial field topologies are discussed

below [4]

Axial fieldrsquos strengths

A balanced rotor-stator attractive forces with two air-gaps

The grinding to an arc shape is skipped as the permanent magnets have two planar

surfaces

There is an adjustable air-gap

Magnet retainment is not needed

Axial fieldrsquos weakness

There is a poor winding utilization

Restricted size of the end turns at the internal radius

Cogging torque existed

Radial fieldrsquos strengths

There is no radial force on the rotor

Easier removal of heat from the stator winding due to the big surface area of the

stator back iron

7

Skewing is not needed

Radial fieldrsquos weakness

The magnets surface must be arced

Fixed air-gap

An air-gap is formed between rotor magnets with the rotor back iron

Figure 21 and Figure 22 show the axial and radial field structure of PMSM

respectively [5]

Figure 21 Axial Flux PMSMrsquos Structure [5]

Figure 22 Radial Flux PMSMrsquos Structure [5]

8

Figure 23 24 25 and 26 show the radial field of the PMSM with different

positions of permanent magnets [3]

Figure 23 Surface PMSM [3] Figure 24 Surface Inset PMSM [3]

Figure 25 Interior PMSM [3] Figure 26 Interior PMSM with

Circumferential Orientation [3]

The permanent magnets of the surface PMSM are directly mounted on the rotorrsquos

surface as shown in Figure 23 Figure 24 shows that the permanent magnets of the

surface inset PMSM are fixed at the rotor inner surface The Figure 25 depicts that the

permanent magnets of the PMSM are implanted inside the rotor meanwhile the permanent

magnets are aligned in a circular orientation inside the rotor of the PMSM as shown in

Figure 26

Page 2: COMPARISON ON WINDING METHOD FOR ELECTRICAL …

UNIVERSITI MALAYSIA SARAWAK

Grade

Please tick (v)

Final Year Project Report [ZJ Masters D PhD D

DECLARATION OF ORIGINAL WORK

J i J-eThis declaration is made on the day of 2017

Students Declaration

I CtUJ rENt1QU lt~Q~mD from fJCUL1yQfENmNEERNQ hereby decla re that the work entitled COMPMU~ON oN WNPJNGME1BOP fOR ELECrRIGN GENiRA1QR is my original work I have not copied from any other students work or from any other SOurces except where due reference or acknowledgement is made explicitly in the text nor has any part been ~ritten for me by another person

Date submitted CHUA TEN HOU (40938)

Supervisors Declaration

I OJLNGU SZESQlG hereby certifies that the work entitiedCOMPARISONQNWmWNQ METBQP fQR ELEGTRtCMQENERA1QR was prepared by the above named student and was submitted to the FACULTY as a partialfull fulfillment for the conferment of JlACHELQR

QL ENGtNEERJNG ltHQNSl IN ELECTRQNJCS lt1ELECQMM1-JNJCATJONSJ and the aforementioned work to the best of my knowledge is the said students work

lu - G - Date _______ _

(DR NGU SZE SONG) Received for examination by

_ _

I declare that ProjectThesis is classified as (please tick (gti))

o CONFIDENTIAL (Contains confidential iriiormation under the Official Secret Act 1972)

D R ESTRICTED (Contains restricted information as specified by the organisation where

research was done)

IZi O PEN ACCESS

Validation of ProjectThesis

I therefore duly affIrmed with free consent and willingness declare that this said ProjectThesis shall

be placed officially in the Centre for Academic Iriiormation Services with the abiding interest and

rights as follows

bull This ProjectThesis is the sole legal property of Universiti Malaysia Sarawak (UNIMAS)

bull The Centre for Academic Iriiormation Services has the lawful right to make copies for the

purpose of academic and research only and not for other purpose

bull The Centre for Academic Iriiormation Services has the lawful right to digitahse the

content for the Local Content Database

bull The Centre for Academic Iriiormation Services has the lawful right to make copies of the

ProjectThesis for academic exchange between Higher Learning Institute

bull No dispute or any claim shall arise from the student itself neither third party on this ProjectrThesis once it becomes the sole property of UNIMAS

bull This ProjectThesis or any material data and information related to it shall not be

distributed published or disclosed to any party by the student except with UNIMAS

permlSSlOll

()~Student signature ____ --_-_ _ _ _ Supervisor signature __4__--_

(~~bllaquoJJ7 ) ( 10 - b- )

Current Address

2E LORONG 5 JALAN MERDEKA 96000 SIBU SARAWAK

Notes If the ProjectThesis is CONFIDENTIAL or RESTRICTED please attach together as

annexure a letter from the organisation with the period and reasons of confidentiality and

restriction

[The instrument is duly prepared by The Centre for Academic Iniormation Services]

COMPARISON ON WINDING METHOD FOR ELECTRICAL

GENERATOR

CHUA TEN HOU

A dissertation submitted in partial fulfillment

of the requirement for the degree of

Bachelor of Engineering (Hons) in Electronics (Telecommunications)

Faculty of Engineering

Universiti Malaysia Sarawak

2017

To my beloved family and friends

i

ACKNOWLEDGEMENT

First of all my special thanks gratitude and respect go to my final year projectrsquos

supervisor Dr Ngu Sze Song His endless patience persistent encouragements valuable

guidance and advice throughout this project are highly appreciated His timely

supervision on my project had helped me to accomplish my project in time Special thanks to all my friends and staff of Universiti Malaysia Sarawak that

helped me during my degree study Without their contribution and support I would not

be able to finish my project

Last but not least I would like to thank my parents for their mentally and

physically support not only for finishing this project but also during my whole degree

studies in UNIMAS

ii

ABSTRACT

Permanent Magnet Synchronous Generator (PMSG) is the most favorable

generator in producing the electricity especially in wind turbine industry The PMSG has

a higher efficiency compared to other generators as its excitation field is provided by the

permanent magnet This is an advantage for the generator as it reduces the maintenance

cost of the generator

A suitable winding method for the PMSG can increase the performance of the

generator There are four types of winding methods that are widely used in the generator

which are single layer winding double layer winding concentrated winding and

distributed winding In this thesis the single layer concentrated winding double layer

concentrated winding single layer distributed winding and double layer distributed

winding are simulated in Finite Element Method Magnetics (FEMM) The PMSG is

simulated and analyzed according to different winding methods This analysis is aimed

to compare different type of winding methods in order to enhance the efficiency of the

PMSG

iii

ABSTRAK

Permanent Magnet Synchronous Generator (PMSG) adalah penjana yang paling

baik dalam menghasilkan elektrik terutamanya dalam industri turbin angin PMSG

mempunyai kecekapan yang lebih tinggi berbanding dengan penjana lain disebabkan

medan pengujaannya diperoleh daripada magnet kekal Hal ini merupakan satu kelebihan

untuk generator tersebut kerana ia mengurangkan kos penyelenggaraan penjana

Kaedah penggulungan yang sesuai untuk PMSG boleh meningkatkan prestasi

penjana Terdapat 4 jenis kaedah penggulungan yang digunakan secara meluas dalam

penjana iaitu single layer winding double layer winding concentrated winding dan

distributed winding Dalam tesis ini single layer concentrated winding double layer

concentrated winding single layer distributed winding dan double layer distributed

winding disimulasikan dengan Finite Element Method Magnetics (FEMM) PMSG

disimulasikan dan dianalisiskan mengikut kaedah penggulungan yang berbeza Analisis

ini bertujuan untuk membandingkan kaedah penggulungan yang berbeza bagi

meningkatkan kecekapan PMSG

iv

TABLE OF CONTENTS

Page

Acknowledgement i

Abstract ii

Abstrak iii

Table of Contents iv

List of Tables vii

List of Figures viii

List of Abbreviations xi

Chapter 1 INTRODUCTION 1

11 Overview 1

12 Problem Statement 3

13 Objectives 4

14 Expected Outcomes 4

15 Project Outlines 4

Chapter 2 LITERATURE REVIEW 6

21 Permanent Magnet Alternating Current Machine 6

22 Winding Approaches 9

221 Single Layer Winding 9

222 Double Layer Winding 11

223 Distributed Winding 12

224 Concentrated Winding 13

23 Fundamental PMSM Relationships 14

231 Speed 14

232 Winding Factor 15

233 Electromagnetic Torque 15

24 No Load Operation 16

25 Winding Function Analysis 17

v

26 Magnetomotive Force (MMF) 19

261 Concentrated Full-Pitch Coil 19

262 Distributed Full-Pitch Coil Phase Winding 19

263 Three Phase Full-Pitch (Single-Layer) Winding 20

264 Three Phase Shorted-Pitch Coil (Double-Layer) 20

Winding

27 Inductance 20

28 Reactance 21

281 Synchronous Reactance 21

282 Leakage Reactance 21

29 Losses 22

291 Copper Loss 22

292 Core Loss 22

210 Back-EMF 23

Chapter 3 METHODOLOGY 24

31 Overview 24

32 Work Plan Flow Chart 25

33 Finite Element Method Magnetics 42 27

34 Block Integral 27

35 Lua Programming Language 28

36 Magnetics Preprocessor 29

37 Analysis Processor 30

38 Magnetics Postprocessor 32

Chapter 4 RESULTS AND DISCUSSIONS 34

41 Overview 34

42 Design Specification of PMSG 34

43 The Structure of PMSG 36

44 Winding Patterns 37

441 Single Layer Concentrated Winding 37

442 Double Layer Concentrated Winding 39

443 Single Layer Distributed Winding 41

444 Double Layer Distributed Winding 43

vi

45 Flux Linkage 45

46 Back-EMF 50

47 Air-gap Flux Density 55

48 Cogging Torque 58

49 Copper Loss 61

410 Summary 65

Chapter 5 CONCLUSION AND RECOMMENDATION 66

51 Conclusion 66

52 Recommendation 67

REFERENCES 68

APPENDIX A 71

APPENDIX B 72

APPENDIX C 73

APPENDIX D 74

vii

LIST OF TABLES

Table Page

41 Design Parameter of the PMSG 35

42 Materials of the Generator 35

43 The Current and Flux Linkage of SLCW PMSG 45

44 The Current and Flux Linkage of DLCW PMSG 46

45 The Current and Flux Linkage of SLDW PMSG 47

46 The Current and Flux Linkage of DLDW PMSG 48

47 The Back-EMF of SLCW PMSG 50

48 The Back-EMF of DLCW PMSG 51

49 The Back-EMF of SLDW PMSG 52

410 The Back-EMF of DLDW PMSG 53

411 The Air-gap Flux Density of PMSG for each Winding Patterns 55

412 The Cogging Torque of PMSG for each Winding Patterns 58

413 The Copper Loss of SLCW PMSG 61

414 The Copper Loss of DLCW PMSG 62

415 The Copper Loss of SLDW PMSG 63

416 The Copper Loss of DLDW PMSG 64

viii

LIST OF FIGURES

Figure Page

11 Global Electricity Production of Renewable Energy Share 2015 1

12 Global Capacity of Wind Power in the year 2005-2015 2

21 Axial Flux PMSMrsquos Structure 7

22 Radial Flux PMSMrsquos Structure 7

23 Surface PMSM 8

24 Surface Inset PMSM 8

25 Interior PMSM 8

26 Interior PMSM with Circumferential Orientation 8

27 Schematic Layout for Single Layer Winding 10

28 Winding Diagram with a Single Conductor per Slot 10

29 Winding Diagram with Multiple Conductors per Slot 11

210 Schematic Layout for Double Layer Winding 11

211 Winding Diagram for Double Layer Winding 12

212 Distributed Winding 13

213 FSCW-IPM with Double Layer Winding 13

214 FSCW-IPM with Single Layer Winding 14

215 Phasor Diagram for No Load Motor and Generator Operation for 16

Underexcited Condition respectively

216 Phasor Diagram for No Load Motor and Generator Operation for 16

Overexcited Condition respectively

217 Turns Function Definition 18

31 The Flow Chart of the Project 25

32 Drawing Mode Toolbar 29

33 Grid Manipulation Toolbar 30

34 Toolbar for Analysis Processor 30

35 Mesh for the PMSG Model 31

36 Status of the Model 31

37 Analysis Mode Toolbar 32

ix

38 The Depiction of Model in Point Values Mode 32

39 The Depiction of Model in Contour Mode 33

310 The Depiction of Model in Block Mode 33

41 Part of the Structure of the PMSG Model 36

42 The Structure of SLCW PMSG 37

43 SLCW Configuration 38

44 Flux Line and Flux Density of SLCW PMSG 38

45 Vector Plot of SLCW PMSG 38

46 The Structure of DLCW PMSG 39

47 DLCW Configuration 40

48 Flux Line and Flux Density of DLCW PMSG 40

49 Vector Plot of DLCW PMSG 40

410 The Structure of SLDW PMSG 41

411 SLDW Configuration 42

412 Flux Line and Flux Density of SLDW PMSG 42

413 Vector Plot of SLDW PMSG 42

414 The Structure of DLDW PMSG 43

415 DLDW Configuration 44

416 Flux Line and Flux Density of DLDW PMSG 44

417 Vector Plot of DLDW PMSG 44

418 The Flux Linkage of SLCW PMSG 46

419 The Flux Linkage of DLCW PMSG 47

420 The Flux Linkage of SLDW PMSG 48

421 The Flux Linkage of DLDW PMSG 49

422 The Back-EMF of SLCW PMSG 51

423 The Back-EMF of DLCW PMSG 52

424 The Back-EMF of SLDW PMSG 53

425 The Back-EMF of DLDW PMSG 54

426 The Air-gap Flux Density of SLCW PMSG 56

427 The Air-gap Flux Density of DLCW PMSG 56

428 The Air-gap Flux Density of SLDW PMSG 57

429 The Air-gap Flux Density of DLDW PMSG 57

430 The Cogging Torque of SLCW PMSG 59

431 The Cogging Torque of DLCW PMSG 59

x

432 The Cogging Torque of SLDW PMSG 60

433 The Cogging Torque of DLDW PMSG 60

434 The Copper Loss of SLCW PMSG 62

435 The Copper Loss of DLCW PMSG 63

436 The Copper Loss of SLDW PMSG 64

437 The Copper Loss of DLDW PMSG 65

xi

LIST OF ABBREVIATIONS

PM - Permanent Magnet

PMSG - Permanent Magnet Synchronous Generator

FEMM - Finite Element Method Magnetics

PMSM - Permanent Magnet Synchronous Machine

MMF - Magnetomotive Force

FSCW - Fractional-slot Concentrated Winding

IPM - Interior Permanent Magnet

RPM - Revolutions per Minute

EMF - Electromotive Force

SLCW - Single Layer Concentrated Winding

DLCW - Double Layer Concentrated Winding

SLDW - Single Layer Distributed Winding

DLDW - Double Layer Distributed Winding

1

CHAPTER 1

INTRODUCTION

11 Overview

Electricity is one of our essential needs especially in our daily life as most of the

appliances in the home office or even factories depend on electricity to function Almost

all the electricity produced in the world is generated by the electric machine Electricity

exists in nature as a form of lightning It also can be generated from the electrical power

generator Electricity can be produced through various ways such as wind water nuclear

or even combustion of coal and oil Figure 11 below depicts that the wind energy is the

second highest of the renewable energy in the electricity generation which is 37 [1]

Figure 11 Global Electricity Production of Renewable Energy Share 2015 [1]

2

A synchronous machine is an alternating current rotating machine that its speed

is proportional to the frequency of the current in its armature under steady state condition

This means that the magnetic field of the armature currents will rotate at the same

synchronous speed as the permanent magnets (PM) or the field current on the rotor Due

to the characteristic of the synchronous speed the synchronous generator is applied to the

constant speed drive

Figure 12 Global Capacity of Wind Power in the year 2005-2015 [1]

Figure 12 shows that the wind power global capacity had increased continuously

for each year from the year 2005 until 2015 In the year 2015 the global capacity for wind

power had reached 433 Gigawatts [1] This concluded that the demand for the electricity

from wind energy had risen In wind turbine industry permanent magnet synchronous

generator (PMSG) is widely used to produce electricity Permanent magnet is used for

the synchronous generator instead of the coil for excitation field PMSG does not require

slip rings to operate There is no direct current supply that is needed for excitation circuit

Without the need of slip rings PMSG is easier to be constructed and lower maintenance

cost The permanent magnet minimizes the rotor losses and this indirectly improves the

efficiency of the generator

PMSG offers a great privilege due to its stable operation [2] However the

construction fee for PMSG is costly due to its rare earth material permanent magnet

3

Despite the high cost of the permanent magnet the PMSG is widely used in the concern

of the environmental conservation The air-gap magnetic flux density also increased with

the use of permanent magnet PMSG has a smaller volume and lower density The

permanent magnet can be positioned inside the rotor or even mounted on the rotorrsquos

surface The maximum efficiency can be achieved by minimizing the air-gap between

rotor and stator

There are various ways for coils to be wound in the stator of the generator Each

of the forms has its own drawbacks and advantages The main purpose of varying the

forms of the coil distribution is to produce three balanced sinusoidal voltages with a little

harmonic voltage and current for three phase machine In other words the output power

is maximized and the losses are minimized with different patterns of coil distribution The

number of slots at the stator can be varied which will affect the manner of the coil

connection and hence different winding patterns can be formed

12 Problem Statement

The PMSG is a part of the wind turbine system Nowadays as the demand for the

electrical energy had increased rapidly around the world the efficiency for the PMSG is

seeking more attention from the researcher With an attempt to increase the performance

of the PMSG the world non-renewable energy consumption can be reduced and the

global warming issue can be minimized or even rectified Moreover the global economy

will also be improved and this will eventually enhance the quality living of life

Furthermore a better performance of PMSG can surely aid in the prevention of climate

change All these advantages come with the energy efficiency Hence various design on

the PMSG had been researched to increase the power output and reduce the losses of the

generator

There is no doubt that the PMSG is well known for its high efficiency and long

lasting performance which can be used in wind turbine However there are various ways

to enhance the performance of the PMSG One of the factors that determine the efficiency

of the PMSG is the winding method In this thesis the winding patterns that are compared

are single layer concentrated winding (SLCW) double layer concentrated winding

(DLCW) single layer distributed winding (SLDW) and double layer distributed winding

(DLDW) In order to improve the efficiency of the PMSG the most suitable winding

pattern has to be chosen

4

13 Objectives

The objectives of this project are

To study and investigate the winding methods for PMSG

To determine the efficiency of PMSG for each type of the windings

To compare the winding methods for the PMSG

To perform analytical analysis and simulation by using Finite Element

Method Magnetics (FEMM) to maximize the efficiency of the PMSG

14 Expected Outcomes

In this project the expected outcomes are listed below

The winding methods of the stator for the PMSG are studied and compared

The simulation of the PMSG is done by using FEMM software

The efficiency of each of the winding methods is analyzed and compared

The winding method that yields the highest performance of the PMSG is

determined

15 Project Outlines

This project contains five chapters These chapters comprised of Introduction

Literature Review Methodology Result and Discussion and Conclusion and

Recommendation These chapters are arranged from Chapter 1 to Chapter 5 respectively

Chapter 1 provides a brief introduction to the electricity generation together with

a short review on the PMSG the problem statement and objectives of this project The

expected outcomes at the end of the project are also included in this chapter

Chapter 2 reviews and compiles all the studies and research that are related to the

project The topologies for the PMSG different winding methods of the stator parameter

that determine the efficiency of the PMSG and analysis approach are discussed in this

chapter

Chapter 3 discusses the methodology that is needed to carry out the project In this

chapter the PMSG model that is used in this project is presented and explained The

5

terminology and the analytical approach by using the FEMM software are depicted in this

section

Chapter 4 computes the performance of the PMSG either through mathematical

calculation or via the 2 dimension simulation of the FEMM The parameters that affect

the efficiency of PMSG is evaluated All the graphical results and the magnetic field maps

are delineated in this chapter

Chapter 5 concludes all the results of the project and summarize the outcomes

The recommendations after carrying out this project are discussed in this chapter Any

limitation of this project is included too

6

CHAPTER 2

LITERATURE REVIEW

21 Permanent Magnet Alternating Current Machine

The Permanent Magnet Synchronous Machine (PMSM) can be divided into two

categories which are axial field and radial field For axial field topology the flux is

moving parallel to the rotor shaft whereas the flux is moving along the machinersquos radius

for the radial field topology [3] The permanent magnet can be placed at a various position

on the rotor The pro and cons of the axial field and radial field topologies are discussed

below [4]

Axial fieldrsquos strengths

A balanced rotor-stator attractive forces with two air-gaps

The grinding to an arc shape is skipped as the permanent magnets have two planar

surfaces

There is an adjustable air-gap

Magnet retainment is not needed

Axial fieldrsquos weakness

There is a poor winding utilization

Restricted size of the end turns at the internal radius

Cogging torque existed

Radial fieldrsquos strengths

There is no radial force on the rotor

Easier removal of heat from the stator winding due to the big surface area of the

stator back iron

7

Skewing is not needed

Radial fieldrsquos weakness

The magnets surface must be arced

Fixed air-gap

An air-gap is formed between rotor magnets with the rotor back iron

Figure 21 and Figure 22 show the axial and radial field structure of PMSM

respectively [5]

Figure 21 Axial Flux PMSMrsquos Structure [5]

Figure 22 Radial Flux PMSMrsquos Structure [5]

8

Figure 23 24 25 and 26 show the radial field of the PMSM with different

positions of permanent magnets [3]

Figure 23 Surface PMSM [3] Figure 24 Surface Inset PMSM [3]

Figure 25 Interior PMSM [3] Figure 26 Interior PMSM with

Circumferential Orientation [3]

The permanent magnets of the surface PMSM are directly mounted on the rotorrsquos

surface as shown in Figure 23 Figure 24 shows that the permanent magnets of the

surface inset PMSM are fixed at the rotor inner surface The Figure 25 depicts that the

permanent magnets of the PMSM are implanted inside the rotor meanwhile the permanent

magnets are aligned in a circular orientation inside the rotor of the PMSM as shown in

Figure 26

Page 3: COMPARISON ON WINDING METHOD FOR ELECTRICAL …

_ _

I declare that ProjectThesis is classified as (please tick (gti))

o CONFIDENTIAL (Contains confidential iriiormation under the Official Secret Act 1972)

D R ESTRICTED (Contains restricted information as specified by the organisation where

research was done)

IZi O PEN ACCESS

Validation of ProjectThesis

I therefore duly affIrmed with free consent and willingness declare that this said ProjectThesis shall

be placed officially in the Centre for Academic Iriiormation Services with the abiding interest and

rights as follows

bull This ProjectThesis is the sole legal property of Universiti Malaysia Sarawak (UNIMAS)

bull The Centre for Academic Iriiormation Services has the lawful right to make copies for the

purpose of academic and research only and not for other purpose

bull The Centre for Academic Iriiormation Services has the lawful right to digitahse the

content for the Local Content Database

bull The Centre for Academic Iriiormation Services has the lawful right to make copies of the

ProjectThesis for academic exchange between Higher Learning Institute

bull No dispute or any claim shall arise from the student itself neither third party on this ProjectrThesis once it becomes the sole property of UNIMAS

bull This ProjectThesis or any material data and information related to it shall not be

distributed published or disclosed to any party by the student except with UNIMAS

permlSSlOll

()~Student signature ____ --_-_ _ _ _ Supervisor signature __4__--_

(~~bllaquoJJ7 ) ( 10 - b- )

Current Address

2E LORONG 5 JALAN MERDEKA 96000 SIBU SARAWAK

Notes If the ProjectThesis is CONFIDENTIAL or RESTRICTED please attach together as

annexure a letter from the organisation with the period and reasons of confidentiality and

restriction

[The instrument is duly prepared by The Centre for Academic Iniormation Services]

COMPARISON ON WINDING METHOD FOR ELECTRICAL

GENERATOR

CHUA TEN HOU

A dissertation submitted in partial fulfillment

of the requirement for the degree of

Bachelor of Engineering (Hons) in Electronics (Telecommunications)

Faculty of Engineering

Universiti Malaysia Sarawak

2017

To my beloved family and friends

i

ACKNOWLEDGEMENT

First of all my special thanks gratitude and respect go to my final year projectrsquos

supervisor Dr Ngu Sze Song His endless patience persistent encouragements valuable

guidance and advice throughout this project are highly appreciated His timely

supervision on my project had helped me to accomplish my project in time Special thanks to all my friends and staff of Universiti Malaysia Sarawak that

helped me during my degree study Without their contribution and support I would not

be able to finish my project

Last but not least I would like to thank my parents for their mentally and

physically support not only for finishing this project but also during my whole degree

studies in UNIMAS

ii

ABSTRACT

Permanent Magnet Synchronous Generator (PMSG) is the most favorable

generator in producing the electricity especially in wind turbine industry The PMSG has

a higher efficiency compared to other generators as its excitation field is provided by the

permanent magnet This is an advantage for the generator as it reduces the maintenance

cost of the generator

A suitable winding method for the PMSG can increase the performance of the

generator There are four types of winding methods that are widely used in the generator

which are single layer winding double layer winding concentrated winding and

distributed winding In this thesis the single layer concentrated winding double layer

concentrated winding single layer distributed winding and double layer distributed

winding are simulated in Finite Element Method Magnetics (FEMM) The PMSG is

simulated and analyzed according to different winding methods This analysis is aimed

to compare different type of winding methods in order to enhance the efficiency of the

PMSG

iii

ABSTRAK

Permanent Magnet Synchronous Generator (PMSG) adalah penjana yang paling

baik dalam menghasilkan elektrik terutamanya dalam industri turbin angin PMSG

mempunyai kecekapan yang lebih tinggi berbanding dengan penjana lain disebabkan

medan pengujaannya diperoleh daripada magnet kekal Hal ini merupakan satu kelebihan

untuk generator tersebut kerana ia mengurangkan kos penyelenggaraan penjana

Kaedah penggulungan yang sesuai untuk PMSG boleh meningkatkan prestasi

penjana Terdapat 4 jenis kaedah penggulungan yang digunakan secara meluas dalam

penjana iaitu single layer winding double layer winding concentrated winding dan

distributed winding Dalam tesis ini single layer concentrated winding double layer

concentrated winding single layer distributed winding dan double layer distributed

winding disimulasikan dengan Finite Element Method Magnetics (FEMM) PMSG

disimulasikan dan dianalisiskan mengikut kaedah penggulungan yang berbeza Analisis

ini bertujuan untuk membandingkan kaedah penggulungan yang berbeza bagi

meningkatkan kecekapan PMSG

iv

TABLE OF CONTENTS

Page

Acknowledgement i

Abstract ii

Abstrak iii

Table of Contents iv

List of Tables vii

List of Figures viii

List of Abbreviations xi

Chapter 1 INTRODUCTION 1

11 Overview 1

12 Problem Statement 3

13 Objectives 4

14 Expected Outcomes 4

15 Project Outlines 4

Chapter 2 LITERATURE REVIEW 6

21 Permanent Magnet Alternating Current Machine 6

22 Winding Approaches 9

221 Single Layer Winding 9

222 Double Layer Winding 11

223 Distributed Winding 12

224 Concentrated Winding 13

23 Fundamental PMSM Relationships 14

231 Speed 14

232 Winding Factor 15

233 Electromagnetic Torque 15

24 No Load Operation 16

25 Winding Function Analysis 17

v

26 Magnetomotive Force (MMF) 19

261 Concentrated Full-Pitch Coil 19

262 Distributed Full-Pitch Coil Phase Winding 19

263 Three Phase Full-Pitch (Single-Layer) Winding 20

264 Three Phase Shorted-Pitch Coil (Double-Layer) 20

Winding

27 Inductance 20

28 Reactance 21

281 Synchronous Reactance 21

282 Leakage Reactance 21

29 Losses 22

291 Copper Loss 22

292 Core Loss 22

210 Back-EMF 23

Chapter 3 METHODOLOGY 24

31 Overview 24

32 Work Plan Flow Chart 25

33 Finite Element Method Magnetics 42 27

34 Block Integral 27

35 Lua Programming Language 28

36 Magnetics Preprocessor 29

37 Analysis Processor 30

38 Magnetics Postprocessor 32

Chapter 4 RESULTS AND DISCUSSIONS 34

41 Overview 34

42 Design Specification of PMSG 34

43 The Structure of PMSG 36

44 Winding Patterns 37

441 Single Layer Concentrated Winding 37

442 Double Layer Concentrated Winding 39

443 Single Layer Distributed Winding 41

444 Double Layer Distributed Winding 43

vi

45 Flux Linkage 45

46 Back-EMF 50

47 Air-gap Flux Density 55

48 Cogging Torque 58

49 Copper Loss 61

410 Summary 65

Chapter 5 CONCLUSION AND RECOMMENDATION 66

51 Conclusion 66

52 Recommendation 67

REFERENCES 68

APPENDIX A 71

APPENDIX B 72

APPENDIX C 73

APPENDIX D 74

vii

LIST OF TABLES

Table Page

41 Design Parameter of the PMSG 35

42 Materials of the Generator 35

43 The Current and Flux Linkage of SLCW PMSG 45

44 The Current and Flux Linkage of DLCW PMSG 46

45 The Current and Flux Linkage of SLDW PMSG 47

46 The Current and Flux Linkage of DLDW PMSG 48

47 The Back-EMF of SLCW PMSG 50

48 The Back-EMF of DLCW PMSG 51

49 The Back-EMF of SLDW PMSG 52

410 The Back-EMF of DLDW PMSG 53

411 The Air-gap Flux Density of PMSG for each Winding Patterns 55

412 The Cogging Torque of PMSG for each Winding Patterns 58

413 The Copper Loss of SLCW PMSG 61

414 The Copper Loss of DLCW PMSG 62

415 The Copper Loss of SLDW PMSG 63

416 The Copper Loss of DLDW PMSG 64

viii

LIST OF FIGURES

Figure Page

11 Global Electricity Production of Renewable Energy Share 2015 1

12 Global Capacity of Wind Power in the year 2005-2015 2

21 Axial Flux PMSMrsquos Structure 7

22 Radial Flux PMSMrsquos Structure 7

23 Surface PMSM 8

24 Surface Inset PMSM 8

25 Interior PMSM 8

26 Interior PMSM with Circumferential Orientation 8

27 Schematic Layout for Single Layer Winding 10

28 Winding Diagram with a Single Conductor per Slot 10

29 Winding Diagram with Multiple Conductors per Slot 11

210 Schematic Layout for Double Layer Winding 11

211 Winding Diagram for Double Layer Winding 12

212 Distributed Winding 13

213 FSCW-IPM with Double Layer Winding 13

214 FSCW-IPM with Single Layer Winding 14

215 Phasor Diagram for No Load Motor and Generator Operation for 16

Underexcited Condition respectively

216 Phasor Diagram for No Load Motor and Generator Operation for 16

Overexcited Condition respectively

217 Turns Function Definition 18

31 The Flow Chart of the Project 25

32 Drawing Mode Toolbar 29

33 Grid Manipulation Toolbar 30

34 Toolbar for Analysis Processor 30

35 Mesh for the PMSG Model 31

36 Status of the Model 31

37 Analysis Mode Toolbar 32

ix

38 The Depiction of Model in Point Values Mode 32

39 The Depiction of Model in Contour Mode 33

310 The Depiction of Model in Block Mode 33

41 Part of the Structure of the PMSG Model 36

42 The Structure of SLCW PMSG 37

43 SLCW Configuration 38

44 Flux Line and Flux Density of SLCW PMSG 38

45 Vector Plot of SLCW PMSG 38

46 The Structure of DLCW PMSG 39

47 DLCW Configuration 40

48 Flux Line and Flux Density of DLCW PMSG 40

49 Vector Plot of DLCW PMSG 40

410 The Structure of SLDW PMSG 41

411 SLDW Configuration 42

412 Flux Line and Flux Density of SLDW PMSG 42

413 Vector Plot of SLDW PMSG 42

414 The Structure of DLDW PMSG 43

415 DLDW Configuration 44

416 Flux Line and Flux Density of DLDW PMSG 44

417 Vector Plot of DLDW PMSG 44

418 The Flux Linkage of SLCW PMSG 46

419 The Flux Linkage of DLCW PMSG 47

420 The Flux Linkage of SLDW PMSG 48

421 The Flux Linkage of DLDW PMSG 49

422 The Back-EMF of SLCW PMSG 51

423 The Back-EMF of DLCW PMSG 52

424 The Back-EMF of SLDW PMSG 53

425 The Back-EMF of DLDW PMSG 54

426 The Air-gap Flux Density of SLCW PMSG 56

427 The Air-gap Flux Density of DLCW PMSG 56

428 The Air-gap Flux Density of SLDW PMSG 57

429 The Air-gap Flux Density of DLDW PMSG 57

430 The Cogging Torque of SLCW PMSG 59

431 The Cogging Torque of DLCW PMSG 59

x

432 The Cogging Torque of SLDW PMSG 60

433 The Cogging Torque of DLDW PMSG 60

434 The Copper Loss of SLCW PMSG 62

435 The Copper Loss of DLCW PMSG 63

436 The Copper Loss of SLDW PMSG 64

437 The Copper Loss of DLDW PMSG 65

xi

LIST OF ABBREVIATIONS

PM - Permanent Magnet

PMSG - Permanent Magnet Synchronous Generator

FEMM - Finite Element Method Magnetics

PMSM - Permanent Magnet Synchronous Machine

MMF - Magnetomotive Force

FSCW - Fractional-slot Concentrated Winding

IPM - Interior Permanent Magnet

RPM - Revolutions per Minute

EMF - Electromotive Force

SLCW - Single Layer Concentrated Winding

DLCW - Double Layer Concentrated Winding

SLDW - Single Layer Distributed Winding

DLDW - Double Layer Distributed Winding

1

CHAPTER 1

INTRODUCTION

11 Overview

Electricity is one of our essential needs especially in our daily life as most of the

appliances in the home office or even factories depend on electricity to function Almost

all the electricity produced in the world is generated by the electric machine Electricity

exists in nature as a form of lightning It also can be generated from the electrical power

generator Electricity can be produced through various ways such as wind water nuclear

or even combustion of coal and oil Figure 11 below depicts that the wind energy is the

second highest of the renewable energy in the electricity generation which is 37 [1]

Figure 11 Global Electricity Production of Renewable Energy Share 2015 [1]

2

A synchronous machine is an alternating current rotating machine that its speed

is proportional to the frequency of the current in its armature under steady state condition

This means that the magnetic field of the armature currents will rotate at the same

synchronous speed as the permanent magnets (PM) or the field current on the rotor Due

to the characteristic of the synchronous speed the synchronous generator is applied to the

constant speed drive

Figure 12 Global Capacity of Wind Power in the year 2005-2015 [1]

Figure 12 shows that the wind power global capacity had increased continuously

for each year from the year 2005 until 2015 In the year 2015 the global capacity for wind

power had reached 433 Gigawatts [1] This concluded that the demand for the electricity

from wind energy had risen In wind turbine industry permanent magnet synchronous

generator (PMSG) is widely used to produce electricity Permanent magnet is used for

the synchronous generator instead of the coil for excitation field PMSG does not require

slip rings to operate There is no direct current supply that is needed for excitation circuit

Without the need of slip rings PMSG is easier to be constructed and lower maintenance

cost The permanent magnet minimizes the rotor losses and this indirectly improves the

efficiency of the generator

PMSG offers a great privilege due to its stable operation [2] However the

construction fee for PMSG is costly due to its rare earth material permanent magnet

3

Despite the high cost of the permanent magnet the PMSG is widely used in the concern

of the environmental conservation The air-gap magnetic flux density also increased with

the use of permanent magnet PMSG has a smaller volume and lower density The

permanent magnet can be positioned inside the rotor or even mounted on the rotorrsquos

surface The maximum efficiency can be achieved by minimizing the air-gap between

rotor and stator

There are various ways for coils to be wound in the stator of the generator Each

of the forms has its own drawbacks and advantages The main purpose of varying the

forms of the coil distribution is to produce three balanced sinusoidal voltages with a little

harmonic voltage and current for three phase machine In other words the output power

is maximized and the losses are minimized with different patterns of coil distribution The

number of slots at the stator can be varied which will affect the manner of the coil

connection and hence different winding patterns can be formed

12 Problem Statement

The PMSG is a part of the wind turbine system Nowadays as the demand for the

electrical energy had increased rapidly around the world the efficiency for the PMSG is

seeking more attention from the researcher With an attempt to increase the performance

of the PMSG the world non-renewable energy consumption can be reduced and the

global warming issue can be minimized or even rectified Moreover the global economy

will also be improved and this will eventually enhance the quality living of life

Furthermore a better performance of PMSG can surely aid in the prevention of climate

change All these advantages come with the energy efficiency Hence various design on

the PMSG had been researched to increase the power output and reduce the losses of the

generator

There is no doubt that the PMSG is well known for its high efficiency and long

lasting performance which can be used in wind turbine However there are various ways

to enhance the performance of the PMSG One of the factors that determine the efficiency

of the PMSG is the winding method In this thesis the winding patterns that are compared

are single layer concentrated winding (SLCW) double layer concentrated winding

(DLCW) single layer distributed winding (SLDW) and double layer distributed winding

(DLDW) In order to improve the efficiency of the PMSG the most suitable winding

pattern has to be chosen

4

13 Objectives

The objectives of this project are

To study and investigate the winding methods for PMSG

To determine the efficiency of PMSG for each type of the windings

To compare the winding methods for the PMSG

To perform analytical analysis and simulation by using Finite Element

Method Magnetics (FEMM) to maximize the efficiency of the PMSG

14 Expected Outcomes

In this project the expected outcomes are listed below

The winding methods of the stator for the PMSG are studied and compared

The simulation of the PMSG is done by using FEMM software

The efficiency of each of the winding methods is analyzed and compared

The winding method that yields the highest performance of the PMSG is

determined

15 Project Outlines

This project contains five chapters These chapters comprised of Introduction

Literature Review Methodology Result and Discussion and Conclusion and

Recommendation These chapters are arranged from Chapter 1 to Chapter 5 respectively

Chapter 1 provides a brief introduction to the electricity generation together with

a short review on the PMSG the problem statement and objectives of this project The

expected outcomes at the end of the project are also included in this chapter

Chapter 2 reviews and compiles all the studies and research that are related to the

project The topologies for the PMSG different winding methods of the stator parameter

that determine the efficiency of the PMSG and analysis approach are discussed in this

chapter

Chapter 3 discusses the methodology that is needed to carry out the project In this

chapter the PMSG model that is used in this project is presented and explained The

5

terminology and the analytical approach by using the FEMM software are depicted in this

section

Chapter 4 computes the performance of the PMSG either through mathematical

calculation or via the 2 dimension simulation of the FEMM The parameters that affect

the efficiency of PMSG is evaluated All the graphical results and the magnetic field maps

are delineated in this chapter

Chapter 5 concludes all the results of the project and summarize the outcomes

The recommendations after carrying out this project are discussed in this chapter Any

limitation of this project is included too

6

CHAPTER 2

LITERATURE REVIEW

21 Permanent Magnet Alternating Current Machine

The Permanent Magnet Synchronous Machine (PMSM) can be divided into two

categories which are axial field and radial field For axial field topology the flux is

moving parallel to the rotor shaft whereas the flux is moving along the machinersquos radius

for the radial field topology [3] The permanent magnet can be placed at a various position

on the rotor The pro and cons of the axial field and radial field topologies are discussed

below [4]

Axial fieldrsquos strengths

A balanced rotor-stator attractive forces with two air-gaps

The grinding to an arc shape is skipped as the permanent magnets have two planar

surfaces

There is an adjustable air-gap

Magnet retainment is not needed

Axial fieldrsquos weakness

There is a poor winding utilization

Restricted size of the end turns at the internal radius

Cogging torque existed

Radial fieldrsquos strengths

There is no radial force on the rotor

Easier removal of heat from the stator winding due to the big surface area of the

stator back iron

7

Skewing is not needed

Radial fieldrsquos weakness

The magnets surface must be arced

Fixed air-gap

An air-gap is formed between rotor magnets with the rotor back iron

Figure 21 and Figure 22 show the axial and radial field structure of PMSM

respectively [5]

Figure 21 Axial Flux PMSMrsquos Structure [5]

Figure 22 Radial Flux PMSMrsquos Structure [5]

8

Figure 23 24 25 and 26 show the radial field of the PMSM with different

positions of permanent magnets [3]

Figure 23 Surface PMSM [3] Figure 24 Surface Inset PMSM [3]

Figure 25 Interior PMSM [3] Figure 26 Interior PMSM with

Circumferential Orientation [3]

The permanent magnets of the surface PMSM are directly mounted on the rotorrsquos

surface as shown in Figure 23 Figure 24 shows that the permanent magnets of the

surface inset PMSM are fixed at the rotor inner surface The Figure 25 depicts that the

permanent magnets of the PMSM are implanted inside the rotor meanwhile the permanent

magnets are aligned in a circular orientation inside the rotor of the PMSM as shown in

Figure 26

Page 4: COMPARISON ON WINDING METHOD FOR ELECTRICAL …

COMPARISON ON WINDING METHOD FOR ELECTRICAL

GENERATOR

CHUA TEN HOU

A dissertation submitted in partial fulfillment

of the requirement for the degree of

Bachelor of Engineering (Hons) in Electronics (Telecommunications)

Faculty of Engineering

Universiti Malaysia Sarawak

2017

To my beloved family and friends

i

ACKNOWLEDGEMENT

First of all my special thanks gratitude and respect go to my final year projectrsquos

supervisor Dr Ngu Sze Song His endless patience persistent encouragements valuable

guidance and advice throughout this project are highly appreciated His timely

supervision on my project had helped me to accomplish my project in time Special thanks to all my friends and staff of Universiti Malaysia Sarawak that

helped me during my degree study Without their contribution and support I would not

be able to finish my project

Last but not least I would like to thank my parents for their mentally and

physically support not only for finishing this project but also during my whole degree

studies in UNIMAS

ii

ABSTRACT

Permanent Magnet Synchronous Generator (PMSG) is the most favorable

generator in producing the electricity especially in wind turbine industry The PMSG has

a higher efficiency compared to other generators as its excitation field is provided by the

permanent magnet This is an advantage for the generator as it reduces the maintenance

cost of the generator

A suitable winding method for the PMSG can increase the performance of the

generator There are four types of winding methods that are widely used in the generator

which are single layer winding double layer winding concentrated winding and

distributed winding In this thesis the single layer concentrated winding double layer

concentrated winding single layer distributed winding and double layer distributed

winding are simulated in Finite Element Method Magnetics (FEMM) The PMSG is

simulated and analyzed according to different winding methods This analysis is aimed

to compare different type of winding methods in order to enhance the efficiency of the

PMSG

iii

ABSTRAK

Permanent Magnet Synchronous Generator (PMSG) adalah penjana yang paling

baik dalam menghasilkan elektrik terutamanya dalam industri turbin angin PMSG

mempunyai kecekapan yang lebih tinggi berbanding dengan penjana lain disebabkan

medan pengujaannya diperoleh daripada magnet kekal Hal ini merupakan satu kelebihan

untuk generator tersebut kerana ia mengurangkan kos penyelenggaraan penjana

Kaedah penggulungan yang sesuai untuk PMSG boleh meningkatkan prestasi

penjana Terdapat 4 jenis kaedah penggulungan yang digunakan secara meluas dalam

penjana iaitu single layer winding double layer winding concentrated winding dan

distributed winding Dalam tesis ini single layer concentrated winding double layer

concentrated winding single layer distributed winding dan double layer distributed

winding disimulasikan dengan Finite Element Method Magnetics (FEMM) PMSG

disimulasikan dan dianalisiskan mengikut kaedah penggulungan yang berbeza Analisis

ini bertujuan untuk membandingkan kaedah penggulungan yang berbeza bagi

meningkatkan kecekapan PMSG

iv

TABLE OF CONTENTS

Page

Acknowledgement i

Abstract ii

Abstrak iii

Table of Contents iv

List of Tables vii

List of Figures viii

List of Abbreviations xi

Chapter 1 INTRODUCTION 1

11 Overview 1

12 Problem Statement 3

13 Objectives 4

14 Expected Outcomes 4

15 Project Outlines 4

Chapter 2 LITERATURE REVIEW 6

21 Permanent Magnet Alternating Current Machine 6

22 Winding Approaches 9

221 Single Layer Winding 9

222 Double Layer Winding 11

223 Distributed Winding 12

224 Concentrated Winding 13

23 Fundamental PMSM Relationships 14

231 Speed 14

232 Winding Factor 15

233 Electromagnetic Torque 15

24 No Load Operation 16

25 Winding Function Analysis 17

v

26 Magnetomotive Force (MMF) 19

261 Concentrated Full-Pitch Coil 19

262 Distributed Full-Pitch Coil Phase Winding 19

263 Three Phase Full-Pitch (Single-Layer) Winding 20

264 Three Phase Shorted-Pitch Coil (Double-Layer) 20

Winding

27 Inductance 20

28 Reactance 21

281 Synchronous Reactance 21

282 Leakage Reactance 21

29 Losses 22

291 Copper Loss 22

292 Core Loss 22

210 Back-EMF 23

Chapter 3 METHODOLOGY 24

31 Overview 24

32 Work Plan Flow Chart 25

33 Finite Element Method Magnetics 42 27

34 Block Integral 27

35 Lua Programming Language 28

36 Magnetics Preprocessor 29

37 Analysis Processor 30

38 Magnetics Postprocessor 32

Chapter 4 RESULTS AND DISCUSSIONS 34

41 Overview 34

42 Design Specification of PMSG 34

43 The Structure of PMSG 36

44 Winding Patterns 37

441 Single Layer Concentrated Winding 37

442 Double Layer Concentrated Winding 39

443 Single Layer Distributed Winding 41

444 Double Layer Distributed Winding 43

vi

45 Flux Linkage 45

46 Back-EMF 50

47 Air-gap Flux Density 55

48 Cogging Torque 58

49 Copper Loss 61

410 Summary 65

Chapter 5 CONCLUSION AND RECOMMENDATION 66

51 Conclusion 66

52 Recommendation 67

REFERENCES 68

APPENDIX A 71

APPENDIX B 72

APPENDIX C 73

APPENDIX D 74

vii

LIST OF TABLES

Table Page

41 Design Parameter of the PMSG 35

42 Materials of the Generator 35

43 The Current and Flux Linkage of SLCW PMSG 45

44 The Current and Flux Linkage of DLCW PMSG 46

45 The Current and Flux Linkage of SLDW PMSG 47

46 The Current and Flux Linkage of DLDW PMSG 48

47 The Back-EMF of SLCW PMSG 50

48 The Back-EMF of DLCW PMSG 51

49 The Back-EMF of SLDW PMSG 52

410 The Back-EMF of DLDW PMSG 53

411 The Air-gap Flux Density of PMSG for each Winding Patterns 55

412 The Cogging Torque of PMSG for each Winding Patterns 58

413 The Copper Loss of SLCW PMSG 61

414 The Copper Loss of DLCW PMSG 62

415 The Copper Loss of SLDW PMSG 63

416 The Copper Loss of DLDW PMSG 64

viii

LIST OF FIGURES

Figure Page

11 Global Electricity Production of Renewable Energy Share 2015 1

12 Global Capacity of Wind Power in the year 2005-2015 2

21 Axial Flux PMSMrsquos Structure 7

22 Radial Flux PMSMrsquos Structure 7

23 Surface PMSM 8

24 Surface Inset PMSM 8

25 Interior PMSM 8

26 Interior PMSM with Circumferential Orientation 8

27 Schematic Layout for Single Layer Winding 10

28 Winding Diagram with a Single Conductor per Slot 10

29 Winding Diagram with Multiple Conductors per Slot 11

210 Schematic Layout for Double Layer Winding 11

211 Winding Diagram for Double Layer Winding 12

212 Distributed Winding 13

213 FSCW-IPM with Double Layer Winding 13

214 FSCW-IPM with Single Layer Winding 14

215 Phasor Diagram for No Load Motor and Generator Operation for 16

Underexcited Condition respectively

216 Phasor Diagram for No Load Motor and Generator Operation for 16

Overexcited Condition respectively

217 Turns Function Definition 18

31 The Flow Chart of the Project 25

32 Drawing Mode Toolbar 29

33 Grid Manipulation Toolbar 30

34 Toolbar for Analysis Processor 30

35 Mesh for the PMSG Model 31

36 Status of the Model 31

37 Analysis Mode Toolbar 32

ix

38 The Depiction of Model in Point Values Mode 32

39 The Depiction of Model in Contour Mode 33

310 The Depiction of Model in Block Mode 33

41 Part of the Structure of the PMSG Model 36

42 The Structure of SLCW PMSG 37

43 SLCW Configuration 38

44 Flux Line and Flux Density of SLCW PMSG 38

45 Vector Plot of SLCW PMSG 38

46 The Structure of DLCW PMSG 39

47 DLCW Configuration 40

48 Flux Line and Flux Density of DLCW PMSG 40

49 Vector Plot of DLCW PMSG 40

410 The Structure of SLDW PMSG 41

411 SLDW Configuration 42

412 Flux Line and Flux Density of SLDW PMSG 42

413 Vector Plot of SLDW PMSG 42

414 The Structure of DLDW PMSG 43

415 DLDW Configuration 44

416 Flux Line and Flux Density of DLDW PMSG 44

417 Vector Plot of DLDW PMSG 44

418 The Flux Linkage of SLCW PMSG 46

419 The Flux Linkage of DLCW PMSG 47

420 The Flux Linkage of SLDW PMSG 48

421 The Flux Linkage of DLDW PMSG 49

422 The Back-EMF of SLCW PMSG 51

423 The Back-EMF of DLCW PMSG 52

424 The Back-EMF of SLDW PMSG 53

425 The Back-EMF of DLDW PMSG 54

426 The Air-gap Flux Density of SLCW PMSG 56

427 The Air-gap Flux Density of DLCW PMSG 56

428 The Air-gap Flux Density of SLDW PMSG 57

429 The Air-gap Flux Density of DLDW PMSG 57

430 The Cogging Torque of SLCW PMSG 59

431 The Cogging Torque of DLCW PMSG 59

x

432 The Cogging Torque of SLDW PMSG 60

433 The Cogging Torque of DLDW PMSG 60

434 The Copper Loss of SLCW PMSG 62

435 The Copper Loss of DLCW PMSG 63

436 The Copper Loss of SLDW PMSG 64

437 The Copper Loss of DLDW PMSG 65

xi

LIST OF ABBREVIATIONS

PM - Permanent Magnet

PMSG - Permanent Magnet Synchronous Generator

FEMM - Finite Element Method Magnetics

PMSM - Permanent Magnet Synchronous Machine

MMF - Magnetomotive Force

FSCW - Fractional-slot Concentrated Winding

IPM - Interior Permanent Magnet

RPM - Revolutions per Minute

EMF - Electromotive Force

SLCW - Single Layer Concentrated Winding

DLCW - Double Layer Concentrated Winding

SLDW - Single Layer Distributed Winding

DLDW - Double Layer Distributed Winding

1

CHAPTER 1

INTRODUCTION

11 Overview

Electricity is one of our essential needs especially in our daily life as most of the

appliances in the home office or even factories depend on electricity to function Almost

all the electricity produced in the world is generated by the electric machine Electricity

exists in nature as a form of lightning It also can be generated from the electrical power

generator Electricity can be produced through various ways such as wind water nuclear

or even combustion of coal and oil Figure 11 below depicts that the wind energy is the

second highest of the renewable energy in the electricity generation which is 37 [1]

Figure 11 Global Electricity Production of Renewable Energy Share 2015 [1]

2

A synchronous machine is an alternating current rotating machine that its speed

is proportional to the frequency of the current in its armature under steady state condition

This means that the magnetic field of the armature currents will rotate at the same

synchronous speed as the permanent magnets (PM) or the field current on the rotor Due

to the characteristic of the synchronous speed the synchronous generator is applied to the

constant speed drive

Figure 12 Global Capacity of Wind Power in the year 2005-2015 [1]

Figure 12 shows that the wind power global capacity had increased continuously

for each year from the year 2005 until 2015 In the year 2015 the global capacity for wind

power had reached 433 Gigawatts [1] This concluded that the demand for the electricity

from wind energy had risen In wind turbine industry permanent magnet synchronous

generator (PMSG) is widely used to produce electricity Permanent magnet is used for

the synchronous generator instead of the coil for excitation field PMSG does not require

slip rings to operate There is no direct current supply that is needed for excitation circuit

Without the need of slip rings PMSG is easier to be constructed and lower maintenance

cost The permanent magnet minimizes the rotor losses and this indirectly improves the

efficiency of the generator

PMSG offers a great privilege due to its stable operation [2] However the

construction fee for PMSG is costly due to its rare earth material permanent magnet

3

Despite the high cost of the permanent magnet the PMSG is widely used in the concern

of the environmental conservation The air-gap magnetic flux density also increased with

the use of permanent magnet PMSG has a smaller volume and lower density The

permanent magnet can be positioned inside the rotor or even mounted on the rotorrsquos

surface The maximum efficiency can be achieved by minimizing the air-gap between

rotor and stator

There are various ways for coils to be wound in the stator of the generator Each

of the forms has its own drawbacks and advantages The main purpose of varying the

forms of the coil distribution is to produce three balanced sinusoidal voltages with a little

harmonic voltage and current for three phase machine In other words the output power

is maximized and the losses are minimized with different patterns of coil distribution The

number of slots at the stator can be varied which will affect the manner of the coil

connection and hence different winding patterns can be formed

12 Problem Statement

The PMSG is a part of the wind turbine system Nowadays as the demand for the

electrical energy had increased rapidly around the world the efficiency for the PMSG is

seeking more attention from the researcher With an attempt to increase the performance

of the PMSG the world non-renewable energy consumption can be reduced and the

global warming issue can be minimized or even rectified Moreover the global economy

will also be improved and this will eventually enhance the quality living of life

Furthermore a better performance of PMSG can surely aid in the prevention of climate

change All these advantages come with the energy efficiency Hence various design on

the PMSG had been researched to increase the power output and reduce the losses of the

generator

There is no doubt that the PMSG is well known for its high efficiency and long

lasting performance which can be used in wind turbine However there are various ways

to enhance the performance of the PMSG One of the factors that determine the efficiency

of the PMSG is the winding method In this thesis the winding patterns that are compared

are single layer concentrated winding (SLCW) double layer concentrated winding

(DLCW) single layer distributed winding (SLDW) and double layer distributed winding

(DLDW) In order to improve the efficiency of the PMSG the most suitable winding

pattern has to be chosen

4

13 Objectives

The objectives of this project are

To study and investigate the winding methods for PMSG

To determine the efficiency of PMSG for each type of the windings

To compare the winding methods for the PMSG

To perform analytical analysis and simulation by using Finite Element

Method Magnetics (FEMM) to maximize the efficiency of the PMSG

14 Expected Outcomes

In this project the expected outcomes are listed below

The winding methods of the stator for the PMSG are studied and compared

The simulation of the PMSG is done by using FEMM software

The efficiency of each of the winding methods is analyzed and compared

The winding method that yields the highest performance of the PMSG is

determined

15 Project Outlines

This project contains five chapters These chapters comprised of Introduction

Literature Review Methodology Result and Discussion and Conclusion and

Recommendation These chapters are arranged from Chapter 1 to Chapter 5 respectively

Chapter 1 provides a brief introduction to the electricity generation together with

a short review on the PMSG the problem statement and objectives of this project The

expected outcomes at the end of the project are also included in this chapter

Chapter 2 reviews and compiles all the studies and research that are related to the

project The topologies for the PMSG different winding methods of the stator parameter

that determine the efficiency of the PMSG and analysis approach are discussed in this

chapter

Chapter 3 discusses the methodology that is needed to carry out the project In this

chapter the PMSG model that is used in this project is presented and explained The

5

terminology and the analytical approach by using the FEMM software are depicted in this

section

Chapter 4 computes the performance of the PMSG either through mathematical

calculation or via the 2 dimension simulation of the FEMM The parameters that affect

the efficiency of PMSG is evaluated All the graphical results and the magnetic field maps

are delineated in this chapter

Chapter 5 concludes all the results of the project and summarize the outcomes

The recommendations after carrying out this project are discussed in this chapter Any

limitation of this project is included too

6

CHAPTER 2

LITERATURE REVIEW

21 Permanent Magnet Alternating Current Machine

The Permanent Magnet Synchronous Machine (PMSM) can be divided into two

categories which are axial field and radial field For axial field topology the flux is

moving parallel to the rotor shaft whereas the flux is moving along the machinersquos radius

for the radial field topology [3] The permanent magnet can be placed at a various position

on the rotor The pro and cons of the axial field and radial field topologies are discussed

below [4]

Axial fieldrsquos strengths

A balanced rotor-stator attractive forces with two air-gaps

The grinding to an arc shape is skipped as the permanent magnets have two planar

surfaces

There is an adjustable air-gap

Magnet retainment is not needed

Axial fieldrsquos weakness

There is a poor winding utilization

Restricted size of the end turns at the internal radius

Cogging torque existed

Radial fieldrsquos strengths

There is no radial force on the rotor

Easier removal of heat from the stator winding due to the big surface area of the

stator back iron

7

Skewing is not needed

Radial fieldrsquos weakness

The magnets surface must be arced

Fixed air-gap

An air-gap is formed between rotor magnets with the rotor back iron

Figure 21 and Figure 22 show the axial and radial field structure of PMSM

respectively [5]

Figure 21 Axial Flux PMSMrsquos Structure [5]

Figure 22 Radial Flux PMSMrsquos Structure [5]

8

Figure 23 24 25 and 26 show the radial field of the PMSM with different

positions of permanent magnets [3]

Figure 23 Surface PMSM [3] Figure 24 Surface Inset PMSM [3]

Figure 25 Interior PMSM [3] Figure 26 Interior PMSM with

Circumferential Orientation [3]

The permanent magnets of the surface PMSM are directly mounted on the rotorrsquos

surface as shown in Figure 23 Figure 24 shows that the permanent magnets of the

surface inset PMSM are fixed at the rotor inner surface The Figure 25 depicts that the

permanent magnets of the PMSM are implanted inside the rotor meanwhile the permanent

magnets are aligned in a circular orientation inside the rotor of the PMSM as shown in

Figure 26

Page 5: COMPARISON ON WINDING METHOD FOR ELECTRICAL …

To my beloved family and friends

i

ACKNOWLEDGEMENT

First of all my special thanks gratitude and respect go to my final year projectrsquos

supervisor Dr Ngu Sze Song His endless patience persistent encouragements valuable

guidance and advice throughout this project are highly appreciated His timely

supervision on my project had helped me to accomplish my project in time Special thanks to all my friends and staff of Universiti Malaysia Sarawak that

helped me during my degree study Without their contribution and support I would not

be able to finish my project

Last but not least I would like to thank my parents for their mentally and

physically support not only for finishing this project but also during my whole degree

studies in UNIMAS

ii

ABSTRACT

Permanent Magnet Synchronous Generator (PMSG) is the most favorable

generator in producing the electricity especially in wind turbine industry The PMSG has

a higher efficiency compared to other generators as its excitation field is provided by the

permanent magnet This is an advantage for the generator as it reduces the maintenance

cost of the generator

A suitable winding method for the PMSG can increase the performance of the

generator There are four types of winding methods that are widely used in the generator

which are single layer winding double layer winding concentrated winding and

distributed winding In this thesis the single layer concentrated winding double layer

concentrated winding single layer distributed winding and double layer distributed

winding are simulated in Finite Element Method Magnetics (FEMM) The PMSG is

simulated and analyzed according to different winding methods This analysis is aimed

to compare different type of winding methods in order to enhance the efficiency of the

PMSG

iii

ABSTRAK

Permanent Magnet Synchronous Generator (PMSG) adalah penjana yang paling

baik dalam menghasilkan elektrik terutamanya dalam industri turbin angin PMSG

mempunyai kecekapan yang lebih tinggi berbanding dengan penjana lain disebabkan

medan pengujaannya diperoleh daripada magnet kekal Hal ini merupakan satu kelebihan

untuk generator tersebut kerana ia mengurangkan kos penyelenggaraan penjana

Kaedah penggulungan yang sesuai untuk PMSG boleh meningkatkan prestasi

penjana Terdapat 4 jenis kaedah penggulungan yang digunakan secara meluas dalam

penjana iaitu single layer winding double layer winding concentrated winding dan

distributed winding Dalam tesis ini single layer concentrated winding double layer

concentrated winding single layer distributed winding dan double layer distributed

winding disimulasikan dengan Finite Element Method Magnetics (FEMM) PMSG

disimulasikan dan dianalisiskan mengikut kaedah penggulungan yang berbeza Analisis

ini bertujuan untuk membandingkan kaedah penggulungan yang berbeza bagi

meningkatkan kecekapan PMSG

iv

TABLE OF CONTENTS

Page

Acknowledgement i

Abstract ii

Abstrak iii

Table of Contents iv

List of Tables vii

List of Figures viii

List of Abbreviations xi

Chapter 1 INTRODUCTION 1

11 Overview 1

12 Problem Statement 3

13 Objectives 4

14 Expected Outcomes 4

15 Project Outlines 4

Chapter 2 LITERATURE REVIEW 6

21 Permanent Magnet Alternating Current Machine 6

22 Winding Approaches 9

221 Single Layer Winding 9

222 Double Layer Winding 11

223 Distributed Winding 12

224 Concentrated Winding 13

23 Fundamental PMSM Relationships 14

231 Speed 14

232 Winding Factor 15

233 Electromagnetic Torque 15

24 No Load Operation 16

25 Winding Function Analysis 17

v

26 Magnetomotive Force (MMF) 19

261 Concentrated Full-Pitch Coil 19

262 Distributed Full-Pitch Coil Phase Winding 19

263 Three Phase Full-Pitch (Single-Layer) Winding 20

264 Three Phase Shorted-Pitch Coil (Double-Layer) 20

Winding

27 Inductance 20

28 Reactance 21

281 Synchronous Reactance 21

282 Leakage Reactance 21

29 Losses 22

291 Copper Loss 22

292 Core Loss 22

210 Back-EMF 23

Chapter 3 METHODOLOGY 24

31 Overview 24

32 Work Plan Flow Chart 25

33 Finite Element Method Magnetics 42 27

34 Block Integral 27

35 Lua Programming Language 28

36 Magnetics Preprocessor 29

37 Analysis Processor 30

38 Magnetics Postprocessor 32

Chapter 4 RESULTS AND DISCUSSIONS 34

41 Overview 34

42 Design Specification of PMSG 34

43 The Structure of PMSG 36

44 Winding Patterns 37

441 Single Layer Concentrated Winding 37

442 Double Layer Concentrated Winding 39

443 Single Layer Distributed Winding 41

444 Double Layer Distributed Winding 43

vi

45 Flux Linkage 45

46 Back-EMF 50

47 Air-gap Flux Density 55

48 Cogging Torque 58

49 Copper Loss 61

410 Summary 65

Chapter 5 CONCLUSION AND RECOMMENDATION 66

51 Conclusion 66

52 Recommendation 67

REFERENCES 68

APPENDIX A 71

APPENDIX B 72

APPENDIX C 73

APPENDIX D 74

vii

LIST OF TABLES

Table Page

41 Design Parameter of the PMSG 35

42 Materials of the Generator 35

43 The Current and Flux Linkage of SLCW PMSG 45

44 The Current and Flux Linkage of DLCW PMSG 46

45 The Current and Flux Linkage of SLDW PMSG 47

46 The Current and Flux Linkage of DLDW PMSG 48

47 The Back-EMF of SLCW PMSG 50

48 The Back-EMF of DLCW PMSG 51

49 The Back-EMF of SLDW PMSG 52

410 The Back-EMF of DLDW PMSG 53

411 The Air-gap Flux Density of PMSG for each Winding Patterns 55

412 The Cogging Torque of PMSG for each Winding Patterns 58

413 The Copper Loss of SLCW PMSG 61

414 The Copper Loss of DLCW PMSG 62

415 The Copper Loss of SLDW PMSG 63

416 The Copper Loss of DLDW PMSG 64

viii

LIST OF FIGURES

Figure Page

11 Global Electricity Production of Renewable Energy Share 2015 1

12 Global Capacity of Wind Power in the year 2005-2015 2

21 Axial Flux PMSMrsquos Structure 7

22 Radial Flux PMSMrsquos Structure 7

23 Surface PMSM 8

24 Surface Inset PMSM 8

25 Interior PMSM 8

26 Interior PMSM with Circumferential Orientation 8

27 Schematic Layout for Single Layer Winding 10

28 Winding Diagram with a Single Conductor per Slot 10

29 Winding Diagram with Multiple Conductors per Slot 11

210 Schematic Layout for Double Layer Winding 11

211 Winding Diagram for Double Layer Winding 12

212 Distributed Winding 13

213 FSCW-IPM with Double Layer Winding 13

214 FSCW-IPM with Single Layer Winding 14

215 Phasor Diagram for No Load Motor and Generator Operation for 16

Underexcited Condition respectively

216 Phasor Diagram for No Load Motor and Generator Operation for 16

Overexcited Condition respectively

217 Turns Function Definition 18

31 The Flow Chart of the Project 25

32 Drawing Mode Toolbar 29

33 Grid Manipulation Toolbar 30

34 Toolbar for Analysis Processor 30

35 Mesh for the PMSG Model 31

36 Status of the Model 31

37 Analysis Mode Toolbar 32

ix

38 The Depiction of Model in Point Values Mode 32

39 The Depiction of Model in Contour Mode 33

310 The Depiction of Model in Block Mode 33

41 Part of the Structure of the PMSG Model 36

42 The Structure of SLCW PMSG 37

43 SLCW Configuration 38

44 Flux Line and Flux Density of SLCW PMSG 38

45 Vector Plot of SLCW PMSG 38

46 The Structure of DLCW PMSG 39

47 DLCW Configuration 40

48 Flux Line and Flux Density of DLCW PMSG 40

49 Vector Plot of DLCW PMSG 40

410 The Structure of SLDW PMSG 41

411 SLDW Configuration 42

412 Flux Line and Flux Density of SLDW PMSG 42

413 Vector Plot of SLDW PMSG 42

414 The Structure of DLDW PMSG 43

415 DLDW Configuration 44

416 Flux Line and Flux Density of DLDW PMSG 44

417 Vector Plot of DLDW PMSG 44

418 The Flux Linkage of SLCW PMSG 46

419 The Flux Linkage of DLCW PMSG 47

420 The Flux Linkage of SLDW PMSG 48

421 The Flux Linkage of DLDW PMSG 49

422 The Back-EMF of SLCW PMSG 51

423 The Back-EMF of DLCW PMSG 52

424 The Back-EMF of SLDW PMSG 53

425 The Back-EMF of DLDW PMSG 54

426 The Air-gap Flux Density of SLCW PMSG 56

427 The Air-gap Flux Density of DLCW PMSG 56

428 The Air-gap Flux Density of SLDW PMSG 57

429 The Air-gap Flux Density of DLDW PMSG 57

430 The Cogging Torque of SLCW PMSG 59

431 The Cogging Torque of DLCW PMSG 59

x

432 The Cogging Torque of SLDW PMSG 60

433 The Cogging Torque of DLDW PMSG 60

434 The Copper Loss of SLCW PMSG 62

435 The Copper Loss of DLCW PMSG 63

436 The Copper Loss of SLDW PMSG 64

437 The Copper Loss of DLDW PMSG 65

xi

LIST OF ABBREVIATIONS

PM - Permanent Magnet

PMSG - Permanent Magnet Synchronous Generator

FEMM - Finite Element Method Magnetics

PMSM - Permanent Magnet Synchronous Machine

MMF - Magnetomotive Force

FSCW - Fractional-slot Concentrated Winding

IPM - Interior Permanent Magnet

RPM - Revolutions per Minute

EMF - Electromotive Force

SLCW - Single Layer Concentrated Winding

DLCW - Double Layer Concentrated Winding

SLDW - Single Layer Distributed Winding

DLDW - Double Layer Distributed Winding

1

CHAPTER 1

INTRODUCTION

11 Overview

Electricity is one of our essential needs especially in our daily life as most of the

appliances in the home office or even factories depend on electricity to function Almost

all the electricity produced in the world is generated by the electric machine Electricity

exists in nature as a form of lightning It also can be generated from the electrical power

generator Electricity can be produced through various ways such as wind water nuclear

or even combustion of coal and oil Figure 11 below depicts that the wind energy is the

second highest of the renewable energy in the electricity generation which is 37 [1]

Figure 11 Global Electricity Production of Renewable Energy Share 2015 [1]

2

A synchronous machine is an alternating current rotating machine that its speed

is proportional to the frequency of the current in its armature under steady state condition

This means that the magnetic field of the armature currents will rotate at the same

synchronous speed as the permanent magnets (PM) or the field current on the rotor Due

to the characteristic of the synchronous speed the synchronous generator is applied to the

constant speed drive

Figure 12 Global Capacity of Wind Power in the year 2005-2015 [1]

Figure 12 shows that the wind power global capacity had increased continuously

for each year from the year 2005 until 2015 In the year 2015 the global capacity for wind

power had reached 433 Gigawatts [1] This concluded that the demand for the electricity

from wind energy had risen In wind turbine industry permanent magnet synchronous

generator (PMSG) is widely used to produce electricity Permanent magnet is used for

the synchronous generator instead of the coil for excitation field PMSG does not require

slip rings to operate There is no direct current supply that is needed for excitation circuit

Without the need of slip rings PMSG is easier to be constructed and lower maintenance

cost The permanent magnet minimizes the rotor losses and this indirectly improves the

efficiency of the generator

PMSG offers a great privilege due to its stable operation [2] However the

construction fee for PMSG is costly due to its rare earth material permanent magnet

3

Despite the high cost of the permanent magnet the PMSG is widely used in the concern

of the environmental conservation The air-gap magnetic flux density also increased with

the use of permanent magnet PMSG has a smaller volume and lower density The

permanent magnet can be positioned inside the rotor or even mounted on the rotorrsquos

surface The maximum efficiency can be achieved by minimizing the air-gap between

rotor and stator

There are various ways for coils to be wound in the stator of the generator Each

of the forms has its own drawbacks and advantages The main purpose of varying the

forms of the coil distribution is to produce three balanced sinusoidal voltages with a little

harmonic voltage and current for three phase machine In other words the output power

is maximized and the losses are minimized with different patterns of coil distribution The

number of slots at the stator can be varied which will affect the manner of the coil

connection and hence different winding patterns can be formed

12 Problem Statement

The PMSG is a part of the wind turbine system Nowadays as the demand for the

electrical energy had increased rapidly around the world the efficiency for the PMSG is

seeking more attention from the researcher With an attempt to increase the performance

of the PMSG the world non-renewable energy consumption can be reduced and the

global warming issue can be minimized or even rectified Moreover the global economy

will also be improved and this will eventually enhance the quality living of life

Furthermore a better performance of PMSG can surely aid in the prevention of climate

change All these advantages come with the energy efficiency Hence various design on

the PMSG had been researched to increase the power output and reduce the losses of the

generator

There is no doubt that the PMSG is well known for its high efficiency and long

lasting performance which can be used in wind turbine However there are various ways

to enhance the performance of the PMSG One of the factors that determine the efficiency

of the PMSG is the winding method In this thesis the winding patterns that are compared

are single layer concentrated winding (SLCW) double layer concentrated winding

(DLCW) single layer distributed winding (SLDW) and double layer distributed winding

(DLDW) In order to improve the efficiency of the PMSG the most suitable winding

pattern has to be chosen

4

13 Objectives

The objectives of this project are

To study and investigate the winding methods for PMSG

To determine the efficiency of PMSG for each type of the windings

To compare the winding methods for the PMSG

To perform analytical analysis and simulation by using Finite Element

Method Magnetics (FEMM) to maximize the efficiency of the PMSG

14 Expected Outcomes

In this project the expected outcomes are listed below

The winding methods of the stator for the PMSG are studied and compared

The simulation of the PMSG is done by using FEMM software

The efficiency of each of the winding methods is analyzed and compared

The winding method that yields the highest performance of the PMSG is

determined

15 Project Outlines

This project contains five chapters These chapters comprised of Introduction

Literature Review Methodology Result and Discussion and Conclusion and

Recommendation These chapters are arranged from Chapter 1 to Chapter 5 respectively

Chapter 1 provides a brief introduction to the electricity generation together with

a short review on the PMSG the problem statement and objectives of this project The

expected outcomes at the end of the project are also included in this chapter

Chapter 2 reviews and compiles all the studies and research that are related to the

project The topologies for the PMSG different winding methods of the stator parameter

that determine the efficiency of the PMSG and analysis approach are discussed in this

chapter

Chapter 3 discusses the methodology that is needed to carry out the project In this

chapter the PMSG model that is used in this project is presented and explained The

5

terminology and the analytical approach by using the FEMM software are depicted in this

section

Chapter 4 computes the performance of the PMSG either through mathematical

calculation or via the 2 dimension simulation of the FEMM The parameters that affect

the efficiency of PMSG is evaluated All the graphical results and the magnetic field maps

are delineated in this chapter

Chapter 5 concludes all the results of the project and summarize the outcomes

The recommendations after carrying out this project are discussed in this chapter Any

limitation of this project is included too

6

CHAPTER 2

LITERATURE REVIEW

21 Permanent Magnet Alternating Current Machine

The Permanent Magnet Synchronous Machine (PMSM) can be divided into two

categories which are axial field and radial field For axial field topology the flux is

moving parallel to the rotor shaft whereas the flux is moving along the machinersquos radius

for the radial field topology [3] The permanent magnet can be placed at a various position

on the rotor The pro and cons of the axial field and radial field topologies are discussed

below [4]

Axial fieldrsquos strengths

A balanced rotor-stator attractive forces with two air-gaps

The grinding to an arc shape is skipped as the permanent magnets have two planar

surfaces

There is an adjustable air-gap

Magnet retainment is not needed

Axial fieldrsquos weakness

There is a poor winding utilization

Restricted size of the end turns at the internal radius

Cogging torque existed

Radial fieldrsquos strengths

There is no radial force on the rotor

Easier removal of heat from the stator winding due to the big surface area of the

stator back iron

7

Skewing is not needed

Radial fieldrsquos weakness

The magnets surface must be arced

Fixed air-gap

An air-gap is formed between rotor magnets with the rotor back iron

Figure 21 and Figure 22 show the axial and radial field structure of PMSM

respectively [5]

Figure 21 Axial Flux PMSMrsquos Structure [5]

Figure 22 Radial Flux PMSMrsquos Structure [5]

8

Figure 23 24 25 and 26 show the radial field of the PMSM with different

positions of permanent magnets [3]

Figure 23 Surface PMSM [3] Figure 24 Surface Inset PMSM [3]

Figure 25 Interior PMSM [3] Figure 26 Interior PMSM with

Circumferential Orientation [3]

The permanent magnets of the surface PMSM are directly mounted on the rotorrsquos

surface as shown in Figure 23 Figure 24 shows that the permanent magnets of the

surface inset PMSM are fixed at the rotor inner surface The Figure 25 depicts that the

permanent magnets of the PMSM are implanted inside the rotor meanwhile the permanent

magnets are aligned in a circular orientation inside the rotor of the PMSM as shown in

Figure 26

Page 6: COMPARISON ON WINDING METHOD FOR ELECTRICAL …

i

ACKNOWLEDGEMENT

First of all my special thanks gratitude and respect go to my final year projectrsquos

supervisor Dr Ngu Sze Song His endless patience persistent encouragements valuable

guidance and advice throughout this project are highly appreciated His timely

supervision on my project had helped me to accomplish my project in time Special thanks to all my friends and staff of Universiti Malaysia Sarawak that

helped me during my degree study Without their contribution and support I would not

be able to finish my project

Last but not least I would like to thank my parents for their mentally and

physically support not only for finishing this project but also during my whole degree

studies in UNIMAS

ii

ABSTRACT

Permanent Magnet Synchronous Generator (PMSG) is the most favorable

generator in producing the electricity especially in wind turbine industry The PMSG has

a higher efficiency compared to other generators as its excitation field is provided by the

permanent magnet This is an advantage for the generator as it reduces the maintenance

cost of the generator

A suitable winding method for the PMSG can increase the performance of the

generator There are four types of winding methods that are widely used in the generator

which are single layer winding double layer winding concentrated winding and

distributed winding In this thesis the single layer concentrated winding double layer

concentrated winding single layer distributed winding and double layer distributed

winding are simulated in Finite Element Method Magnetics (FEMM) The PMSG is

simulated and analyzed according to different winding methods This analysis is aimed

to compare different type of winding methods in order to enhance the efficiency of the

PMSG

iii

ABSTRAK

Permanent Magnet Synchronous Generator (PMSG) adalah penjana yang paling

baik dalam menghasilkan elektrik terutamanya dalam industri turbin angin PMSG

mempunyai kecekapan yang lebih tinggi berbanding dengan penjana lain disebabkan

medan pengujaannya diperoleh daripada magnet kekal Hal ini merupakan satu kelebihan

untuk generator tersebut kerana ia mengurangkan kos penyelenggaraan penjana

Kaedah penggulungan yang sesuai untuk PMSG boleh meningkatkan prestasi

penjana Terdapat 4 jenis kaedah penggulungan yang digunakan secara meluas dalam

penjana iaitu single layer winding double layer winding concentrated winding dan

distributed winding Dalam tesis ini single layer concentrated winding double layer

concentrated winding single layer distributed winding dan double layer distributed

winding disimulasikan dengan Finite Element Method Magnetics (FEMM) PMSG

disimulasikan dan dianalisiskan mengikut kaedah penggulungan yang berbeza Analisis

ini bertujuan untuk membandingkan kaedah penggulungan yang berbeza bagi

meningkatkan kecekapan PMSG

iv

TABLE OF CONTENTS

Page

Acknowledgement i

Abstract ii

Abstrak iii

Table of Contents iv

List of Tables vii

List of Figures viii

List of Abbreviations xi

Chapter 1 INTRODUCTION 1

11 Overview 1

12 Problem Statement 3

13 Objectives 4

14 Expected Outcomes 4

15 Project Outlines 4

Chapter 2 LITERATURE REVIEW 6

21 Permanent Magnet Alternating Current Machine 6

22 Winding Approaches 9

221 Single Layer Winding 9

222 Double Layer Winding 11

223 Distributed Winding 12

224 Concentrated Winding 13

23 Fundamental PMSM Relationships 14

231 Speed 14

232 Winding Factor 15

233 Electromagnetic Torque 15

24 No Load Operation 16

25 Winding Function Analysis 17

v

26 Magnetomotive Force (MMF) 19

261 Concentrated Full-Pitch Coil 19

262 Distributed Full-Pitch Coil Phase Winding 19

263 Three Phase Full-Pitch (Single-Layer) Winding 20

264 Three Phase Shorted-Pitch Coil (Double-Layer) 20

Winding

27 Inductance 20

28 Reactance 21

281 Synchronous Reactance 21

282 Leakage Reactance 21

29 Losses 22

291 Copper Loss 22

292 Core Loss 22

210 Back-EMF 23

Chapter 3 METHODOLOGY 24

31 Overview 24

32 Work Plan Flow Chart 25

33 Finite Element Method Magnetics 42 27

34 Block Integral 27

35 Lua Programming Language 28

36 Magnetics Preprocessor 29

37 Analysis Processor 30

38 Magnetics Postprocessor 32

Chapter 4 RESULTS AND DISCUSSIONS 34

41 Overview 34

42 Design Specification of PMSG 34

43 The Structure of PMSG 36

44 Winding Patterns 37

441 Single Layer Concentrated Winding 37

442 Double Layer Concentrated Winding 39

443 Single Layer Distributed Winding 41

444 Double Layer Distributed Winding 43

vi

45 Flux Linkage 45

46 Back-EMF 50

47 Air-gap Flux Density 55

48 Cogging Torque 58

49 Copper Loss 61

410 Summary 65

Chapter 5 CONCLUSION AND RECOMMENDATION 66

51 Conclusion 66

52 Recommendation 67

REFERENCES 68

APPENDIX A 71

APPENDIX B 72

APPENDIX C 73

APPENDIX D 74

vii

LIST OF TABLES

Table Page

41 Design Parameter of the PMSG 35

42 Materials of the Generator 35

43 The Current and Flux Linkage of SLCW PMSG 45

44 The Current and Flux Linkage of DLCW PMSG 46

45 The Current and Flux Linkage of SLDW PMSG 47

46 The Current and Flux Linkage of DLDW PMSG 48

47 The Back-EMF of SLCW PMSG 50

48 The Back-EMF of DLCW PMSG 51

49 The Back-EMF of SLDW PMSG 52

410 The Back-EMF of DLDW PMSG 53

411 The Air-gap Flux Density of PMSG for each Winding Patterns 55

412 The Cogging Torque of PMSG for each Winding Patterns 58

413 The Copper Loss of SLCW PMSG 61

414 The Copper Loss of DLCW PMSG 62

415 The Copper Loss of SLDW PMSG 63

416 The Copper Loss of DLDW PMSG 64

viii

LIST OF FIGURES

Figure Page

11 Global Electricity Production of Renewable Energy Share 2015 1

12 Global Capacity of Wind Power in the year 2005-2015 2

21 Axial Flux PMSMrsquos Structure 7

22 Radial Flux PMSMrsquos Structure 7

23 Surface PMSM 8

24 Surface Inset PMSM 8

25 Interior PMSM 8

26 Interior PMSM with Circumferential Orientation 8

27 Schematic Layout for Single Layer Winding 10

28 Winding Diagram with a Single Conductor per Slot 10

29 Winding Diagram with Multiple Conductors per Slot 11

210 Schematic Layout for Double Layer Winding 11

211 Winding Diagram for Double Layer Winding 12

212 Distributed Winding 13

213 FSCW-IPM with Double Layer Winding 13

214 FSCW-IPM with Single Layer Winding 14

215 Phasor Diagram for No Load Motor and Generator Operation for 16

Underexcited Condition respectively

216 Phasor Diagram for No Load Motor and Generator Operation for 16

Overexcited Condition respectively

217 Turns Function Definition 18

31 The Flow Chart of the Project 25

32 Drawing Mode Toolbar 29

33 Grid Manipulation Toolbar 30

34 Toolbar for Analysis Processor 30

35 Mesh for the PMSG Model 31

36 Status of the Model 31

37 Analysis Mode Toolbar 32

ix

38 The Depiction of Model in Point Values Mode 32

39 The Depiction of Model in Contour Mode 33

310 The Depiction of Model in Block Mode 33

41 Part of the Structure of the PMSG Model 36

42 The Structure of SLCW PMSG 37

43 SLCW Configuration 38

44 Flux Line and Flux Density of SLCW PMSG 38

45 Vector Plot of SLCW PMSG 38

46 The Structure of DLCW PMSG 39

47 DLCW Configuration 40

48 Flux Line and Flux Density of DLCW PMSG 40

49 Vector Plot of DLCW PMSG 40

410 The Structure of SLDW PMSG 41

411 SLDW Configuration 42

412 Flux Line and Flux Density of SLDW PMSG 42

413 Vector Plot of SLDW PMSG 42

414 The Structure of DLDW PMSG 43

415 DLDW Configuration 44

416 Flux Line and Flux Density of DLDW PMSG 44

417 Vector Plot of DLDW PMSG 44

418 The Flux Linkage of SLCW PMSG 46

419 The Flux Linkage of DLCW PMSG 47

420 The Flux Linkage of SLDW PMSG 48

421 The Flux Linkage of DLDW PMSG 49

422 The Back-EMF of SLCW PMSG 51

423 The Back-EMF of DLCW PMSG 52

424 The Back-EMF of SLDW PMSG 53

425 The Back-EMF of DLDW PMSG 54

426 The Air-gap Flux Density of SLCW PMSG 56

427 The Air-gap Flux Density of DLCW PMSG 56

428 The Air-gap Flux Density of SLDW PMSG 57

429 The Air-gap Flux Density of DLDW PMSG 57

430 The Cogging Torque of SLCW PMSG 59

431 The Cogging Torque of DLCW PMSG 59

x

432 The Cogging Torque of SLDW PMSG 60

433 The Cogging Torque of DLDW PMSG 60

434 The Copper Loss of SLCW PMSG 62

435 The Copper Loss of DLCW PMSG 63

436 The Copper Loss of SLDW PMSG 64

437 The Copper Loss of DLDW PMSG 65

xi

LIST OF ABBREVIATIONS

PM - Permanent Magnet

PMSG - Permanent Magnet Synchronous Generator

FEMM - Finite Element Method Magnetics

PMSM - Permanent Magnet Synchronous Machine

MMF - Magnetomotive Force

FSCW - Fractional-slot Concentrated Winding

IPM - Interior Permanent Magnet

RPM - Revolutions per Minute

EMF - Electromotive Force

SLCW - Single Layer Concentrated Winding

DLCW - Double Layer Concentrated Winding

SLDW - Single Layer Distributed Winding

DLDW - Double Layer Distributed Winding

1

CHAPTER 1

INTRODUCTION

11 Overview

Electricity is one of our essential needs especially in our daily life as most of the

appliances in the home office or even factories depend on electricity to function Almost

all the electricity produced in the world is generated by the electric machine Electricity

exists in nature as a form of lightning It also can be generated from the electrical power

generator Electricity can be produced through various ways such as wind water nuclear

or even combustion of coal and oil Figure 11 below depicts that the wind energy is the

second highest of the renewable energy in the electricity generation which is 37 [1]

Figure 11 Global Electricity Production of Renewable Energy Share 2015 [1]

2

A synchronous machine is an alternating current rotating machine that its speed

is proportional to the frequency of the current in its armature under steady state condition

This means that the magnetic field of the armature currents will rotate at the same

synchronous speed as the permanent magnets (PM) or the field current on the rotor Due

to the characteristic of the synchronous speed the synchronous generator is applied to the

constant speed drive

Figure 12 Global Capacity of Wind Power in the year 2005-2015 [1]

Figure 12 shows that the wind power global capacity had increased continuously

for each year from the year 2005 until 2015 In the year 2015 the global capacity for wind

power had reached 433 Gigawatts [1] This concluded that the demand for the electricity

from wind energy had risen In wind turbine industry permanent magnet synchronous

generator (PMSG) is widely used to produce electricity Permanent magnet is used for

the synchronous generator instead of the coil for excitation field PMSG does not require

slip rings to operate There is no direct current supply that is needed for excitation circuit

Without the need of slip rings PMSG is easier to be constructed and lower maintenance

cost The permanent magnet minimizes the rotor losses and this indirectly improves the

efficiency of the generator

PMSG offers a great privilege due to its stable operation [2] However the

construction fee for PMSG is costly due to its rare earth material permanent magnet

3

Despite the high cost of the permanent magnet the PMSG is widely used in the concern

of the environmental conservation The air-gap magnetic flux density also increased with

the use of permanent magnet PMSG has a smaller volume and lower density The

permanent magnet can be positioned inside the rotor or even mounted on the rotorrsquos

surface The maximum efficiency can be achieved by minimizing the air-gap between

rotor and stator

There are various ways for coils to be wound in the stator of the generator Each

of the forms has its own drawbacks and advantages The main purpose of varying the

forms of the coil distribution is to produce three balanced sinusoidal voltages with a little

harmonic voltage and current for three phase machine In other words the output power

is maximized and the losses are minimized with different patterns of coil distribution The

number of slots at the stator can be varied which will affect the manner of the coil

connection and hence different winding patterns can be formed

12 Problem Statement

The PMSG is a part of the wind turbine system Nowadays as the demand for the

electrical energy had increased rapidly around the world the efficiency for the PMSG is

seeking more attention from the researcher With an attempt to increase the performance

of the PMSG the world non-renewable energy consumption can be reduced and the

global warming issue can be minimized or even rectified Moreover the global economy

will also be improved and this will eventually enhance the quality living of life

Furthermore a better performance of PMSG can surely aid in the prevention of climate

change All these advantages come with the energy efficiency Hence various design on

the PMSG had been researched to increase the power output and reduce the losses of the

generator

There is no doubt that the PMSG is well known for its high efficiency and long

lasting performance which can be used in wind turbine However there are various ways

to enhance the performance of the PMSG One of the factors that determine the efficiency

of the PMSG is the winding method In this thesis the winding patterns that are compared

are single layer concentrated winding (SLCW) double layer concentrated winding

(DLCW) single layer distributed winding (SLDW) and double layer distributed winding

(DLDW) In order to improve the efficiency of the PMSG the most suitable winding

pattern has to be chosen

4

13 Objectives

The objectives of this project are

To study and investigate the winding methods for PMSG

To determine the efficiency of PMSG for each type of the windings

To compare the winding methods for the PMSG

To perform analytical analysis and simulation by using Finite Element

Method Magnetics (FEMM) to maximize the efficiency of the PMSG

14 Expected Outcomes

In this project the expected outcomes are listed below

The winding methods of the stator for the PMSG are studied and compared

The simulation of the PMSG is done by using FEMM software

The efficiency of each of the winding methods is analyzed and compared

The winding method that yields the highest performance of the PMSG is

determined

15 Project Outlines

This project contains five chapters These chapters comprised of Introduction

Literature Review Methodology Result and Discussion and Conclusion and

Recommendation These chapters are arranged from Chapter 1 to Chapter 5 respectively

Chapter 1 provides a brief introduction to the electricity generation together with

a short review on the PMSG the problem statement and objectives of this project The

expected outcomes at the end of the project are also included in this chapter

Chapter 2 reviews and compiles all the studies and research that are related to the

project The topologies for the PMSG different winding methods of the stator parameter

that determine the efficiency of the PMSG and analysis approach are discussed in this

chapter

Chapter 3 discusses the methodology that is needed to carry out the project In this

chapter the PMSG model that is used in this project is presented and explained The

5

terminology and the analytical approach by using the FEMM software are depicted in this

section

Chapter 4 computes the performance of the PMSG either through mathematical

calculation or via the 2 dimension simulation of the FEMM The parameters that affect

the efficiency of PMSG is evaluated All the graphical results and the magnetic field maps

are delineated in this chapter

Chapter 5 concludes all the results of the project and summarize the outcomes

The recommendations after carrying out this project are discussed in this chapter Any

limitation of this project is included too

6

CHAPTER 2

LITERATURE REVIEW

21 Permanent Magnet Alternating Current Machine

The Permanent Magnet Synchronous Machine (PMSM) can be divided into two

categories which are axial field and radial field For axial field topology the flux is

moving parallel to the rotor shaft whereas the flux is moving along the machinersquos radius

for the radial field topology [3] The permanent magnet can be placed at a various position

on the rotor The pro and cons of the axial field and radial field topologies are discussed

below [4]

Axial fieldrsquos strengths

A balanced rotor-stator attractive forces with two air-gaps

The grinding to an arc shape is skipped as the permanent magnets have two planar

surfaces

There is an adjustable air-gap

Magnet retainment is not needed

Axial fieldrsquos weakness

There is a poor winding utilization

Restricted size of the end turns at the internal radius

Cogging torque existed

Radial fieldrsquos strengths

There is no radial force on the rotor

Easier removal of heat from the stator winding due to the big surface area of the

stator back iron

7

Skewing is not needed

Radial fieldrsquos weakness

The magnets surface must be arced

Fixed air-gap

An air-gap is formed between rotor magnets with the rotor back iron

Figure 21 and Figure 22 show the axial and radial field structure of PMSM

respectively [5]

Figure 21 Axial Flux PMSMrsquos Structure [5]

Figure 22 Radial Flux PMSMrsquos Structure [5]

8

Figure 23 24 25 and 26 show the radial field of the PMSM with different

positions of permanent magnets [3]

Figure 23 Surface PMSM [3] Figure 24 Surface Inset PMSM [3]

Figure 25 Interior PMSM [3] Figure 26 Interior PMSM with

Circumferential Orientation [3]

The permanent magnets of the surface PMSM are directly mounted on the rotorrsquos

surface as shown in Figure 23 Figure 24 shows that the permanent magnets of the

surface inset PMSM are fixed at the rotor inner surface The Figure 25 depicts that the

permanent magnets of the PMSM are implanted inside the rotor meanwhile the permanent

magnets are aligned in a circular orientation inside the rotor of the PMSM as shown in

Figure 26

Page 7: COMPARISON ON WINDING METHOD FOR ELECTRICAL …

ii

ABSTRACT

Permanent Magnet Synchronous Generator (PMSG) is the most favorable

generator in producing the electricity especially in wind turbine industry The PMSG has

a higher efficiency compared to other generators as its excitation field is provided by the

permanent magnet This is an advantage for the generator as it reduces the maintenance

cost of the generator

A suitable winding method for the PMSG can increase the performance of the

generator There are four types of winding methods that are widely used in the generator

which are single layer winding double layer winding concentrated winding and

distributed winding In this thesis the single layer concentrated winding double layer

concentrated winding single layer distributed winding and double layer distributed

winding are simulated in Finite Element Method Magnetics (FEMM) The PMSG is

simulated and analyzed according to different winding methods This analysis is aimed

to compare different type of winding methods in order to enhance the efficiency of the

PMSG

iii

ABSTRAK

Permanent Magnet Synchronous Generator (PMSG) adalah penjana yang paling

baik dalam menghasilkan elektrik terutamanya dalam industri turbin angin PMSG

mempunyai kecekapan yang lebih tinggi berbanding dengan penjana lain disebabkan

medan pengujaannya diperoleh daripada magnet kekal Hal ini merupakan satu kelebihan

untuk generator tersebut kerana ia mengurangkan kos penyelenggaraan penjana

Kaedah penggulungan yang sesuai untuk PMSG boleh meningkatkan prestasi

penjana Terdapat 4 jenis kaedah penggulungan yang digunakan secara meluas dalam

penjana iaitu single layer winding double layer winding concentrated winding dan

distributed winding Dalam tesis ini single layer concentrated winding double layer

concentrated winding single layer distributed winding dan double layer distributed

winding disimulasikan dengan Finite Element Method Magnetics (FEMM) PMSG

disimulasikan dan dianalisiskan mengikut kaedah penggulungan yang berbeza Analisis

ini bertujuan untuk membandingkan kaedah penggulungan yang berbeza bagi

meningkatkan kecekapan PMSG

iv

TABLE OF CONTENTS

Page

Acknowledgement i

Abstract ii

Abstrak iii

Table of Contents iv

List of Tables vii

List of Figures viii

List of Abbreviations xi

Chapter 1 INTRODUCTION 1

11 Overview 1

12 Problem Statement 3

13 Objectives 4

14 Expected Outcomes 4

15 Project Outlines 4

Chapter 2 LITERATURE REVIEW 6

21 Permanent Magnet Alternating Current Machine 6

22 Winding Approaches 9

221 Single Layer Winding 9

222 Double Layer Winding 11

223 Distributed Winding 12

224 Concentrated Winding 13

23 Fundamental PMSM Relationships 14

231 Speed 14

232 Winding Factor 15

233 Electromagnetic Torque 15

24 No Load Operation 16

25 Winding Function Analysis 17

v

26 Magnetomotive Force (MMF) 19

261 Concentrated Full-Pitch Coil 19

262 Distributed Full-Pitch Coil Phase Winding 19

263 Three Phase Full-Pitch (Single-Layer) Winding 20

264 Three Phase Shorted-Pitch Coil (Double-Layer) 20

Winding

27 Inductance 20

28 Reactance 21

281 Synchronous Reactance 21

282 Leakage Reactance 21

29 Losses 22

291 Copper Loss 22

292 Core Loss 22

210 Back-EMF 23

Chapter 3 METHODOLOGY 24

31 Overview 24

32 Work Plan Flow Chart 25

33 Finite Element Method Magnetics 42 27

34 Block Integral 27

35 Lua Programming Language 28

36 Magnetics Preprocessor 29

37 Analysis Processor 30

38 Magnetics Postprocessor 32

Chapter 4 RESULTS AND DISCUSSIONS 34

41 Overview 34

42 Design Specification of PMSG 34

43 The Structure of PMSG 36

44 Winding Patterns 37

441 Single Layer Concentrated Winding 37

442 Double Layer Concentrated Winding 39

443 Single Layer Distributed Winding 41

444 Double Layer Distributed Winding 43

vi

45 Flux Linkage 45

46 Back-EMF 50

47 Air-gap Flux Density 55

48 Cogging Torque 58

49 Copper Loss 61

410 Summary 65

Chapter 5 CONCLUSION AND RECOMMENDATION 66

51 Conclusion 66

52 Recommendation 67

REFERENCES 68

APPENDIX A 71

APPENDIX B 72

APPENDIX C 73

APPENDIX D 74

vii

LIST OF TABLES

Table Page

41 Design Parameter of the PMSG 35

42 Materials of the Generator 35

43 The Current and Flux Linkage of SLCW PMSG 45

44 The Current and Flux Linkage of DLCW PMSG 46

45 The Current and Flux Linkage of SLDW PMSG 47

46 The Current and Flux Linkage of DLDW PMSG 48

47 The Back-EMF of SLCW PMSG 50

48 The Back-EMF of DLCW PMSG 51

49 The Back-EMF of SLDW PMSG 52

410 The Back-EMF of DLDW PMSG 53

411 The Air-gap Flux Density of PMSG for each Winding Patterns 55

412 The Cogging Torque of PMSG for each Winding Patterns 58

413 The Copper Loss of SLCW PMSG 61

414 The Copper Loss of DLCW PMSG 62

415 The Copper Loss of SLDW PMSG 63

416 The Copper Loss of DLDW PMSG 64

viii

LIST OF FIGURES

Figure Page

11 Global Electricity Production of Renewable Energy Share 2015 1

12 Global Capacity of Wind Power in the year 2005-2015 2

21 Axial Flux PMSMrsquos Structure 7

22 Radial Flux PMSMrsquos Structure 7

23 Surface PMSM 8

24 Surface Inset PMSM 8

25 Interior PMSM 8

26 Interior PMSM with Circumferential Orientation 8

27 Schematic Layout for Single Layer Winding 10

28 Winding Diagram with a Single Conductor per Slot 10

29 Winding Diagram with Multiple Conductors per Slot 11

210 Schematic Layout for Double Layer Winding 11

211 Winding Diagram for Double Layer Winding 12

212 Distributed Winding 13

213 FSCW-IPM with Double Layer Winding 13

214 FSCW-IPM with Single Layer Winding 14

215 Phasor Diagram for No Load Motor and Generator Operation for 16

Underexcited Condition respectively

216 Phasor Diagram for No Load Motor and Generator Operation for 16

Overexcited Condition respectively

217 Turns Function Definition 18

31 The Flow Chart of the Project 25

32 Drawing Mode Toolbar 29

33 Grid Manipulation Toolbar 30

34 Toolbar for Analysis Processor 30

35 Mesh for the PMSG Model 31

36 Status of the Model 31

37 Analysis Mode Toolbar 32

ix

38 The Depiction of Model in Point Values Mode 32

39 The Depiction of Model in Contour Mode 33

310 The Depiction of Model in Block Mode 33

41 Part of the Structure of the PMSG Model 36

42 The Structure of SLCW PMSG 37

43 SLCW Configuration 38

44 Flux Line and Flux Density of SLCW PMSG 38

45 Vector Plot of SLCW PMSG 38

46 The Structure of DLCW PMSG 39

47 DLCW Configuration 40

48 Flux Line and Flux Density of DLCW PMSG 40

49 Vector Plot of DLCW PMSG 40

410 The Structure of SLDW PMSG 41

411 SLDW Configuration 42

412 Flux Line and Flux Density of SLDW PMSG 42

413 Vector Plot of SLDW PMSG 42

414 The Structure of DLDW PMSG 43

415 DLDW Configuration 44

416 Flux Line and Flux Density of DLDW PMSG 44

417 Vector Plot of DLDW PMSG 44

418 The Flux Linkage of SLCW PMSG 46

419 The Flux Linkage of DLCW PMSG 47

420 The Flux Linkage of SLDW PMSG 48

421 The Flux Linkage of DLDW PMSG 49

422 The Back-EMF of SLCW PMSG 51

423 The Back-EMF of DLCW PMSG 52

424 The Back-EMF of SLDW PMSG 53

425 The Back-EMF of DLDW PMSG 54

426 The Air-gap Flux Density of SLCW PMSG 56

427 The Air-gap Flux Density of DLCW PMSG 56

428 The Air-gap Flux Density of SLDW PMSG 57

429 The Air-gap Flux Density of DLDW PMSG 57

430 The Cogging Torque of SLCW PMSG 59

431 The Cogging Torque of DLCW PMSG 59

x

432 The Cogging Torque of SLDW PMSG 60

433 The Cogging Torque of DLDW PMSG 60

434 The Copper Loss of SLCW PMSG 62

435 The Copper Loss of DLCW PMSG 63

436 The Copper Loss of SLDW PMSG 64

437 The Copper Loss of DLDW PMSG 65

xi

LIST OF ABBREVIATIONS

PM - Permanent Magnet

PMSG - Permanent Magnet Synchronous Generator

FEMM - Finite Element Method Magnetics

PMSM - Permanent Magnet Synchronous Machine

MMF - Magnetomotive Force

FSCW - Fractional-slot Concentrated Winding

IPM - Interior Permanent Magnet

RPM - Revolutions per Minute

EMF - Electromotive Force

SLCW - Single Layer Concentrated Winding

DLCW - Double Layer Concentrated Winding

SLDW - Single Layer Distributed Winding

DLDW - Double Layer Distributed Winding

1

CHAPTER 1

INTRODUCTION

11 Overview

Electricity is one of our essential needs especially in our daily life as most of the

appliances in the home office or even factories depend on electricity to function Almost

all the electricity produced in the world is generated by the electric machine Electricity

exists in nature as a form of lightning It also can be generated from the electrical power

generator Electricity can be produced through various ways such as wind water nuclear

or even combustion of coal and oil Figure 11 below depicts that the wind energy is the

second highest of the renewable energy in the electricity generation which is 37 [1]

Figure 11 Global Electricity Production of Renewable Energy Share 2015 [1]

2

A synchronous machine is an alternating current rotating machine that its speed

is proportional to the frequency of the current in its armature under steady state condition

This means that the magnetic field of the armature currents will rotate at the same

synchronous speed as the permanent magnets (PM) or the field current on the rotor Due

to the characteristic of the synchronous speed the synchronous generator is applied to the

constant speed drive

Figure 12 Global Capacity of Wind Power in the year 2005-2015 [1]

Figure 12 shows that the wind power global capacity had increased continuously

for each year from the year 2005 until 2015 In the year 2015 the global capacity for wind

power had reached 433 Gigawatts [1] This concluded that the demand for the electricity

from wind energy had risen In wind turbine industry permanent magnet synchronous

generator (PMSG) is widely used to produce electricity Permanent magnet is used for

the synchronous generator instead of the coil for excitation field PMSG does not require

slip rings to operate There is no direct current supply that is needed for excitation circuit

Without the need of slip rings PMSG is easier to be constructed and lower maintenance

cost The permanent magnet minimizes the rotor losses and this indirectly improves the

efficiency of the generator

PMSG offers a great privilege due to its stable operation [2] However the

construction fee for PMSG is costly due to its rare earth material permanent magnet

3

Despite the high cost of the permanent magnet the PMSG is widely used in the concern

of the environmental conservation The air-gap magnetic flux density also increased with

the use of permanent magnet PMSG has a smaller volume and lower density The

permanent magnet can be positioned inside the rotor or even mounted on the rotorrsquos

surface The maximum efficiency can be achieved by minimizing the air-gap between

rotor and stator

There are various ways for coils to be wound in the stator of the generator Each

of the forms has its own drawbacks and advantages The main purpose of varying the

forms of the coil distribution is to produce three balanced sinusoidal voltages with a little

harmonic voltage and current for three phase machine In other words the output power

is maximized and the losses are minimized with different patterns of coil distribution The

number of slots at the stator can be varied which will affect the manner of the coil

connection and hence different winding patterns can be formed

12 Problem Statement

The PMSG is a part of the wind turbine system Nowadays as the demand for the

electrical energy had increased rapidly around the world the efficiency for the PMSG is

seeking more attention from the researcher With an attempt to increase the performance

of the PMSG the world non-renewable energy consumption can be reduced and the

global warming issue can be minimized or even rectified Moreover the global economy

will also be improved and this will eventually enhance the quality living of life

Furthermore a better performance of PMSG can surely aid in the prevention of climate

change All these advantages come with the energy efficiency Hence various design on

the PMSG had been researched to increase the power output and reduce the losses of the

generator

There is no doubt that the PMSG is well known for its high efficiency and long

lasting performance which can be used in wind turbine However there are various ways

to enhance the performance of the PMSG One of the factors that determine the efficiency

of the PMSG is the winding method In this thesis the winding patterns that are compared

are single layer concentrated winding (SLCW) double layer concentrated winding

(DLCW) single layer distributed winding (SLDW) and double layer distributed winding

(DLDW) In order to improve the efficiency of the PMSG the most suitable winding

pattern has to be chosen

4

13 Objectives

The objectives of this project are

To study and investigate the winding methods for PMSG

To determine the efficiency of PMSG for each type of the windings

To compare the winding methods for the PMSG

To perform analytical analysis and simulation by using Finite Element

Method Magnetics (FEMM) to maximize the efficiency of the PMSG

14 Expected Outcomes

In this project the expected outcomes are listed below

The winding methods of the stator for the PMSG are studied and compared

The simulation of the PMSG is done by using FEMM software

The efficiency of each of the winding methods is analyzed and compared

The winding method that yields the highest performance of the PMSG is

determined

15 Project Outlines

This project contains five chapters These chapters comprised of Introduction

Literature Review Methodology Result and Discussion and Conclusion and

Recommendation These chapters are arranged from Chapter 1 to Chapter 5 respectively

Chapter 1 provides a brief introduction to the electricity generation together with

a short review on the PMSG the problem statement and objectives of this project The

expected outcomes at the end of the project are also included in this chapter

Chapter 2 reviews and compiles all the studies and research that are related to the

project The topologies for the PMSG different winding methods of the stator parameter

that determine the efficiency of the PMSG and analysis approach are discussed in this

chapter

Chapter 3 discusses the methodology that is needed to carry out the project In this

chapter the PMSG model that is used in this project is presented and explained The

5

terminology and the analytical approach by using the FEMM software are depicted in this

section

Chapter 4 computes the performance of the PMSG either through mathematical

calculation or via the 2 dimension simulation of the FEMM The parameters that affect

the efficiency of PMSG is evaluated All the graphical results and the magnetic field maps

are delineated in this chapter

Chapter 5 concludes all the results of the project and summarize the outcomes

The recommendations after carrying out this project are discussed in this chapter Any

limitation of this project is included too

6

CHAPTER 2

LITERATURE REVIEW

21 Permanent Magnet Alternating Current Machine

The Permanent Magnet Synchronous Machine (PMSM) can be divided into two

categories which are axial field and radial field For axial field topology the flux is

moving parallel to the rotor shaft whereas the flux is moving along the machinersquos radius

for the radial field topology [3] The permanent magnet can be placed at a various position

on the rotor The pro and cons of the axial field and radial field topologies are discussed

below [4]

Axial fieldrsquos strengths

A balanced rotor-stator attractive forces with two air-gaps

The grinding to an arc shape is skipped as the permanent magnets have two planar

surfaces

There is an adjustable air-gap

Magnet retainment is not needed

Axial fieldrsquos weakness

There is a poor winding utilization

Restricted size of the end turns at the internal radius

Cogging torque existed

Radial fieldrsquos strengths

There is no radial force on the rotor

Easier removal of heat from the stator winding due to the big surface area of the

stator back iron

7

Skewing is not needed

Radial fieldrsquos weakness

The magnets surface must be arced

Fixed air-gap

An air-gap is formed between rotor magnets with the rotor back iron

Figure 21 and Figure 22 show the axial and radial field structure of PMSM

respectively [5]

Figure 21 Axial Flux PMSMrsquos Structure [5]

Figure 22 Radial Flux PMSMrsquos Structure [5]

8

Figure 23 24 25 and 26 show the radial field of the PMSM with different

positions of permanent magnets [3]

Figure 23 Surface PMSM [3] Figure 24 Surface Inset PMSM [3]

Figure 25 Interior PMSM [3] Figure 26 Interior PMSM with

Circumferential Orientation [3]

The permanent magnets of the surface PMSM are directly mounted on the rotorrsquos

surface as shown in Figure 23 Figure 24 shows that the permanent magnets of the

surface inset PMSM are fixed at the rotor inner surface The Figure 25 depicts that the

permanent magnets of the PMSM are implanted inside the rotor meanwhile the permanent

magnets are aligned in a circular orientation inside the rotor of the PMSM as shown in

Figure 26

Page 8: COMPARISON ON WINDING METHOD FOR ELECTRICAL …

iii

ABSTRAK

Permanent Magnet Synchronous Generator (PMSG) adalah penjana yang paling

baik dalam menghasilkan elektrik terutamanya dalam industri turbin angin PMSG

mempunyai kecekapan yang lebih tinggi berbanding dengan penjana lain disebabkan

medan pengujaannya diperoleh daripada magnet kekal Hal ini merupakan satu kelebihan

untuk generator tersebut kerana ia mengurangkan kos penyelenggaraan penjana

Kaedah penggulungan yang sesuai untuk PMSG boleh meningkatkan prestasi

penjana Terdapat 4 jenis kaedah penggulungan yang digunakan secara meluas dalam

penjana iaitu single layer winding double layer winding concentrated winding dan

distributed winding Dalam tesis ini single layer concentrated winding double layer

concentrated winding single layer distributed winding dan double layer distributed

winding disimulasikan dengan Finite Element Method Magnetics (FEMM) PMSG

disimulasikan dan dianalisiskan mengikut kaedah penggulungan yang berbeza Analisis

ini bertujuan untuk membandingkan kaedah penggulungan yang berbeza bagi

meningkatkan kecekapan PMSG

iv

TABLE OF CONTENTS

Page

Acknowledgement i

Abstract ii

Abstrak iii

Table of Contents iv

List of Tables vii

List of Figures viii

List of Abbreviations xi

Chapter 1 INTRODUCTION 1

11 Overview 1

12 Problem Statement 3

13 Objectives 4

14 Expected Outcomes 4

15 Project Outlines 4

Chapter 2 LITERATURE REVIEW 6

21 Permanent Magnet Alternating Current Machine 6

22 Winding Approaches 9

221 Single Layer Winding 9

222 Double Layer Winding 11

223 Distributed Winding 12

224 Concentrated Winding 13

23 Fundamental PMSM Relationships 14

231 Speed 14

232 Winding Factor 15

233 Electromagnetic Torque 15

24 No Load Operation 16

25 Winding Function Analysis 17

v

26 Magnetomotive Force (MMF) 19

261 Concentrated Full-Pitch Coil 19

262 Distributed Full-Pitch Coil Phase Winding 19

263 Three Phase Full-Pitch (Single-Layer) Winding 20

264 Three Phase Shorted-Pitch Coil (Double-Layer) 20

Winding

27 Inductance 20

28 Reactance 21

281 Synchronous Reactance 21

282 Leakage Reactance 21

29 Losses 22

291 Copper Loss 22

292 Core Loss 22

210 Back-EMF 23

Chapter 3 METHODOLOGY 24

31 Overview 24

32 Work Plan Flow Chart 25

33 Finite Element Method Magnetics 42 27

34 Block Integral 27

35 Lua Programming Language 28

36 Magnetics Preprocessor 29

37 Analysis Processor 30

38 Magnetics Postprocessor 32

Chapter 4 RESULTS AND DISCUSSIONS 34

41 Overview 34

42 Design Specification of PMSG 34

43 The Structure of PMSG 36

44 Winding Patterns 37

441 Single Layer Concentrated Winding 37

442 Double Layer Concentrated Winding 39

443 Single Layer Distributed Winding 41

444 Double Layer Distributed Winding 43

vi

45 Flux Linkage 45

46 Back-EMF 50

47 Air-gap Flux Density 55

48 Cogging Torque 58

49 Copper Loss 61

410 Summary 65

Chapter 5 CONCLUSION AND RECOMMENDATION 66

51 Conclusion 66

52 Recommendation 67

REFERENCES 68

APPENDIX A 71

APPENDIX B 72

APPENDIX C 73

APPENDIX D 74

vii

LIST OF TABLES

Table Page

41 Design Parameter of the PMSG 35

42 Materials of the Generator 35

43 The Current and Flux Linkage of SLCW PMSG 45

44 The Current and Flux Linkage of DLCW PMSG 46

45 The Current and Flux Linkage of SLDW PMSG 47

46 The Current and Flux Linkage of DLDW PMSG 48

47 The Back-EMF of SLCW PMSG 50

48 The Back-EMF of DLCW PMSG 51

49 The Back-EMF of SLDW PMSG 52

410 The Back-EMF of DLDW PMSG 53

411 The Air-gap Flux Density of PMSG for each Winding Patterns 55

412 The Cogging Torque of PMSG for each Winding Patterns 58

413 The Copper Loss of SLCW PMSG 61

414 The Copper Loss of DLCW PMSG 62

415 The Copper Loss of SLDW PMSG 63

416 The Copper Loss of DLDW PMSG 64

viii

LIST OF FIGURES

Figure Page

11 Global Electricity Production of Renewable Energy Share 2015 1

12 Global Capacity of Wind Power in the year 2005-2015 2

21 Axial Flux PMSMrsquos Structure 7

22 Radial Flux PMSMrsquos Structure 7

23 Surface PMSM 8

24 Surface Inset PMSM 8

25 Interior PMSM 8

26 Interior PMSM with Circumferential Orientation 8

27 Schematic Layout for Single Layer Winding 10

28 Winding Diagram with a Single Conductor per Slot 10

29 Winding Diagram with Multiple Conductors per Slot 11

210 Schematic Layout for Double Layer Winding 11

211 Winding Diagram for Double Layer Winding 12

212 Distributed Winding 13

213 FSCW-IPM with Double Layer Winding 13

214 FSCW-IPM with Single Layer Winding 14

215 Phasor Diagram for No Load Motor and Generator Operation for 16

Underexcited Condition respectively

216 Phasor Diagram for No Load Motor and Generator Operation for 16

Overexcited Condition respectively

217 Turns Function Definition 18

31 The Flow Chart of the Project 25

32 Drawing Mode Toolbar 29

33 Grid Manipulation Toolbar 30

34 Toolbar for Analysis Processor 30

35 Mesh for the PMSG Model 31

36 Status of the Model 31

37 Analysis Mode Toolbar 32

ix

38 The Depiction of Model in Point Values Mode 32

39 The Depiction of Model in Contour Mode 33

310 The Depiction of Model in Block Mode 33

41 Part of the Structure of the PMSG Model 36

42 The Structure of SLCW PMSG 37

43 SLCW Configuration 38

44 Flux Line and Flux Density of SLCW PMSG 38

45 Vector Plot of SLCW PMSG 38

46 The Structure of DLCW PMSG 39

47 DLCW Configuration 40

48 Flux Line and Flux Density of DLCW PMSG 40

49 Vector Plot of DLCW PMSG 40

410 The Structure of SLDW PMSG 41

411 SLDW Configuration 42

412 Flux Line and Flux Density of SLDW PMSG 42

413 Vector Plot of SLDW PMSG 42

414 The Structure of DLDW PMSG 43

415 DLDW Configuration 44

416 Flux Line and Flux Density of DLDW PMSG 44

417 Vector Plot of DLDW PMSG 44

418 The Flux Linkage of SLCW PMSG 46

419 The Flux Linkage of DLCW PMSG 47

420 The Flux Linkage of SLDW PMSG 48

421 The Flux Linkage of DLDW PMSG 49

422 The Back-EMF of SLCW PMSG 51

423 The Back-EMF of DLCW PMSG 52

424 The Back-EMF of SLDW PMSG 53

425 The Back-EMF of DLDW PMSG 54

426 The Air-gap Flux Density of SLCW PMSG 56

427 The Air-gap Flux Density of DLCW PMSG 56

428 The Air-gap Flux Density of SLDW PMSG 57

429 The Air-gap Flux Density of DLDW PMSG 57

430 The Cogging Torque of SLCW PMSG 59

431 The Cogging Torque of DLCW PMSG 59

x

432 The Cogging Torque of SLDW PMSG 60

433 The Cogging Torque of DLDW PMSG 60

434 The Copper Loss of SLCW PMSG 62

435 The Copper Loss of DLCW PMSG 63

436 The Copper Loss of SLDW PMSG 64

437 The Copper Loss of DLDW PMSG 65

xi

LIST OF ABBREVIATIONS

PM - Permanent Magnet

PMSG - Permanent Magnet Synchronous Generator

FEMM - Finite Element Method Magnetics

PMSM - Permanent Magnet Synchronous Machine

MMF - Magnetomotive Force

FSCW - Fractional-slot Concentrated Winding

IPM - Interior Permanent Magnet

RPM - Revolutions per Minute

EMF - Electromotive Force

SLCW - Single Layer Concentrated Winding

DLCW - Double Layer Concentrated Winding

SLDW - Single Layer Distributed Winding

DLDW - Double Layer Distributed Winding

1

CHAPTER 1

INTRODUCTION

11 Overview

Electricity is one of our essential needs especially in our daily life as most of the

appliances in the home office or even factories depend on electricity to function Almost

all the electricity produced in the world is generated by the electric machine Electricity

exists in nature as a form of lightning It also can be generated from the electrical power

generator Electricity can be produced through various ways such as wind water nuclear

or even combustion of coal and oil Figure 11 below depicts that the wind energy is the

second highest of the renewable energy in the electricity generation which is 37 [1]

Figure 11 Global Electricity Production of Renewable Energy Share 2015 [1]

2

A synchronous machine is an alternating current rotating machine that its speed

is proportional to the frequency of the current in its armature under steady state condition

This means that the magnetic field of the armature currents will rotate at the same

synchronous speed as the permanent magnets (PM) or the field current on the rotor Due

to the characteristic of the synchronous speed the synchronous generator is applied to the

constant speed drive

Figure 12 Global Capacity of Wind Power in the year 2005-2015 [1]

Figure 12 shows that the wind power global capacity had increased continuously

for each year from the year 2005 until 2015 In the year 2015 the global capacity for wind

power had reached 433 Gigawatts [1] This concluded that the demand for the electricity

from wind energy had risen In wind turbine industry permanent magnet synchronous

generator (PMSG) is widely used to produce electricity Permanent magnet is used for

the synchronous generator instead of the coil for excitation field PMSG does not require

slip rings to operate There is no direct current supply that is needed for excitation circuit

Without the need of slip rings PMSG is easier to be constructed and lower maintenance

cost The permanent magnet minimizes the rotor losses and this indirectly improves the

efficiency of the generator

PMSG offers a great privilege due to its stable operation [2] However the

construction fee for PMSG is costly due to its rare earth material permanent magnet

3

Despite the high cost of the permanent magnet the PMSG is widely used in the concern

of the environmental conservation The air-gap magnetic flux density also increased with

the use of permanent magnet PMSG has a smaller volume and lower density The

permanent magnet can be positioned inside the rotor or even mounted on the rotorrsquos

surface The maximum efficiency can be achieved by minimizing the air-gap between

rotor and stator

There are various ways for coils to be wound in the stator of the generator Each

of the forms has its own drawbacks and advantages The main purpose of varying the

forms of the coil distribution is to produce three balanced sinusoidal voltages with a little

harmonic voltage and current for three phase machine In other words the output power

is maximized and the losses are minimized with different patterns of coil distribution The

number of slots at the stator can be varied which will affect the manner of the coil

connection and hence different winding patterns can be formed

12 Problem Statement

The PMSG is a part of the wind turbine system Nowadays as the demand for the

electrical energy had increased rapidly around the world the efficiency for the PMSG is

seeking more attention from the researcher With an attempt to increase the performance

of the PMSG the world non-renewable energy consumption can be reduced and the

global warming issue can be minimized or even rectified Moreover the global economy

will also be improved and this will eventually enhance the quality living of life

Furthermore a better performance of PMSG can surely aid in the prevention of climate

change All these advantages come with the energy efficiency Hence various design on

the PMSG had been researched to increase the power output and reduce the losses of the

generator

There is no doubt that the PMSG is well known for its high efficiency and long

lasting performance which can be used in wind turbine However there are various ways

to enhance the performance of the PMSG One of the factors that determine the efficiency

of the PMSG is the winding method In this thesis the winding patterns that are compared

are single layer concentrated winding (SLCW) double layer concentrated winding

(DLCW) single layer distributed winding (SLDW) and double layer distributed winding

(DLDW) In order to improve the efficiency of the PMSG the most suitable winding

pattern has to be chosen

4

13 Objectives

The objectives of this project are

To study and investigate the winding methods for PMSG

To determine the efficiency of PMSG for each type of the windings

To compare the winding methods for the PMSG

To perform analytical analysis and simulation by using Finite Element

Method Magnetics (FEMM) to maximize the efficiency of the PMSG

14 Expected Outcomes

In this project the expected outcomes are listed below

The winding methods of the stator for the PMSG are studied and compared

The simulation of the PMSG is done by using FEMM software

The efficiency of each of the winding methods is analyzed and compared

The winding method that yields the highest performance of the PMSG is

determined

15 Project Outlines

This project contains five chapters These chapters comprised of Introduction

Literature Review Methodology Result and Discussion and Conclusion and

Recommendation These chapters are arranged from Chapter 1 to Chapter 5 respectively

Chapter 1 provides a brief introduction to the electricity generation together with

a short review on the PMSG the problem statement and objectives of this project The

expected outcomes at the end of the project are also included in this chapter

Chapter 2 reviews and compiles all the studies and research that are related to the

project The topologies for the PMSG different winding methods of the stator parameter

that determine the efficiency of the PMSG and analysis approach are discussed in this

chapter

Chapter 3 discusses the methodology that is needed to carry out the project In this

chapter the PMSG model that is used in this project is presented and explained The

5

terminology and the analytical approach by using the FEMM software are depicted in this

section

Chapter 4 computes the performance of the PMSG either through mathematical

calculation or via the 2 dimension simulation of the FEMM The parameters that affect

the efficiency of PMSG is evaluated All the graphical results and the magnetic field maps

are delineated in this chapter

Chapter 5 concludes all the results of the project and summarize the outcomes

The recommendations after carrying out this project are discussed in this chapter Any

limitation of this project is included too

6

CHAPTER 2

LITERATURE REVIEW

21 Permanent Magnet Alternating Current Machine

The Permanent Magnet Synchronous Machine (PMSM) can be divided into two

categories which are axial field and radial field For axial field topology the flux is

moving parallel to the rotor shaft whereas the flux is moving along the machinersquos radius

for the radial field topology [3] The permanent magnet can be placed at a various position

on the rotor The pro and cons of the axial field and radial field topologies are discussed

below [4]

Axial fieldrsquos strengths

A balanced rotor-stator attractive forces with two air-gaps

The grinding to an arc shape is skipped as the permanent magnets have two planar

surfaces

There is an adjustable air-gap

Magnet retainment is not needed

Axial fieldrsquos weakness

There is a poor winding utilization

Restricted size of the end turns at the internal radius

Cogging torque existed

Radial fieldrsquos strengths

There is no radial force on the rotor

Easier removal of heat from the stator winding due to the big surface area of the

stator back iron

7

Skewing is not needed

Radial fieldrsquos weakness

The magnets surface must be arced

Fixed air-gap

An air-gap is formed between rotor magnets with the rotor back iron

Figure 21 and Figure 22 show the axial and radial field structure of PMSM

respectively [5]

Figure 21 Axial Flux PMSMrsquos Structure [5]

Figure 22 Radial Flux PMSMrsquos Structure [5]

8

Figure 23 24 25 and 26 show the radial field of the PMSM with different

positions of permanent magnets [3]

Figure 23 Surface PMSM [3] Figure 24 Surface Inset PMSM [3]

Figure 25 Interior PMSM [3] Figure 26 Interior PMSM with

Circumferential Orientation [3]

The permanent magnets of the surface PMSM are directly mounted on the rotorrsquos

surface as shown in Figure 23 Figure 24 shows that the permanent magnets of the

surface inset PMSM are fixed at the rotor inner surface The Figure 25 depicts that the

permanent magnets of the PMSM are implanted inside the rotor meanwhile the permanent

magnets are aligned in a circular orientation inside the rotor of the PMSM as shown in

Figure 26

Page 9: COMPARISON ON WINDING METHOD FOR ELECTRICAL …

iv

TABLE OF CONTENTS

Page

Acknowledgement i

Abstract ii

Abstrak iii

Table of Contents iv

List of Tables vii

List of Figures viii

List of Abbreviations xi

Chapter 1 INTRODUCTION 1

11 Overview 1

12 Problem Statement 3

13 Objectives 4

14 Expected Outcomes 4

15 Project Outlines 4

Chapter 2 LITERATURE REVIEW 6

21 Permanent Magnet Alternating Current Machine 6

22 Winding Approaches 9

221 Single Layer Winding 9

222 Double Layer Winding 11

223 Distributed Winding 12

224 Concentrated Winding 13

23 Fundamental PMSM Relationships 14

231 Speed 14

232 Winding Factor 15

233 Electromagnetic Torque 15

24 No Load Operation 16

25 Winding Function Analysis 17

v

26 Magnetomotive Force (MMF) 19

261 Concentrated Full-Pitch Coil 19

262 Distributed Full-Pitch Coil Phase Winding 19

263 Three Phase Full-Pitch (Single-Layer) Winding 20

264 Three Phase Shorted-Pitch Coil (Double-Layer) 20

Winding

27 Inductance 20

28 Reactance 21

281 Synchronous Reactance 21

282 Leakage Reactance 21

29 Losses 22

291 Copper Loss 22

292 Core Loss 22

210 Back-EMF 23

Chapter 3 METHODOLOGY 24

31 Overview 24

32 Work Plan Flow Chart 25

33 Finite Element Method Magnetics 42 27

34 Block Integral 27

35 Lua Programming Language 28

36 Magnetics Preprocessor 29

37 Analysis Processor 30

38 Magnetics Postprocessor 32

Chapter 4 RESULTS AND DISCUSSIONS 34

41 Overview 34

42 Design Specification of PMSG 34

43 The Structure of PMSG 36

44 Winding Patterns 37

441 Single Layer Concentrated Winding 37

442 Double Layer Concentrated Winding 39

443 Single Layer Distributed Winding 41

444 Double Layer Distributed Winding 43

vi

45 Flux Linkage 45

46 Back-EMF 50

47 Air-gap Flux Density 55

48 Cogging Torque 58

49 Copper Loss 61

410 Summary 65

Chapter 5 CONCLUSION AND RECOMMENDATION 66

51 Conclusion 66

52 Recommendation 67

REFERENCES 68

APPENDIX A 71

APPENDIX B 72

APPENDIX C 73

APPENDIX D 74

vii

LIST OF TABLES

Table Page

41 Design Parameter of the PMSG 35

42 Materials of the Generator 35

43 The Current and Flux Linkage of SLCW PMSG 45

44 The Current and Flux Linkage of DLCW PMSG 46

45 The Current and Flux Linkage of SLDW PMSG 47

46 The Current and Flux Linkage of DLDW PMSG 48

47 The Back-EMF of SLCW PMSG 50

48 The Back-EMF of DLCW PMSG 51

49 The Back-EMF of SLDW PMSG 52

410 The Back-EMF of DLDW PMSG 53

411 The Air-gap Flux Density of PMSG for each Winding Patterns 55

412 The Cogging Torque of PMSG for each Winding Patterns 58

413 The Copper Loss of SLCW PMSG 61

414 The Copper Loss of DLCW PMSG 62

415 The Copper Loss of SLDW PMSG 63

416 The Copper Loss of DLDW PMSG 64

viii

LIST OF FIGURES

Figure Page

11 Global Electricity Production of Renewable Energy Share 2015 1

12 Global Capacity of Wind Power in the year 2005-2015 2

21 Axial Flux PMSMrsquos Structure 7

22 Radial Flux PMSMrsquos Structure 7

23 Surface PMSM 8

24 Surface Inset PMSM 8

25 Interior PMSM 8

26 Interior PMSM with Circumferential Orientation 8

27 Schematic Layout for Single Layer Winding 10

28 Winding Diagram with a Single Conductor per Slot 10

29 Winding Diagram with Multiple Conductors per Slot 11

210 Schematic Layout for Double Layer Winding 11

211 Winding Diagram for Double Layer Winding 12

212 Distributed Winding 13

213 FSCW-IPM with Double Layer Winding 13

214 FSCW-IPM with Single Layer Winding 14

215 Phasor Diagram for No Load Motor and Generator Operation for 16

Underexcited Condition respectively

216 Phasor Diagram for No Load Motor and Generator Operation for 16

Overexcited Condition respectively

217 Turns Function Definition 18

31 The Flow Chart of the Project 25

32 Drawing Mode Toolbar 29

33 Grid Manipulation Toolbar 30

34 Toolbar for Analysis Processor 30

35 Mesh for the PMSG Model 31

36 Status of the Model 31

37 Analysis Mode Toolbar 32

ix

38 The Depiction of Model in Point Values Mode 32

39 The Depiction of Model in Contour Mode 33

310 The Depiction of Model in Block Mode 33

41 Part of the Structure of the PMSG Model 36

42 The Structure of SLCW PMSG 37

43 SLCW Configuration 38

44 Flux Line and Flux Density of SLCW PMSG 38

45 Vector Plot of SLCW PMSG 38

46 The Structure of DLCW PMSG 39

47 DLCW Configuration 40

48 Flux Line and Flux Density of DLCW PMSG 40

49 Vector Plot of DLCW PMSG 40

410 The Structure of SLDW PMSG 41

411 SLDW Configuration 42

412 Flux Line and Flux Density of SLDW PMSG 42

413 Vector Plot of SLDW PMSG 42

414 The Structure of DLDW PMSG 43

415 DLDW Configuration 44

416 Flux Line and Flux Density of DLDW PMSG 44

417 Vector Plot of DLDW PMSG 44

418 The Flux Linkage of SLCW PMSG 46

419 The Flux Linkage of DLCW PMSG 47

420 The Flux Linkage of SLDW PMSG 48

421 The Flux Linkage of DLDW PMSG 49

422 The Back-EMF of SLCW PMSG 51

423 The Back-EMF of DLCW PMSG 52

424 The Back-EMF of SLDW PMSG 53

425 The Back-EMF of DLDW PMSG 54

426 The Air-gap Flux Density of SLCW PMSG 56

427 The Air-gap Flux Density of DLCW PMSG 56

428 The Air-gap Flux Density of SLDW PMSG 57

429 The Air-gap Flux Density of DLDW PMSG 57

430 The Cogging Torque of SLCW PMSG 59

431 The Cogging Torque of DLCW PMSG 59

x

432 The Cogging Torque of SLDW PMSG 60

433 The Cogging Torque of DLDW PMSG 60

434 The Copper Loss of SLCW PMSG 62

435 The Copper Loss of DLCW PMSG 63

436 The Copper Loss of SLDW PMSG 64

437 The Copper Loss of DLDW PMSG 65

xi

LIST OF ABBREVIATIONS

PM - Permanent Magnet

PMSG - Permanent Magnet Synchronous Generator

FEMM - Finite Element Method Magnetics

PMSM - Permanent Magnet Synchronous Machine

MMF - Magnetomotive Force

FSCW - Fractional-slot Concentrated Winding

IPM - Interior Permanent Magnet

RPM - Revolutions per Minute

EMF - Electromotive Force

SLCW - Single Layer Concentrated Winding

DLCW - Double Layer Concentrated Winding

SLDW - Single Layer Distributed Winding

DLDW - Double Layer Distributed Winding

1

CHAPTER 1

INTRODUCTION

11 Overview

Electricity is one of our essential needs especially in our daily life as most of the

appliances in the home office or even factories depend on electricity to function Almost

all the electricity produced in the world is generated by the electric machine Electricity

exists in nature as a form of lightning It also can be generated from the electrical power

generator Electricity can be produced through various ways such as wind water nuclear

or even combustion of coal and oil Figure 11 below depicts that the wind energy is the

second highest of the renewable energy in the electricity generation which is 37 [1]

Figure 11 Global Electricity Production of Renewable Energy Share 2015 [1]

2

A synchronous machine is an alternating current rotating machine that its speed

is proportional to the frequency of the current in its armature under steady state condition

This means that the magnetic field of the armature currents will rotate at the same

synchronous speed as the permanent magnets (PM) or the field current on the rotor Due

to the characteristic of the synchronous speed the synchronous generator is applied to the

constant speed drive

Figure 12 Global Capacity of Wind Power in the year 2005-2015 [1]

Figure 12 shows that the wind power global capacity had increased continuously

for each year from the year 2005 until 2015 In the year 2015 the global capacity for wind

power had reached 433 Gigawatts [1] This concluded that the demand for the electricity

from wind energy had risen In wind turbine industry permanent magnet synchronous

generator (PMSG) is widely used to produce electricity Permanent magnet is used for

the synchronous generator instead of the coil for excitation field PMSG does not require

slip rings to operate There is no direct current supply that is needed for excitation circuit

Without the need of slip rings PMSG is easier to be constructed and lower maintenance

cost The permanent magnet minimizes the rotor losses and this indirectly improves the

efficiency of the generator

PMSG offers a great privilege due to its stable operation [2] However the

construction fee for PMSG is costly due to its rare earth material permanent magnet

3

Despite the high cost of the permanent magnet the PMSG is widely used in the concern

of the environmental conservation The air-gap magnetic flux density also increased with

the use of permanent magnet PMSG has a smaller volume and lower density The

permanent magnet can be positioned inside the rotor or even mounted on the rotorrsquos

surface The maximum efficiency can be achieved by minimizing the air-gap between

rotor and stator

There are various ways for coils to be wound in the stator of the generator Each

of the forms has its own drawbacks and advantages The main purpose of varying the

forms of the coil distribution is to produce three balanced sinusoidal voltages with a little

harmonic voltage and current for three phase machine In other words the output power

is maximized and the losses are minimized with different patterns of coil distribution The

number of slots at the stator can be varied which will affect the manner of the coil

connection and hence different winding patterns can be formed

12 Problem Statement

The PMSG is a part of the wind turbine system Nowadays as the demand for the

electrical energy had increased rapidly around the world the efficiency for the PMSG is

seeking more attention from the researcher With an attempt to increase the performance

of the PMSG the world non-renewable energy consumption can be reduced and the

global warming issue can be minimized or even rectified Moreover the global economy

will also be improved and this will eventually enhance the quality living of life

Furthermore a better performance of PMSG can surely aid in the prevention of climate

change All these advantages come with the energy efficiency Hence various design on

the PMSG had been researched to increase the power output and reduce the losses of the

generator

There is no doubt that the PMSG is well known for its high efficiency and long

lasting performance which can be used in wind turbine However there are various ways

to enhance the performance of the PMSG One of the factors that determine the efficiency

of the PMSG is the winding method In this thesis the winding patterns that are compared

are single layer concentrated winding (SLCW) double layer concentrated winding

(DLCW) single layer distributed winding (SLDW) and double layer distributed winding

(DLDW) In order to improve the efficiency of the PMSG the most suitable winding

pattern has to be chosen

4

13 Objectives

The objectives of this project are

To study and investigate the winding methods for PMSG

To determine the efficiency of PMSG for each type of the windings

To compare the winding methods for the PMSG

To perform analytical analysis and simulation by using Finite Element

Method Magnetics (FEMM) to maximize the efficiency of the PMSG

14 Expected Outcomes

In this project the expected outcomes are listed below

The winding methods of the stator for the PMSG are studied and compared

The simulation of the PMSG is done by using FEMM software

The efficiency of each of the winding methods is analyzed and compared

The winding method that yields the highest performance of the PMSG is

determined

15 Project Outlines

This project contains five chapters These chapters comprised of Introduction

Literature Review Methodology Result and Discussion and Conclusion and

Recommendation These chapters are arranged from Chapter 1 to Chapter 5 respectively

Chapter 1 provides a brief introduction to the electricity generation together with

a short review on the PMSG the problem statement and objectives of this project The

expected outcomes at the end of the project are also included in this chapter

Chapter 2 reviews and compiles all the studies and research that are related to the

project The topologies for the PMSG different winding methods of the stator parameter

that determine the efficiency of the PMSG and analysis approach are discussed in this

chapter

Chapter 3 discusses the methodology that is needed to carry out the project In this

chapter the PMSG model that is used in this project is presented and explained The

5

terminology and the analytical approach by using the FEMM software are depicted in this

section

Chapter 4 computes the performance of the PMSG either through mathematical

calculation or via the 2 dimension simulation of the FEMM The parameters that affect

the efficiency of PMSG is evaluated All the graphical results and the magnetic field maps

are delineated in this chapter

Chapter 5 concludes all the results of the project and summarize the outcomes

The recommendations after carrying out this project are discussed in this chapter Any

limitation of this project is included too

6

CHAPTER 2

LITERATURE REVIEW

21 Permanent Magnet Alternating Current Machine

The Permanent Magnet Synchronous Machine (PMSM) can be divided into two

categories which are axial field and radial field For axial field topology the flux is

moving parallel to the rotor shaft whereas the flux is moving along the machinersquos radius

for the radial field topology [3] The permanent magnet can be placed at a various position

on the rotor The pro and cons of the axial field and radial field topologies are discussed

below [4]

Axial fieldrsquos strengths

A balanced rotor-stator attractive forces with two air-gaps

The grinding to an arc shape is skipped as the permanent magnets have two planar

surfaces

There is an adjustable air-gap

Magnet retainment is not needed

Axial fieldrsquos weakness

There is a poor winding utilization

Restricted size of the end turns at the internal radius

Cogging torque existed

Radial fieldrsquos strengths

There is no radial force on the rotor

Easier removal of heat from the stator winding due to the big surface area of the

stator back iron

7

Skewing is not needed

Radial fieldrsquos weakness

The magnets surface must be arced

Fixed air-gap

An air-gap is formed between rotor magnets with the rotor back iron

Figure 21 and Figure 22 show the axial and radial field structure of PMSM

respectively [5]

Figure 21 Axial Flux PMSMrsquos Structure [5]

Figure 22 Radial Flux PMSMrsquos Structure [5]

8

Figure 23 24 25 and 26 show the radial field of the PMSM with different

positions of permanent magnets [3]

Figure 23 Surface PMSM [3] Figure 24 Surface Inset PMSM [3]

Figure 25 Interior PMSM [3] Figure 26 Interior PMSM with

Circumferential Orientation [3]

The permanent magnets of the surface PMSM are directly mounted on the rotorrsquos

surface as shown in Figure 23 Figure 24 shows that the permanent magnets of the

surface inset PMSM are fixed at the rotor inner surface The Figure 25 depicts that the

permanent magnets of the PMSM are implanted inside the rotor meanwhile the permanent

magnets are aligned in a circular orientation inside the rotor of the PMSM as shown in

Figure 26

Page 10: COMPARISON ON WINDING METHOD FOR ELECTRICAL …

v

26 Magnetomotive Force (MMF) 19

261 Concentrated Full-Pitch Coil 19

262 Distributed Full-Pitch Coil Phase Winding 19

263 Three Phase Full-Pitch (Single-Layer) Winding 20

264 Three Phase Shorted-Pitch Coil (Double-Layer) 20

Winding

27 Inductance 20

28 Reactance 21

281 Synchronous Reactance 21

282 Leakage Reactance 21

29 Losses 22

291 Copper Loss 22

292 Core Loss 22

210 Back-EMF 23

Chapter 3 METHODOLOGY 24

31 Overview 24

32 Work Plan Flow Chart 25

33 Finite Element Method Magnetics 42 27

34 Block Integral 27

35 Lua Programming Language 28

36 Magnetics Preprocessor 29

37 Analysis Processor 30

38 Magnetics Postprocessor 32

Chapter 4 RESULTS AND DISCUSSIONS 34

41 Overview 34

42 Design Specification of PMSG 34

43 The Structure of PMSG 36

44 Winding Patterns 37

441 Single Layer Concentrated Winding 37

442 Double Layer Concentrated Winding 39

443 Single Layer Distributed Winding 41

444 Double Layer Distributed Winding 43

vi

45 Flux Linkage 45

46 Back-EMF 50

47 Air-gap Flux Density 55

48 Cogging Torque 58

49 Copper Loss 61

410 Summary 65

Chapter 5 CONCLUSION AND RECOMMENDATION 66

51 Conclusion 66

52 Recommendation 67

REFERENCES 68

APPENDIX A 71

APPENDIX B 72

APPENDIX C 73

APPENDIX D 74

vii

LIST OF TABLES

Table Page

41 Design Parameter of the PMSG 35

42 Materials of the Generator 35

43 The Current and Flux Linkage of SLCW PMSG 45

44 The Current and Flux Linkage of DLCW PMSG 46

45 The Current and Flux Linkage of SLDW PMSG 47

46 The Current and Flux Linkage of DLDW PMSG 48

47 The Back-EMF of SLCW PMSG 50

48 The Back-EMF of DLCW PMSG 51

49 The Back-EMF of SLDW PMSG 52

410 The Back-EMF of DLDW PMSG 53

411 The Air-gap Flux Density of PMSG for each Winding Patterns 55

412 The Cogging Torque of PMSG for each Winding Patterns 58

413 The Copper Loss of SLCW PMSG 61

414 The Copper Loss of DLCW PMSG 62

415 The Copper Loss of SLDW PMSG 63

416 The Copper Loss of DLDW PMSG 64

viii

LIST OF FIGURES

Figure Page

11 Global Electricity Production of Renewable Energy Share 2015 1

12 Global Capacity of Wind Power in the year 2005-2015 2

21 Axial Flux PMSMrsquos Structure 7

22 Radial Flux PMSMrsquos Structure 7

23 Surface PMSM 8

24 Surface Inset PMSM 8

25 Interior PMSM 8

26 Interior PMSM with Circumferential Orientation 8

27 Schematic Layout for Single Layer Winding 10

28 Winding Diagram with a Single Conductor per Slot 10

29 Winding Diagram with Multiple Conductors per Slot 11

210 Schematic Layout for Double Layer Winding 11

211 Winding Diagram for Double Layer Winding 12

212 Distributed Winding 13

213 FSCW-IPM with Double Layer Winding 13

214 FSCW-IPM with Single Layer Winding 14

215 Phasor Diagram for No Load Motor and Generator Operation for 16

Underexcited Condition respectively

216 Phasor Diagram for No Load Motor and Generator Operation for 16

Overexcited Condition respectively

217 Turns Function Definition 18

31 The Flow Chart of the Project 25

32 Drawing Mode Toolbar 29

33 Grid Manipulation Toolbar 30

34 Toolbar for Analysis Processor 30

35 Mesh for the PMSG Model 31

36 Status of the Model 31

37 Analysis Mode Toolbar 32

ix

38 The Depiction of Model in Point Values Mode 32

39 The Depiction of Model in Contour Mode 33

310 The Depiction of Model in Block Mode 33

41 Part of the Structure of the PMSG Model 36

42 The Structure of SLCW PMSG 37

43 SLCW Configuration 38

44 Flux Line and Flux Density of SLCW PMSG 38

45 Vector Plot of SLCW PMSG 38

46 The Structure of DLCW PMSG 39

47 DLCW Configuration 40

48 Flux Line and Flux Density of DLCW PMSG 40

49 Vector Plot of DLCW PMSG 40

410 The Structure of SLDW PMSG 41

411 SLDW Configuration 42

412 Flux Line and Flux Density of SLDW PMSG 42

413 Vector Plot of SLDW PMSG 42

414 The Structure of DLDW PMSG 43

415 DLDW Configuration 44

416 Flux Line and Flux Density of DLDW PMSG 44

417 Vector Plot of DLDW PMSG 44

418 The Flux Linkage of SLCW PMSG 46

419 The Flux Linkage of DLCW PMSG 47

420 The Flux Linkage of SLDW PMSG 48

421 The Flux Linkage of DLDW PMSG 49

422 The Back-EMF of SLCW PMSG 51

423 The Back-EMF of DLCW PMSG 52

424 The Back-EMF of SLDW PMSG 53

425 The Back-EMF of DLDW PMSG 54

426 The Air-gap Flux Density of SLCW PMSG 56

427 The Air-gap Flux Density of DLCW PMSG 56

428 The Air-gap Flux Density of SLDW PMSG 57

429 The Air-gap Flux Density of DLDW PMSG 57

430 The Cogging Torque of SLCW PMSG 59

431 The Cogging Torque of DLCW PMSG 59

x

432 The Cogging Torque of SLDW PMSG 60

433 The Cogging Torque of DLDW PMSG 60

434 The Copper Loss of SLCW PMSG 62

435 The Copper Loss of DLCW PMSG 63

436 The Copper Loss of SLDW PMSG 64

437 The Copper Loss of DLDW PMSG 65

xi

LIST OF ABBREVIATIONS

PM - Permanent Magnet

PMSG - Permanent Magnet Synchronous Generator

FEMM - Finite Element Method Magnetics

PMSM - Permanent Magnet Synchronous Machine

MMF - Magnetomotive Force

FSCW - Fractional-slot Concentrated Winding

IPM - Interior Permanent Magnet

RPM - Revolutions per Minute

EMF - Electromotive Force

SLCW - Single Layer Concentrated Winding

DLCW - Double Layer Concentrated Winding

SLDW - Single Layer Distributed Winding

DLDW - Double Layer Distributed Winding

1

CHAPTER 1

INTRODUCTION

11 Overview

Electricity is one of our essential needs especially in our daily life as most of the

appliances in the home office or even factories depend on electricity to function Almost

all the electricity produced in the world is generated by the electric machine Electricity

exists in nature as a form of lightning It also can be generated from the electrical power

generator Electricity can be produced through various ways such as wind water nuclear

or even combustion of coal and oil Figure 11 below depicts that the wind energy is the

second highest of the renewable energy in the electricity generation which is 37 [1]

Figure 11 Global Electricity Production of Renewable Energy Share 2015 [1]

2

A synchronous machine is an alternating current rotating machine that its speed

is proportional to the frequency of the current in its armature under steady state condition

This means that the magnetic field of the armature currents will rotate at the same

synchronous speed as the permanent magnets (PM) or the field current on the rotor Due

to the characteristic of the synchronous speed the synchronous generator is applied to the

constant speed drive

Figure 12 Global Capacity of Wind Power in the year 2005-2015 [1]

Figure 12 shows that the wind power global capacity had increased continuously

for each year from the year 2005 until 2015 In the year 2015 the global capacity for wind

power had reached 433 Gigawatts [1] This concluded that the demand for the electricity

from wind energy had risen In wind turbine industry permanent magnet synchronous

generator (PMSG) is widely used to produce electricity Permanent magnet is used for

the synchronous generator instead of the coil for excitation field PMSG does not require

slip rings to operate There is no direct current supply that is needed for excitation circuit

Without the need of slip rings PMSG is easier to be constructed and lower maintenance

cost The permanent magnet minimizes the rotor losses and this indirectly improves the

efficiency of the generator

PMSG offers a great privilege due to its stable operation [2] However the

construction fee for PMSG is costly due to its rare earth material permanent magnet

3

Despite the high cost of the permanent magnet the PMSG is widely used in the concern

of the environmental conservation The air-gap magnetic flux density also increased with

the use of permanent magnet PMSG has a smaller volume and lower density The

permanent magnet can be positioned inside the rotor or even mounted on the rotorrsquos

surface The maximum efficiency can be achieved by minimizing the air-gap between

rotor and stator

There are various ways for coils to be wound in the stator of the generator Each

of the forms has its own drawbacks and advantages The main purpose of varying the

forms of the coil distribution is to produce three balanced sinusoidal voltages with a little

harmonic voltage and current for three phase machine In other words the output power

is maximized and the losses are minimized with different patterns of coil distribution The

number of slots at the stator can be varied which will affect the manner of the coil

connection and hence different winding patterns can be formed

12 Problem Statement

The PMSG is a part of the wind turbine system Nowadays as the demand for the

electrical energy had increased rapidly around the world the efficiency for the PMSG is

seeking more attention from the researcher With an attempt to increase the performance

of the PMSG the world non-renewable energy consumption can be reduced and the

global warming issue can be minimized or even rectified Moreover the global economy

will also be improved and this will eventually enhance the quality living of life

Furthermore a better performance of PMSG can surely aid in the prevention of climate

change All these advantages come with the energy efficiency Hence various design on

the PMSG had been researched to increase the power output and reduce the losses of the

generator

There is no doubt that the PMSG is well known for its high efficiency and long

lasting performance which can be used in wind turbine However there are various ways

to enhance the performance of the PMSG One of the factors that determine the efficiency

of the PMSG is the winding method In this thesis the winding patterns that are compared

are single layer concentrated winding (SLCW) double layer concentrated winding

(DLCW) single layer distributed winding (SLDW) and double layer distributed winding

(DLDW) In order to improve the efficiency of the PMSG the most suitable winding

pattern has to be chosen

4

13 Objectives

The objectives of this project are

To study and investigate the winding methods for PMSG

To determine the efficiency of PMSG for each type of the windings

To compare the winding methods for the PMSG

To perform analytical analysis and simulation by using Finite Element

Method Magnetics (FEMM) to maximize the efficiency of the PMSG

14 Expected Outcomes

In this project the expected outcomes are listed below

The winding methods of the stator for the PMSG are studied and compared

The simulation of the PMSG is done by using FEMM software

The efficiency of each of the winding methods is analyzed and compared

The winding method that yields the highest performance of the PMSG is

determined

15 Project Outlines

This project contains five chapters These chapters comprised of Introduction

Literature Review Methodology Result and Discussion and Conclusion and

Recommendation These chapters are arranged from Chapter 1 to Chapter 5 respectively

Chapter 1 provides a brief introduction to the electricity generation together with

a short review on the PMSG the problem statement and objectives of this project The

expected outcomes at the end of the project are also included in this chapter

Chapter 2 reviews and compiles all the studies and research that are related to the

project The topologies for the PMSG different winding methods of the stator parameter

that determine the efficiency of the PMSG and analysis approach are discussed in this

chapter

Chapter 3 discusses the methodology that is needed to carry out the project In this

chapter the PMSG model that is used in this project is presented and explained The

5

terminology and the analytical approach by using the FEMM software are depicted in this

section

Chapter 4 computes the performance of the PMSG either through mathematical

calculation or via the 2 dimension simulation of the FEMM The parameters that affect

the efficiency of PMSG is evaluated All the graphical results and the magnetic field maps

are delineated in this chapter

Chapter 5 concludes all the results of the project and summarize the outcomes

The recommendations after carrying out this project are discussed in this chapter Any

limitation of this project is included too

6

CHAPTER 2

LITERATURE REVIEW

21 Permanent Magnet Alternating Current Machine

The Permanent Magnet Synchronous Machine (PMSM) can be divided into two

categories which are axial field and radial field For axial field topology the flux is

moving parallel to the rotor shaft whereas the flux is moving along the machinersquos radius

for the radial field topology [3] The permanent magnet can be placed at a various position

on the rotor The pro and cons of the axial field and radial field topologies are discussed

below [4]

Axial fieldrsquos strengths

A balanced rotor-stator attractive forces with two air-gaps

The grinding to an arc shape is skipped as the permanent magnets have two planar

surfaces

There is an adjustable air-gap

Magnet retainment is not needed

Axial fieldrsquos weakness

There is a poor winding utilization

Restricted size of the end turns at the internal radius

Cogging torque existed

Radial fieldrsquos strengths

There is no radial force on the rotor

Easier removal of heat from the stator winding due to the big surface area of the

stator back iron

7

Skewing is not needed

Radial fieldrsquos weakness

The magnets surface must be arced

Fixed air-gap

An air-gap is formed between rotor magnets with the rotor back iron

Figure 21 and Figure 22 show the axial and radial field structure of PMSM

respectively [5]

Figure 21 Axial Flux PMSMrsquos Structure [5]

Figure 22 Radial Flux PMSMrsquos Structure [5]

8

Figure 23 24 25 and 26 show the radial field of the PMSM with different

positions of permanent magnets [3]

Figure 23 Surface PMSM [3] Figure 24 Surface Inset PMSM [3]

Figure 25 Interior PMSM [3] Figure 26 Interior PMSM with

Circumferential Orientation [3]

The permanent magnets of the surface PMSM are directly mounted on the rotorrsquos

surface as shown in Figure 23 Figure 24 shows that the permanent magnets of the

surface inset PMSM are fixed at the rotor inner surface The Figure 25 depicts that the

permanent magnets of the PMSM are implanted inside the rotor meanwhile the permanent

magnets are aligned in a circular orientation inside the rotor of the PMSM as shown in

Figure 26

Page 11: COMPARISON ON WINDING METHOD FOR ELECTRICAL …

vi

45 Flux Linkage 45

46 Back-EMF 50

47 Air-gap Flux Density 55

48 Cogging Torque 58

49 Copper Loss 61

410 Summary 65

Chapter 5 CONCLUSION AND RECOMMENDATION 66

51 Conclusion 66

52 Recommendation 67

REFERENCES 68

APPENDIX A 71

APPENDIX B 72

APPENDIX C 73

APPENDIX D 74

vii

LIST OF TABLES

Table Page

41 Design Parameter of the PMSG 35

42 Materials of the Generator 35

43 The Current and Flux Linkage of SLCW PMSG 45

44 The Current and Flux Linkage of DLCW PMSG 46

45 The Current and Flux Linkage of SLDW PMSG 47

46 The Current and Flux Linkage of DLDW PMSG 48

47 The Back-EMF of SLCW PMSG 50

48 The Back-EMF of DLCW PMSG 51

49 The Back-EMF of SLDW PMSG 52

410 The Back-EMF of DLDW PMSG 53

411 The Air-gap Flux Density of PMSG for each Winding Patterns 55

412 The Cogging Torque of PMSG for each Winding Patterns 58

413 The Copper Loss of SLCW PMSG 61

414 The Copper Loss of DLCW PMSG 62

415 The Copper Loss of SLDW PMSG 63

416 The Copper Loss of DLDW PMSG 64

viii

LIST OF FIGURES

Figure Page

11 Global Electricity Production of Renewable Energy Share 2015 1

12 Global Capacity of Wind Power in the year 2005-2015 2

21 Axial Flux PMSMrsquos Structure 7

22 Radial Flux PMSMrsquos Structure 7

23 Surface PMSM 8

24 Surface Inset PMSM 8

25 Interior PMSM 8

26 Interior PMSM with Circumferential Orientation 8

27 Schematic Layout for Single Layer Winding 10

28 Winding Diagram with a Single Conductor per Slot 10

29 Winding Diagram with Multiple Conductors per Slot 11

210 Schematic Layout for Double Layer Winding 11

211 Winding Diagram for Double Layer Winding 12

212 Distributed Winding 13

213 FSCW-IPM with Double Layer Winding 13

214 FSCW-IPM with Single Layer Winding 14

215 Phasor Diagram for No Load Motor and Generator Operation for 16

Underexcited Condition respectively

216 Phasor Diagram for No Load Motor and Generator Operation for 16

Overexcited Condition respectively

217 Turns Function Definition 18

31 The Flow Chart of the Project 25

32 Drawing Mode Toolbar 29

33 Grid Manipulation Toolbar 30

34 Toolbar for Analysis Processor 30

35 Mesh for the PMSG Model 31

36 Status of the Model 31

37 Analysis Mode Toolbar 32

ix

38 The Depiction of Model in Point Values Mode 32

39 The Depiction of Model in Contour Mode 33

310 The Depiction of Model in Block Mode 33

41 Part of the Structure of the PMSG Model 36

42 The Structure of SLCW PMSG 37

43 SLCW Configuration 38

44 Flux Line and Flux Density of SLCW PMSG 38

45 Vector Plot of SLCW PMSG 38

46 The Structure of DLCW PMSG 39

47 DLCW Configuration 40

48 Flux Line and Flux Density of DLCW PMSG 40

49 Vector Plot of DLCW PMSG 40

410 The Structure of SLDW PMSG 41

411 SLDW Configuration 42

412 Flux Line and Flux Density of SLDW PMSG 42

413 Vector Plot of SLDW PMSG 42

414 The Structure of DLDW PMSG 43

415 DLDW Configuration 44

416 Flux Line and Flux Density of DLDW PMSG 44

417 Vector Plot of DLDW PMSG 44

418 The Flux Linkage of SLCW PMSG 46

419 The Flux Linkage of DLCW PMSG 47

420 The Flux Linkage of SLDW PMSG 48

421 The Flux Linkage of DLDW PMSG 49

422 The Back-EMF of SLCW PMSG 51

423 The Back-EMF of DLCW PMSG 52

424 The Back-EMF of SLDW PMSG 53

425 The Back-EMF of DLDW PMSG 54

426 The Air-gap Flux Density of SLCW PMSG 56

427 The Air-gap Flux Density of DLCW PMSG 56

428 The Air-gap Flux Density of SLDW PMSG 57

429 The Air-gap Flux Density of DLDW PMSG 57

430 The Cogging Torque of SLCW PMSG 59

431 The Cogging Torque of DLCW PMSG 59

x

432 The Cogging Torque of SLDW PMSG 60

433 The Cogging Torque of DLDW PMSG 60

434 The Copper Loss of SLCW PMSG 62

435 The Copper Loss of DLCW PMSG 63

436 The Copper Loss of SLDW PMSG 64

437 The Copper Loss of DLDW PMSG 65

xi

LIST OF ABBREVIATIONS

PM - Permanent Magnet

PMSG - Permanent Magnet Synchronous Generator

FEMM - Finite Element Method Magnetics

PMSM - Permanent Magnet Synchronous Machine

MMF - Magnetomotive Force

FSCW - Fractional-slot Concentrated Winding

IPM - Interior Permanent Magnet

RPM - Revolutions per Minute

EMF - Electromotive Force

SLCW - Single Layer Concentrated Winding

DLCW - Double Layer Concentrated Winding

SLDW - Single Layer Distributed Winding

DLDW - Double Layer Distributed Winding

1

CHAPTER 1

INTRODUCTION

11 Overview

Electricity is one of our essential needs especially in our daily life as most of the

appliances in the home office or even factories depend on electricity to function Almost

all the electricity produced in the world is generated by the electric machine Electricity

exists in nature as a form of lightning It also can be generated from the electrical power

generator Electricity can be produced through various ways such as wind water nuclear

or even combustion of coal and oil Figure 11 below depicts that the wind energy is the

second highest of the renewable energy in the electricity generation which is 37 [1]

Figure 11 Global Electricity Production of Renewable Energy Share 2015 [1]

2

A synchronous machine is an alternating current rotating machine that its speed

is proportional to the frequency of the current in its armature under steady state condition

This means that the magnetic field of the armature currents will rotate at the same

synchronous speed as the permanent magnets (PM) or the field current on the rotor Due

to the characteristic of the synchronous speed the synchronous generator is applied to the

constant speed drive

Figure 12 Global Capacity of Wind Power in the year 2005-2015 [1]

Figure 12 shows that the wind power global capacity had increased continuously

for each year from the year 2005 until 2015 In the year 2015 the global capacity for wind

power had reached 433 Gigawatts [1] This concluded that the demand for the electricity

from wind energy had risen In wind turbine industry permanent magnet synchronous

generator (PMSG) is widely used to produce electricity Permanent magnet is used for

the synchronous generator instead of the coil for excitation field PMSG does not require

slip rings to operate There is no direct current supply that is needed for excitation circuit

Without the need of slip rings PMSG is easier to be constructed and lower maintenance

cost The permanent magnet minimizes the rotor losses and this indirectly improves the

efficiency of the generator

PMSG offers a great privilege due to its stable operation [2] However the

construction fee for PMSG is costly due to its rare earth material permanent magnet

3

Despite the high cost of the permanent magnet the PMSG is widely used in the concern

of the environmental conservation The air-gap magnetic flux density also increased with

the use of permanent magnet PMSG has a smaller volume and lower density The

permanent magnet can be positioned inside the rotor or even mounted on the rotorrsquos

surface The maximum efficiency can be achieved by minimizing the air-gap between

rotor and stator

There are various ways for coils to be wound in the stator of the generator Each

of the forms has its own drawbacks and advantages The main purpose of varying the

forms of the coil distribution is to produce three balanced sinusoidal voltages with a little

harmonic voltage and current for three phase machine In other words the output power

is maximized and the losses are minimized with different patterns of coil distribution The

number of slots at the stator can be varied which will affect the manner of the coil

connection and hence different winding patterns can be formed

12 Problem Statement

The PMSG is a part of the wind turbine system Nowadays as the demand for the

electrical energy had increased rapidly around the world the efficiency for the PMSG is

seeking more attention from the researcher With an attempt to increase the performance

of the PMSG the world non-renewable energy consumption can be reduced and the

global warming issue can be minimized or even rectified Moreover the global economy

will also be improved and this will eventually enhance the quality living of life

Furthermore a better performance of PMSG can surely aid in the prevention of climate

change All these advantages come with the energy efficiency Hence various design on

the PMSG had been researched to increase the power output and reduce the losses of the

generator

There is no doubt that the PMSG is well known for its high efficiency and long

lasting performance which can be used in wind turbine However there are various ways

to enhance the performance of the PMSG One of the factors that determine the efficiency

of the PMSG is the winding method In this thesis the winding patterns that are compared

are single layer concentrated winding (SLCW) double layer concentrated winding

(DLCW) single layer distributed winding (SLDW) and double layer distributed winding

(DLDW) In order to improve the efficiency of the PMSG the most suitable winding

pattern has to be chosen

4

13 Objectives

The objectives of this project are

To study and investigate the winding methods for PMSG

To determine the efficiency of PMSG for each type of the windings

To compare the winding methods for the PMSG

To perform analytical analysis and simulation by using Finite Element

Method Magnetics (FEMM) to maximize the efficiency of the PMSG

14 Expected Outcomes

In this project the expected outcomes are listed below

The winding methods of the stator for the PMSG are studied and compared

The simulation of the PMSG is done by using FEMM software

The efficiency of each of the winding methods is analyzed and compared

The winding method that yields the highest performance of the PMSG is

determined

15 Project Outlines

This project contains five chapters These chapters comprised of Introduction

Literature Review Methodology Result and Discussion and Conclusion and

Recommendation These chapters are arranged from Chapter 1 to Chapter 5 respectively

Chapter 1 provides a brief introduction to the electricity generation together with

a short review on the PMSG the problem statement and objectives of this project The

expected outcomes at the end of the project are also included in this chapter

Chapter 2 reviews and compiles all the studies and research that are related to the

project The topologies for the PMSG different winding methods of the stator parameter

that determine the efficiency of the PMSG and analysis approach are discussed in this

chapter

Chapter 3 discusses the methodology that is needed to carry out the project In this

chapter the PMSG model that is used in this project is presented and explained The

5

terminology and the analytical approach by using the FEMM software are depicted in this

section

Chapter 4 computes the performance of the PMSG either through mathematical

calculation or via the 2 dimension simulation of the FEMM The parameters that affect

the efficiency of PMSG is evaluated All the graphical results and the magnetic field maps

are delineated in this chapter

Chapter 5 concludes all the results of the project and summarize the outcomes

The recommendations after carrying out this project are discussed in this chapter Any

limitation of this project is included too

6

CHAPTER 2

LITERATURE REVIEW

21 Permanent Magnet Alternating Current Machine

The Permanent Magnet Synchronous Machine (PMSM) can be divided into two

categories which are axial field and radial field For axial field topology the flux is

moving parallel to the rotor shaft whereas the flux is moving along the machinersquos radius

for the radial field topology [3] The permanent magnet can be placed at a various position

on the rotor The pro and cons of the axial field and radial field topologies are discussed

below [4]

Axial fieldrsquos strengths

A balanced rotor-stator attractive forces with two air-gaps

The grinding to an arc shape is skipped as the permanent magnets have two planar

surfaces

There is an adjustable air-gap

Magnet retainment is not needed

Axial fieldrsquos weakness

There is a poor winding utilization

Restricted size of the end turns at the internal radius

Cogging torque existed

Radial fieldrsquos strengths

There is no radial force on the rotor

Easier removal of heat from the stator winding due to the big surface area of the

stator back iron

7

Skewing is not needed

Radial fieldrsquos weakness

The magnets surface must be arced

Fixed air-gap

An air-gap is formed between rotor magnets with the rotor back iron

Figure 21 and Figure 22 show the axial and radial field structure of PMSM

respectively [5]

Figure 21 Axial Flux PMSMrsquos Structure [5]

Figure 22 Radial Flux PMSMrsquos Structure [5]

8

Figure 23 24 25 and 26 show the radial field of the PMSM with different

positions of permanent magnets [3]

Figure 23 Surface PMSM [3] Figure 24 Surface Inset PMSM [3]

Figure 25 Interior PMSM [3] Figure 26 Interior PMSM with

Circumferential Orientation [3]

The permanent magnets of the surface PMSM are directly mounted on the rotorrsquos

surface as shown in Figure 23 Figure 24 shows that the permanent magnets of the

surface inset PMSM are fixed at the rotor inner surface The Figure 25 depicts that the

permanent magnets of the PMSM are implanted inside the rotor meanwhile the permanent

magnets are aligned in a circular orientation inside the rotor of the PMSM as shown in

Figure 26

Page 12: COMPARISON ON WINDING METHOD FOR ELECTRICAL …

vii

LIST OF TABLES

Table Page

41 Design Parameter of the PMSG 35

42 Materials of the Generator 35

43 The Current and Flux Linkage of SLCW PMSG 45

44 The Current and Flux Linkage of DLCW PMSG 46

45 The Current and Flux Linkage of SLDW PMSG 47

46 The Current and Flux Linkage of DLDW PMSG 48

47 The Back-EMF of SLCW PMSG 50

48 The Back-EMF of DLCW PMSG 51

49 The Back-EMF of SLDW PMSG 52

410 The Back-EMF of DLDW PMSG 53

411 The Air-gap Flux Density of PMSG for each Winding Patterns 55

412 The Cogging Torque of PMSG for each Winding Patterns 58

413 The Copper Loss of SLCW PMSG 61

414 The Copper Loss of DLCW PMSG 62

415 The Copper Loss of SLDW PMSG 63

416 The Copper Loss of DLDW PMSG 64

viii

LIST OF FIGURES

Figure Page

11 Global Electricity Production of Renewable Energy Share 2015 1

12 Global Capacity of Wind Power in the year 2005-2015 2

21 Axial Flux PMSMrsquos Structure 7

22 Radial Flux PMSMrsquos Structure 7

23 Surface PMSM 8

24 Surface Inset PMSM 8

25 Interior PMSM 8

26 Interior PMSM with Circumferential Orientation 8

27 Schematic Layout for Single Layer Winding 10

28 Winding Diagram with a Single Conductor per Slot 10

29 Winding Diagram with Multiple Conductors per Slot 11

210 Schematic Layout for Double Layer Winding 11

211 Winding Diagram for Double Layer Winding 12

212 Distributed Winding 13

213 FSCW-IPM with Double Layer Winding 13

214 FSCW-IPM with Single Layer Winding 14

215 Phasor Diagram for No Load Motor and Generator Operation for 16

Underexcited Condition respectively

216 Phasor Diagram for No Load Motor and Generator Operation for 16

Overexcited Condition respectively

217 Turns Function Definition 18

31 The Flow Chart of the Project 25

32 Drawing Mode Toolbar 29

33 Grid Manipulation Toolbar 30

34 Toolbar for Analysis Processor 30

35 Mesh for the PMSG Model 31

36 Status of the Model 31

37 Analysis Mode Toolbar 32

ix

38 The Depiction of Model in Point Values Mode 32

39 The Depiction of Model in Contour Mode 33

310 The Depiction of Model in Block Mode 33

41 Part of the Structure of the PMSG Model 36

42 The Structure of SLCW PMSG 37

43 SLCW Configuration 38

44 Flux Line and Flux Density of SLCW PMSG 38

45 Vector Plot of SLCW PMSG 38

46 The Structure of DLCW PMSG 39

47 DLCW Configuration 40

48 Flux Line and Flux Density of DLCW PMSG 40

49 Vector Plot of DLCW PMSG 40

410 The Structure of SLDW PMSG 41

411 SLDW Configuration 42

412 Flux Line and Flux Density of SLDW PMSG 42

413 Vector Plot of SLDW PMSG 42

414 The Structure of DLDW PMSG 43

415 DLDW Configuration 44

416 Flux Line and Flux Density of DLDW PMSG 44

417 Vector Plot of DLDW PMSG 44

418 The Flux Linkage of SLCW PMSG 46

419 The Flux Linkage of DLCW PMSG 47

420 The Flux Linkage of SLDW PMSG 48

421 The Flux Linkage of DLDW PMSG 49

422 The Back-EMF of SLCW PMSG 51

423 The Back-EMF of DLCW PMSG 52

424 The Back-EMF of SLDW PMSG 53

425 The Back-EMF of DLDW PMSG 54

426 The Air-gap Flux Density of SLCW PMSG 56

427 The Air-gap Flux Density of DLCW PMSG 56

428 The Air-gap Flux Density of SLDW PMSG 57

429 The Air-gap Flux Density of DLDW PMSG 57

430 The Cogging Torque of SLCW PMSG 59

431 The Cogging Torque of DLCW PMSG 59

x

432 The Cogging Torque of SLDW PMSG 60

433 The Cogging Torque of DLDW PMSG 60

434 The Copper Loss of SLCW PMSG 62

435 The Copper Loss of DLCW PMSG 63

436 The Copper Loss of SLDW PMSG 64

437 The Copper Loss of DLDW PMSG 65

xi

LIST OF ABBREVIATIONS

PM - Permanent Magnet

PMSG - Permanent Magnet Synchronous Generator

FEMM - Finite Element Method Magnetics

PMSM - Permanent Magnet Synchronous Machine

MMF - Magnetomotive Force

FSCW - Fractional-slot Concentrated Winding

IPM - Interior Permanent Magnet

RPM - Revolutions per Minute

EMF - Electromotive Force

SLCW - Single Layer Concentrated Winding

DLCW - Double Layer Concentrated Winding

SLDW - Single Layer Distributed Winding

DLDW - Double Layer Distributed Winding

1

CHAPTER 1

INTRODUCTION

11 Overview

Electricity is one of our essential needs especially in our daily life as most of the

appliances in the home office or even factories depend on electricity to function Almost

all the electricity produced in the world is generated by the electric machine Electricity

exists in nature as a form of lightning It also can be generated from the electrical power

generator Electricity can be produced through various ways such as wind water nuclear

or even combustion of coal and oil Figure 11 below depicts that the wind energy is the

second highest of the renewable energy in the electricity generation which is 37 [1]

Figure 11 Global Electricity Production of Renewable Energy Share 2015 [1]

2

A synchronous machine is an alternating current rotating machine that its speed

is proportional to the frequency of the current in its armature under steady state condition

This means that the magnetic field of the armature currents will rotate at the same

synchronous speed as the permanent magnets (PM) or the field current on the rotor Due

to the characteristic of the synchronous speed the synchronous generator is applied to the

constant speed drive

Figure 12 Global Capacity of Wind Power in the year 2005-2015 [1]

Figure 12 shows that the wind power global capacity had increased continuously

for each year from the year 2005 until 2015 In the year 2015 the global capacity for wind

power had reached 433 Gigawatts [1] This concluded that the demand for the electricity

from wind energy had risen In wind turbine industry permanent magnet synchronous

generator (PMSG) is widely used to produce electricity Permanent magnet is used for

the synchronous generator instead of the coil for excitation field PMSG does not require

slip rings to operate There is no direct current supply that is needed for excitation circuit

Without the need of slip rings PMSG is easier to be constructed and lower maintenance

cost The permanent magnet minimizes the rotor losses and this indirectly improves the

efficiency of the generator

PMSG offers a great privilege due to its stable operation [2] However the

construction fee for PMSG is costly due to its rare earth material permanent magnet

3

Despite the high cost of the permanent magnet the PMSG is widely used in the concern

of the environmental conservation The air-gap magnetic flux density also increased with

the use of permanent magnet PMSG has a smaller volume and lower density The

permanent magnet can be positioned inside the rotor or even mounted on the rotorrsquos

surface The maximum efficiency can be achieved by minimizing the air-gap between

rotor and stator

There are various ways for coils to be wound in the stator of the generator Each

of the forms has its own drawbacks and advantages The main purpose of varying the

forms of the coil distribution is to produce three balanced sinusoidal voltages with a little

harmonic voltage and current for three phase machine In other words the output power

is maximized and the losses are minimized with different patterns of coil distribution The

number of slots at the stator can be varied which will affect the manner of the coil

connection and hence different winding patterns can be formed

12 Problem Statement

The PMSG is a part of the wind turbine system Nowadays as the demand for the

electrical energy had increased rapidly around the world the efficiency for the PMSG is

seeking more attention from the researcher With an attempt to increase the performance

of the PMSG the world non-renewable energy consumption can be reduced and the

global warming issue can be minimized or even rectified Moreover the global economy

will also be improved and this will eventually enhance the quality living of life

Furthermore a better performance of PMSG can surely aid in the prevention of climate

change All these advantages come with the energy efficiency Hence various design on

the PMSG had been researched to increase the power output and reduce the losses of the

generator

There is no doubt that the PMSG is well known for its high efficiency and long

lasting performance which can be used in wind turbine However there are various ways

to enhance the performance of the PMSG One of the factors that determine the efficiency

of the PMSG is the winding method In this thesis the winding patterns that are compared

are single layer concentrated winding (SLCW) double layer concentrated winding

(DLCW) single layer distributed winding (SLDW) and double layer distributed winding

(DLDW) In order to improve the efficiency of the PMSG the most suitable winding

pattern has to be chosen

4

13 Objectives

The objectives of this project are

To study and investigate the winding methods for PMSG

To determine the efficiency of PMSG for each type of the windings

To compare the winding methods for the PMSG

To perform analytical analysis and simulation by using Finite Element

Method Magnetics (FEMM) to maximize the efficiency of the PMSG

14 Expected Outcomes

In this project the expected outcomes are listed below

The winding methods of the stator for the PMSG are studied and compared

The simulation of the PMSG is done by using FEMM software

The efficiency of each of the winding methods is analyzed and compared

The winding method that yields the highest performance of the PMSG is

determined

15 Project Outlines

This project contains five chapters These chapters comprised of Introduction

Literature Review Methodology Result and Discussion and Conclusion and

Recommendation These chapters are arranged from Chapter 1 to Chapter 5 respectively

Chapter 1 provides a brief introduction to the electricity generation together with

a short review on the PMSG the problem statement and objectives of this project The

expected outcomes at the end of the project are also included in this chapter

Chapter 2 reviews and compiles all the studies and research that are related to the

project The topologies for the PMSG different winding methods of the stator parameter

that determine the efficiency of the PMSG and analysis approach are discussed in this

chapter

Chapter 3 discusses the methodology that is needed to carry out the project In this

chapter the PMSG model that is used in this project is presented and explained The

5

terminology and the analytical approach by using the FEMM software are depicted in this

section

Chapter 4 computes the performance of the PMSG either through mathematical

calculation or via the 2 dimension simulation of the FEMM The parameters that affect

the efficiency of PMSG is evaluated All the graphical results and the magnetic field maps

are delineated in this chapter

Chapter 5 concludes all the results of the project and summarize the outcomes

The recommendations after carrying out this project are discussed in this chapter Any

limitation of this project is included too

6

CHAPTER 2

LITERATURE REVIEW

21 Permanent Magnet Alternating Current Machine

The Permanent Magnet Synchronous Machine (PMSM) can be divided into two

categories which are axial field and radial field For axial field topology the flux is

moving parallel to the rotor shaft whereas the flux is moving along the machinersquos radius

for the radial field topology [3] The permanent magnet can be placed at a various position

on the rotor The pro and cons of the axial field and radial field topologies are discussed

below [4]

Axial fieldrsquos strengths

A balanced rotor-stator attractive forces with two air-gaps

The grinding to an arc shape is skipped as the permanent magnets have two planar

surfaces

There is an adjustable air-gap

Magnet retainment is not needed

Axial fieldrsquos weakness

There is a poor winding utilization

Restricted size of the end turns at the internal radius

Cogging torque existed

Radial fieldrsquos strengths

There is no radial force on the rotor

Easier removal of heat from the stator winding due to the big surface area of the

stator back iron

7

Skewing is not needed

Radial fieldrsquos weakness

The magnets surface must be arced

Fixed air-gap

An air-gap is formed between rotor magnets with the rotor back iron

Figure 21 and Figure 22 show the axial and radial field structure of PMSM

respectively [5]

Figure 21 Axial Flux PMSMrsquos Structure [5]

Figure 22 Radial Flux PMSMrsquos Structure [5]

8

Figure 23 24 25 and 26 show the radial field of the PMSM with different

positions of permanent magnets [3]

Figure 23 Surface PMSM [3] Figure 24 Surface Inset PMSM [3]

Figure 25 Interior PMSM [3] Figure 26 Interior PMSM with

Circumferential Orientation [3]

The permanent magnets of the surface PMSM are directly mounted on the rotorrsquos

surface as shown in Figure 23 Figure 24 shows that the permanent magnets of the

surface inset PMSM are fixed at the rotor inner surface The Figure 25 depicts that the

permanent magnets of the PMSM are implanted inside the rotor meanwhile the permanent

magnets are aligned in a circular orientation inside the rotor of the PMSM as shown in

Figure 26

Page 13: COMPARISON ON WINDING METHOD FOR ELECTRICAL …

viii

LIST OF FIGURES

Figure Page

11 Global Electricity Production of Renewable Energy Share 2015 1

12 Global Capacity of Wind Power in the year 2005-2015 2

21 Axial Flux PMSMrsquos Structure 7

22 Radial Flux PMSMrsquos Structure 7

23 Surface PMSM 8

24 Surface Inset PMSM 8

25 Interior PMSM 8

26 Interior PMSM with Circumferential Orientation 8

27 Schematic Layout for Single Layer Winding 10

28 Winding Diagram with a Single Conductor per Slot 10

29 Winding Diagram with Multiple Conductors per Slot 11

210 Schematic Layout for Double Layer Winding 11

211 Winding Diagram for Double Layer Winding 12

212 Distributed Winding 13

213 FSCW-IPM with Double Layer Winding 13

214 FSCW-IPM with Single Layer Winding 14

215 Phasor Diagram for No Load Motor and Generator Operation for 16

Underexcited Condition respectively

216 Phasor Diagram for No Load Motor and Generator Operation for 16

Overexcited Condition respectively

217 Turns Function Definition 18

31 The Flow Chart of the Project 25

32 Drawing Mode Toolbar 29

33 Grid Manipulation Toolbar 30

34 Toolbar for Analysis Processor 30

35 Mesh for the PMSG Model 31

36 Status of the Model 31

37 Analysis Mode Toolbar 32

ix

38 The Depiction of Model in Point Values Mode 32

39 The Depiction of Model in Contour Mode 33

310 The Depiction of Model in Block Mode 33

41 Part of the Structure of the PMSG Model 36

42 The Structure of SLCW PMSG 37

43 SLCW Configuration 38

44 Flux Line and Flux Density of SLCW PMSG 38

45 Vector Plot of SLCW PMSG 38

46 The Structure of DLCW PMSG 39

47 DLCW Configuration 40

48 Flux Line and Flux Density of DLCW PMSG 40

49 Vector Plot of DLCW PMSG 40

410 The Structure of SLDW PMSG 41

411 SLDW Configuration 42

412 Flux Line and Flux Density of SLDW PMSG 42

413 Vector Plot of SLDW PMSG 42

414 The Structure of DLDW PMSG 43

415 DLDW Configuration 44

416 Flux Line and Flux Density of DLDW PMSG 44

417 Vector Plot of DLDW PMSG 44

418 The Flux Linkage of SLCW PMSG 46

419 The Flux Linkage of DLCW PMSG 47

420 The Flux Linkage of SLDW PMSG 48

421 The Flux Linkage of DLDW PMSG 49

422 The Back-EMF of SLCW PMSG 51

423 The Back-EMF of DLCW PMSG 52

424 The Back-EMF of SLDW PMSG 53

425 The Back-EMF of DLDW PMSG 54

426 The Air-gap Flux Density of SLCW PMSG 56

427 The Air-gap Flux Density of DLCW PMSG 56

428 The Air-gap Flux Density of SLDW PMSG 57

429 The Air-gap Flux Density of DLDW PMSG 57

430 The Cogging Torque of SLCW PMSG 59

431 The Cogging Torque of DLCW PMSG 59

x

432 The Cogging Torque of SLDW PMSG 60

433 The Cogging Torque of DLDW PMSG 60

434 The Copper Loss of SLCW PMSG 62

435 The Copper Loss of DLCW PMSG 63

436 The Copper Loss of SLDW PMSG 64

437 The Copper Loss of DLDW PMSG 65

xi

LIST OF ABBREVIATIONS

PM - Permanent Magnet

PMSG - Permanent Magnet Synchronous Generator

FEMM - Finite Element Method Magnetics

PMSM - Permanent Magnet Synchronous Machine

MMF - Magnetomotive Force

FSCW - Fractional-slot Concentrated Winding

IPM - Interior Permanent Magnet

RPM - Revolutions per Minute

EMF - Electromotive Force

SLCW - Single Layer Concentrated Winding

DLCW - Double Layer Concentrated Winding

SLDW - Single Layer Distributed Winding

DLDW - Double Layer Distributed Winding

1

CHAPTER 1

INTRODUCTION

11 Overview

Electricity is one of our essential needs especially in our daily life as most of the

appliances in the home office or even factories depend on electricity to function Almost

all the electricity produced in the world is generated by the electric machine Electricity

exists in nature as a form of lightning It also can be generated from the electrical power

generator Electricity can be produced through various ways such as wind water nuclear

or even combustion of coal and oil Figure 11 below depicts that the wind energy is the

second highest of the renewable energy in the electricity generation which is 37 [1]

Figure 11 Global Electricity Production of Renewable Energy Share 2015 [1]

2

A synchronous machine is an alternating current rotating machine that its speed

is proportional to the frequency of the current in its armature under steady state condition

This means that the magnetic field of the armature currents will rotate at the same

synchronous speed as the permanent magnets (PM) or the field current on the rotor Due

to the characteristic of the synchronous speed the synchronous generator is applied to the

constant speed drive

Figure 12 Global Capacity of Wind Power in the year 2005-2015 [1]

Figure 12 shows that the wind power global capacity had increased continuously

for each year from the year 2005 until 2015 In the year 2015 the global capacity for wind

power had reached 433 Gigawatts [1] This concluded that the demand for the electricity

from wind energy had risen In wind turbine industry permanent magnet synchronous

generator (PMSG) is widely used to produce electricity Permanent magnet is used for

the synchronous generator instead of the coil for excitation field PMSG does not require

slip rings to operate There is no direct current supply that is needed for excitation circuit

Without the need of slip rings PMSG is easier to be constructed and lower maintenance

cost The permanent magnet minimizes the rotor losses and this indirectly improves the

efficiency of the generator

PMSG offers a great privilege due to its stable operation [2] However the

construction fee for PMSG is costly due to its rare earth material permanent magnet

3

Despite the high cost of the permanent magnet the PMSG is widely used in the concern

of the environmental conservation The air-gap magnetic flux density also increased with

the use of permanent magnet PMSG has a smaller volume and lower density The

permanent magnet can be positioned inside the rotor or even mounted on the rotorrsquos

surface The maximum efficiency can be achieved by minimizing the air-gap between

rotor and stator

There are various ways for coils to be wound in the stator of the generator Each

of the forms has its own drawbacks and advantages The main purpose of varying the

forms of the coil distribution is to produce three balanced sinusoidal voltages with a little

harmonic voltage and current for three phase machine In other words the output power

is maximized and the losses are minimized with different patterns of coil distribution The

number of slots at the stator can be varied which will affect the manner of the coil

connection and hence different winding patterns can be formed

12 Problem Statement

The PMSG is a part of the wind turbine system Nowadays as the demand for the

electrical energy had increased rapidly around the world the efficiency for the PMSG is

seeking more attention from the researcher With an attempt to increase the performance

of the PMSG the world non-renewable energy consumption can be reduced and the

global warming issue can be minimized or even rectified Moreover the global economy

will also be improved and this will eventually enhance the quality living of life

Furthermore a better performance of PMSG can surely aid in the prevention of climate

change All these advantages come with the energy efficiency Hence various design on

the PMSG had been researched to increase the power output and reduce the losses of the

generator

There is no doubt that the PMSG is well known for its high efficiency and long

lasting performance which can be used in wind turbine However there are various ways

to enhance the performance of the PMSG One of the factors that determine the efficiency

of the PMSG is the winding method In this thesis the winding patterns that are compared

are single layer concentrated winding (SLCW) double layer concentrated winding

(DLCW) single layer distributed winding (SLDW) and double layer distributed winding

(DLDW) In order to improve the efficiency of the PMSG the most suitable winding

pattern has to be chosen

4

13 Objectives

The objectives of this project are

To study and investigate the winding methods for PMSG

To determine the efficiency of PMSG for each type of the windings

To compare the winding methods for the PMSG

To perform analytical analysis and simulation by using Finite Element

Method Magnetics (FEMM) to maximize the efficiency of the PMSG

14 Expected Outcomes

In this project the expected outcomes are listed below

The winding methods of the stator for the PMSG are studied and compared

The simulation of the PMSG is done by using FEMM software

The efficiency of each of the winding methods is analyzed and compared

The winding method that yields the highest performance of the PMSG is

determined

15 Project Outlines

This project contains five chapters These chapters comprised of Introduction

Literature Review Methodology Result and Discussion and Conclusion and

Recommendation These chapters are arranged from Chapter 1 to Chapter 5 respectively

Chapter 1 provides a brief introduction to the electricity generation together with

a short review on the PMSG the problem statement and objectives of this project The

expected outcomes at the end of the project are also included in this chapter

Chapter 2 reviews and compiles all the studies and research that are related to the

project The topologies for the PMSG different winding methods of the stator parameter

that determine the efficiency of the PMSG and analysis approach are discussed in this

chapter

Chapter 3 discusses the methodology that is needed to carry out the project In this

chapter the PMSG model that is used in this project is presented and explained The

5

terminology and the analytical approach by using the FEMM software are depicted in this

section

Chapter 4 computes the performance of the PMSG either through mathematical

calculation or via the 2 dimension simulation of the FEMM The parameters that affect

the efficiency of PMSG is evaluated All the graphical results and the magnetic field maps

are delineated in this chapter

Chapter 5 concludes all the results of the project and summarize the outcomes

The recommendations after carrying out this project are discussed in this chapter Any

limitation of this project is included too

6

CHAPTER 2

LITERATURE REVIEW

21 Permanent Magnet Alternating Current Machine

The Permanent Magnet Synchronous Machine (PMSM) can be divided into two

categories which are axial field and radial field For axial field topology the flux is

moving parallel to the rotor shaft whereas the flux is moving along the machinersquos radius

for the radial field topology [3] The permanent magnet can be placed at a various position

on the rotor The pro and cons of the axial field and radial field topologies are discussed

below [4]

Axial fieldrsquos strengths

A balanced rotor-stator attractive forces with two air-gaps

The grinding to an arc shape is skipped as the permanent magnets have two planar

surfaces

There is an adjustable air-gap

Magnet retainment is not needed

Axial fieldrsquos weakness

There is a poor winding utilization

Restricted size of the end turns at the internal radius

Cogging torque existed

Radial fieldrsquos strengths

There is no radial force on the rotor

Easier removal of heat from the stator winding due to the big surface area of the

stator back iron

7

Skewing is not needed

Radial fieldrsquos weakness

The magnets surface must be arced

Fixed air-gap

An air-gap is formed between rotor magnets with the rotor back iron

Figure 21 and Figure 22 show the axial and radial field structure of PMSM

respectively [5]

Figure 21 Axial Flux PMSMrsquos Structure [5]

Figure 22 Radial Flux PMSMrsquos Structure [5]

8

Figure 23 24 25 and 26 show the radial field of the PMSM with different

positions of permanent magnets [3]

Figure 23 Surface PMSM [3] Figure 24 Surface Inset PMSM [3]

Figure 25 Interior PMSM [3] Figure 26 Interior PMSM with

Circumferential Orientation [3]

The permanent magnets of the surface PMSM are directly mounted on the rotorrsquos

surface as shown in Figure 23 Figure 24 shows that the permanent magnets of the

surface inset PMSM are fixed at the rotor inner surface The Figure 25 depicts that the

permanent magnets of the PMSM are implanted inside the rotor meanwhile the permanent

magnets are aligned in a circular orientation inside the rotor of the PMSM as shown in

Figure 26

Page 14: COMPARISON ON WINDING METHOD FOR ELECTRICAL …

ix

38 The Depiction of Model in Point Values Mode 32

39 The Depiction of Model in Contour Mode 33

310 The Depiction of Model in Block Mode 33

41 Part of the Structure of the PMSG Model 36

42 The Structure of SLCW PMSG 37

43 SLCW Configuration 38

44 Flux Line and Flux Density of SLCW PMSG 38

45 Vector Plot of SLCW PMSG 38

46 The Structure of DLCW PMSG 39

47 DLCW Configuration 40

48 Flux Line and Flux Density of DLCW PMSG 40

49 Vector Plot of DLCW PMSG 40

410 The Structure of SLDW PMSG 41

411 SLDW Configuration 42

412 Flux Line and Flux Density of SLDW PMSG 42

413 Vector Plot of SLDW PMSG 42

414 The Structure of DLDW PMSG 43

415 DLDW Configuration 44

416 Flux Line and Flux Density of DLDW PMSG 44

417 Vector Plot of DLDW PMSG 44

418 The Flux Linkage of SLCW PMSG 46

419 The Flux Linkage of DLCW PMSG 47

420 The Flux Linkage of SLDW PMSG 48

421 The Flux Linkage of DLDW PMSG 49

422 The Back-EMF of SLCW PMSG 51

423 The Back-EMF of DLCW PMSG 52

424 The Back-EMF of SLDW PMSG 53

425 The Back-EMF of DLDW PMSG 54

426 The Air-gap Flux Density of SLCW PMSG 56

427 The Air-gap Flux Density of DLCW PMSG 56

428 The Air-gap Flux Density of SLDW PMSG 57

429 The Air-gap Flux Density of DLDW PMSG 57

430 The Cogging Torque of SLCW PMSG 59

431 The Cogging Torque of DLCW PMSG 59

x

432 The Cogging Torque of SLDW PMSG 60

433 The Cogging Torque of DLDW PMSG 60

434 The Copper Loss of SLCW PMSG 62

435 The Copper Loss of DLCW PMSG 63

436 The Copper Loss of SLDW PMSG 64

437 The Copper Loss of DLDW PMSG 65

xi

LIST OF ABBREVIATIONS

PM - Permanent Magnet

PMSG - Permanent Magnet Synchronous Generator

FEMM - Finite Element Method Magnetics

PMSM - Permanent Magnet Synchronous Machine

MMF - Magnetomotive Force

FSCW - Fractional-slot Concentrated Winding

IPM - Interior Permanent Magnet

RPM - Revolutions per Minute

EMF - Electromotive Force

SLCW - Single Layer Concentrated Winding

DLCW - Double Layer Concentrated Winding

SLDW - Single Layer Distributed Winding

DLDW - Double Layer Distributed Winding

1

CHAPTER 1

INTRODUCTION

11 Overview

Electricity is one of our essential needs especially in our daily life as most of the

appliances in the home office or even factories depend on electricity to function Almost

all the electricity produced in the world is generated by the electric machine Electricity

exists in nature as a form of lightning It also can be generated from the electrical power

generator Electricity can be produced through various ways such as wind water nuclear

or even combustion of coal and oil Figure 11 below depicts that the wind energy is the

second highest of the renewable energy in the electricity generation which is 37 [1]

Figure 11 Global Electricity Production of Renewable Energy Share 2015 [1]

2

A synchronous machine is an alternating current rotating machine that its speed

is proportional to the frequency of the current in its armature under steady state condition

This means that the magnetic field of the armature currents will rotate at the same

synchronous speed as the permanent magnets (PM) or the field current on the rotor Due

to the characteristic of the synchronous speed the synchronous generator is applied to the

constant speed drive

Figure 12 Global Capacity of Wind Power in the year 2005-2015 [1]

Figure 12 shows that the wind power global capacity had increased continuously

for each year from the year 2005 until 2015 In the year 2015 the global capacity for wind

power had reached 433 Gigawatts [1] This concluded that the demand for the electricity

from wind energy had risen In wind turbine industry permanent magnet synchronous

generator (PMSG) is widely used to produce electricity Permanent magnet is used for

the synchronous generator instead of the coil for excitation field PMSG does not require

slip rings to operate There is no direct current supply that is needed for excitation circuit

Without the need of slip rings PMSG is easier to be constructed and lower maintenance

cost The permanent magnet minimizes the rotor losses and this indirectly improves the

efficiency of the generator

PMSG offers a great privilege due to its stable operation [2] However the

construction fee for PMSG is costly due to its rare earth material permanent magnet

3

Despite the high cost of the permanent magnet the PMSG is widely used in the concern

of the environmental conservation The air-gap magnetic flux density also increased with

the use of permanent magnet PMSG has a smaller volume and lower density The

permanent magnet can be positioned inside the rotor or even mounted on the rotorrsquos

surface The maximum efficiency can be achieved by minimizing the air-gap between

rotor and stator

There are various ways for coils to be wound in the stator of the generator Each

of the forms has its own drawbacks and advantages The main purpose of varying the

forms of the coil distribution is to produce three balanced sinusoidal voltages with a little

harmonic voltage and current for three phase machine In other words the output power

is maximized and the losses are minimized with different patterns of coil distribution The

number of slots at the stator can be varied which will affect the manner of the coil

connection and hence different winding patterns can be formed

12 Problem Statement

The PMSG is a part of the wind turbine system Nowadays as the demand for the

electrical energy had increased rapidly around the world the efficiency for the PMSG is

seeking more attention from the researcher With an attempt to increase the performance

of the PMSG the world non-renewable energy consumption can be reduced and the

global warming issue can be minimized or even rectified Moreover the global economy

will also be improved and this will eventually enhance the quality living of life

Furthermore a better performance of PMSG can surely aid in the prevention of climate

change All these advantages come with the energy efficiency Hence various design on

the PMSG had been researched to increase the power output and reduce the losses of the

generator

There is no doubt that the PMSG is well known for its high efficiency and long

lasting performance which can be used in wind turbine However there are various ways

to enhance the performance of the PMSG One of the factors that determine the efficiency

of the PMSG is the winding method In this thesis the winding patterns that are compared

are single layer concentrated winding (SLCW) double layer concentrated winding

(DLCW) single layer distributed winding (SLDW) and double layer distributed winding

(DLDW) In order to improve the efficiency of the PMSG the most suitable winding

pattern has to be chosen

4

13 Objectives

The objectives of this project are

To study and investigate the winding methods for PMSG

To determine the efficiency of PMSG for each type of the windings

To compare the winding methods for the PMSG

To perform analytical analysis and simulation by using Finite Element

Method Magnetics (FEMM) to maximize the efficiency of the PMSG

14 Expected Outcomes

In this project the expected outcomes are listed below

The winding methods of the stator for the PMSG are studied and compared

The simulation of the PMSG is done by using FEMM software

The efficiency of each of the winding methods is analyzed and compared

The winding method that yields the highest performance of the PMSG is

determined

15 Project Outlines

This project contains five chapters These chapters comprised of Introduction

Literature Review Methodology Result and Discussion and Conclusion and

Recommendation These chapters are arranged from Chapter 1 to Chapter 5 respectively

Chapter 1 provides a brief introduction to the electricity generation together with

a short review on the PMSG the problem statement and objectives of this project The

expected outcomes at the end of the project are also included in this chapter

Chapter 2 reviews and compiles all the studies and research that are related to the

project The topologies for the PMSG different winding methods of the stator parameter

that determine the efficiency of the PMSG and analysis approach are discussed in this

chapter

Chapter 3 discusses the methodology that is needed to carry out the project In this

chapter the PMSG model that is used in this project is presented and explained The

5

terminology and the analytical approach by using the FEMM software are depicted in this

section

Chapter 4 computes the performance of the PMSG either through mathematical

calculation or via the 2 dimension simulation of the FEMM The parameters that affect

the efficiency of PMSG is evaluated All the graphical results and the magnetic field maps

are delineated in this chapter

Chapter 5 concludes all the results of the project and summarize the outcomes

The recommendations after carrying out this project are discussed in this chapter Any

limitation of this project is included too

6

CHAPTER 2

LITERATURE REVIEW

21 Permanent Magnet Alternating Current Machine

The Permanent Magnet Synchronous Machine (PMSM) can be divided into two

categories which are axial field and radial field For axial field topology the flux is

moving parallel to the rotor shaft whereas the flux is moving along the machinersquos radius

for the radial field topology [3] The permanent magnet can be placed at a various position

on the rotor The pro and cons of the axial field and radial field topologies are discussed

below [4]

Axial fieldrsquos strengths

A balanced rotor-stator attractive forces with two air-gaps

The grinding to an arc shape is skipped as the permanent magnets have two planar

surfaces

There is an adjustable air-gap

Magnet retainment is not needed

Axial fieldrsquos weakness

There is a poor winding utilization

Restricted size of the end turns at the internal radius

Cogging torque existed

Radial fieldrsquos strengths

There is no radial force on the rotor

Easier removal of heat from the stator winding due to the big surface area of the

stator back iron

7

Skewing is not needed

Radial fieldrsquos weakness

The magnets surface must be arced

Fixed air-gap

An air-gap is formed between rotor magnets with the rotor back iron

Figure 21 and Figure 22 show the axial and radial field structure of PMSM

respectively [5]

Figure 21 Axial Flux PMSMrsquos Structure [5]

Figure 22 Radial Flux PMSMrsquos Structure [5]

8

Figure 23 24 25 and 26 show the radial field of the PMSM with different

positions of permanent magnets [3]

Figure 23 Surface PMSM [3] Figure 24 Surface Inset PMSM [3]

Figure 25 Interior PMSM [3] Figure 26 Interior PMSM with

Circumferential Orientation [3]

The permanent magnets of the surface PMSM are directly mounted on the rotorrsquos

surface as shown in Figure 23 Figure 24 shows that the permanent magnets of the

surface inset PMSM are fixed at the rotor inner surface The Figure 25 depicts that the

permanent magnets of the PMSM are implanted inside the rotor meanwhile the permanent

magnets are aligned in a circular orientation inside the rotor of the PMSM as shown in

Figure 26

Page 15: COMPARISON ON WINDING METHOD FOR ELECTRICAL …

x

432 The Cogging Torque of SLDW PMSG 60

433 The Cogging Torque of DLDW PMSG 60

434 The Copper Loss of SLCW PMSG 62

435 The Copper Loss of DLCW PMSG 63

436 The Copper Loss of SLDW PMSG 64

437 The Copper Loss of DLDW PMSG 65

xi

LIST OF ABBREVIATIONS

PM - Permanent Magnet

PMSG - Permanent Magnet Synchronous Generator

FEMM - Finite Element Method Magnetics

PMSM - Permanent Magnet Synchronous Machine

MMF - Magnetomotive Force

FSCW - Fractional-slot Concentrated Winding

IPM - Interior Permanent Magnet

RPM - Revolutions per Minute

EMF - Electromotive Force

SLCW - Single Layer Concentrated Winding

DLCW - Double Layer Concentrated Winding

SLDW - Single Layer Distributed Winding

DLDW - Double Layer Distributed Winding

1

CHAPTER 1

INTRODUCTION

11 Overview

Electricity is one of our essential needs especially in our daily life as most of the

appliances in the home office or even factories depend on electricity to function Almost

all the electricity produced in the world is generated by the electric machine Electricity

exists in nature as a form of lightning It also can be generated from the electrical power

generator Electricity can be produced through various ways such as wind water nuclear

or even combustion of coal and oil Figure 11 below depicts that the wind energy is the

second highest of the renewable energy in the electricity generation which is 37 [1]

Figure 11 Global Electricity Production of Renewable Energy Share 2015 [1]

2

A synchronous machine is an alternating current rotating machine that its speed

is proportional to the frequency of the current in its armature under steady state condition

This means that the magnetic field of the armature currents will rotate at the same

synchronous speed as the permanent magnets (PM) or the field current on the rotor Due

to the characteristic of the synchronous speed the synchronous generator is applied to the

constant speed drive

Figure 12 Global Capacity of Wind Power in the year 2005-2015 [1]

Figure 12 shows that the wind power global capacity had increased continuously

for each year from the year 2005 until 2015 In the year 2015 the global capacity for wind

power had reached 433 Gigawatts [1] This concluded that the demand for the electricity

from wind energy had risen In wind turbine industry permanent magnet synchronous

generator (PMSG) is widely used to produce electricity Permanent magnet is used for

the synchronous generator instead of the coil for excitation field PMSG does not require

slip rings to operate There is no direct current supply that is needed for excitation circuit

Without the need of slip rings PMSG is easier to be constructed and lower maintenance

cost The permanent magnet minimizes the rotor losses and this indirectly improves the

efficiency of the generator

PMSG offers a great privilege due to its stable operation [2] However the

construction fee for PMSG is costly due to its rare earth material permanent magnet

3

Despite the high cost of the permanent magnet the PMSG is widely used in the concern

of the environmental conservation The air-gap magnetic flux density also increased with

the use of permanent magnet PMSG has a smaller volume and lower density The

permanent magnet can be positioned inside the rotor or even mounted on the rotorrsquos

surface The maximum efficiency can be achieved by minimizing the air-gap between

rotor and stator

There are various ways for coils to be wound in the stator of the generator Each

of the forms has its own drawbacks and advantages The main purpose of varying the

forms of the coil distribution is to produce three balanced sinusoidal voltages with a little

harmonic voltage and current for three phase machine In other words the output power

is maximized and the losses are minimized with different patterns of coil distribution The

number of slots at the stator can be varied which will affect the manner of the coil

connection and hence different winding patterns can be formed

12 Problem Statement

The PMSG is a part of the wind turbine system Nowadays as the demand for the

electrical energy had increased rapidly around the world the efficiency for the PMSG is

seeking more attention from the researcher With an attempt to increase the performance

of the PMSG the world non-renewable energy consumption can be reduced and the

global warming issue can be minimized or even rectified Moreover the global economy

will also be improved and this will eventually enhance the quality living of life

Furthermore a better performance of PMSG can surely aid in the prevention of climate

change All these advantages come with the energy efficiency Hence various design on

the PMSG had been researched to increase the power output and reduce the losses of the

generator

There is no doubt that the PMSG is well known for its high efficiency and long

lasting performance which can be used in wind turbine However there are various ways

to enhance the performance of the PMSG One of the factors that determine the efficiency

of the PMSG is the winding method In this thesis the winding patterns that are compared

are single layer concentrated winding (SLCW) double layer concentrated winding

(DLCW) single layer distributed winding (SLDW) and double layer distributed winding

(DLDW) In order to improve the efficiency of the PMSG the most suitable winding

pattern has to be chosen

4

13 Objectives

The objectives of this project are

To study and investigate the winding methods for PMSG

To determine the efficiency of PMSG for each type of the windings

To compare the winding methods for the PMSG

To perform analytical analysis and simulation by using Finite Element

Method Magnetics (FEMM) to maximize the efficiency of the PMSG

14 Expected Outcomes

In this project the expected outcomes are listed below

The winding methods of the stator for the PMSG are studied and compared

The simulation of the PMSG is done by using FEMM software

The efficiency of each of the winding methods is analyzed and compared

The winding method that yields the highest performance of the PMSG is

determined

15 Project Outlines

This project contains five chapters These chapters comprised of Introduction

Literature Review Methodology Result and Discussion and Conclusion and

Recommendation These chapters are arranged from Chapter 1 to Chapter 5 respectively

Chapter 1 provides a brief introduction to the electricity generation together with

a short review on the PMSG the problem statement and objectives of this project The

expected outcomes at the end of the project are also included in this chapter

Chapter 2 reviews and compiles all the studies and research that are related to the

project The topologies for the PMSG different winding methods of the stator parameter

that determine the efficiency of the PMSG and analysis approach are discussed in this

chapter

Chapter 3 discusses the methodology that is needed to carry out the project In this

chapter the PMSG model that is used in this project is presented and explained The

5

terminology and the analytical approach by using the FEMM software are depicted in this

section

Chapter 4 computes the performance of the PMSG either through mathematical

calculation or via the 2 dimension simulation of the FEMM The parameters that affect

the efficiency of PMSG is evaluated All the graphical results and the magnetic field maps

are delineated in this chapter

Chapter 5 concludes all the results of the project and summarize the outcomes

The recommendations after carrying out this project are discussed in this chapter Any

limitation of this project is included too

6

CHAPTER 2

LITERATURE REVIEW

21 Permanent Magnet Alternating Current Machine

The Permanent Magnet Synchronous Machine (PMSM) can be divided into two

categories which are axial field and radial field For axial field topology the flux is

moving parallel to the rotor shaft whereas the flux is moving along the machinersquos radius

for the radial field topology [3] The permanent magnet can be placed at a various position

on the rotor The pro and cons of the axial field and radial field topologies are discussed

below [4]

Axial fieldrsquos strengths

A balanced rotor-stator attractive forces with two air-gaps

The grinding to an arc shape is skipped as the permanent magnets have two planar

surfaces

There is an adjustable air-gap

Magnet retainment is not needed

Axial fieldrsquos weakness

There is a poor winding utilization

Restricted size of the end turns at the internal radius

Cogging torque existed

Radial fieldrsquos strengths

There is no radial force on the rotor

Easier removal of heat from the stator winding due to the big surface area of the

stator back iron

7

Skewing is not needed

Radial fieldrsquos weakness

The magnets surface must be arced

Fixed air-gap

An air-gap is formed between rotor magnets with the rotor back iron

Figure 21 and Figure 22 show the axial and radial field structure of PMSM

respectively [5]

Figure 21 Axial Flux PMSMrsquos Structure [5]

Figure 22 Radial Flux PMSMrsquos Structure [5]

8

Figure 23 24 25 and 26 show the radial field of the PMSM with different

positions of permanent magnets [3]

Figure 23 Surface PMSM [3] Figure 24 Surface Inset PMSM [3]

Figure 25 Interior PMSM [3] Figure 26 Interior PMSM with

Circumferential Orientation [3]

The permanent magnets of the surface PMSM are directly mounted on the rotorrsquos

surface as shown in Figure 23 Figure 24 shows that the permanent magnets of the

surface inset PMSM are fixed at the rotor inner surface The Figure 25 depicts that the

permanent magnets of the PMSM are implanted inside the rotor meanwhile the permanent

magnets are aligned in a circular orientation inside the rotor of the PMSM as shown in

Figure 26

Page 16: COMPARISON ON WINDING METHOD FOR ELECTRICAL …

xi

LIST OF ABBREVIATIONS

PM - Permanent Magnet

PMSG - Permanent Magnet Synchronous Generator

FEMM - Finite Element Method Magnetics

PMSM - Permanent Magnet Synchronous Machine

MMF - Magnetomotive Force

FSCW - Fractional-slot Concentrated Winding

IPM - Interior Permanent Magnet

RPM - Revolutions per Minute

EMF - Electromotive Force

SLCW - Single Layer Concentrated Winding

DLCW - Double Layer Concentrated Winding

SLDW - Single Layer Distributed Winding

DLDW - Double Layer Distributed Winding

1

CHAPTER 1

INTRODUCTION

11 Overview

Electricity is one of our essential needs especially in our daily life as most of the

appliances in the home office or even factories depend on electricity to function Almost

all the electricity produced in the world is generated by the electric machine Electricity

exists in nature as a form of lightning It also can be generated from the electrical power

generator Electricity can be produced through various ways such as wind water nuclear

or even combustion of coal and oil Figure 11 below depicts that the wind energy is the

second highest of the renewable energy in the electricity generation which is 37 [1]

Figure 11 Global Electricity Production of Renewable Energy Share 2015 [1]

2

A synchronous machine is an alternating current rotating machine that its speed

is proportional to the frequency of the current in its armature under steady state condition

This means that the magnetic field of the armature currents will rotate at the same

synchronous speed as the permanent magnets (PM) or the field current on the rotor Due

to the characteristic of the synchronous speed the synchronous generator is applied to the

constant speed drive

Figure 12 Global Capacity of Wind Power in the year 2005-2015 [1]

Figure 12 shows that the wind power global capacity had increased continuously

for each year from the year 2005 until 2015 In the year 2015 the global capacity for wind

power had reached 433 Gigawatts [1] This concluded that the demand for the electricity

from wind energy had risen In wind turbine industry permanent magnet synchronous

generator (PMSG) is widely used to produce electricity Permanent magnet is used for

the synchronous generator instead of the coil for excitation field PMSG does not require

slip rings to operate There is no direct current supply that is needed for excitation circuit

Without the need of slip rings PMSG is easier to be constructed and lower maintenance

cost The permanent magnet minimizes the rotor losses and this indirectly improves the

efficiency of the generator

PMSG offers a great privilege due to its stable operation [2] However the

construction fee for PMSG is costly due to its rare earth material permanent magnet

3

Despite the high cost of the permanent magnet the PMSG is widely used in the concern

of the environmental conservation The air-gap magnetic flux density also increased with

the use of permanent magnet PMSG has a smaller volume and lower density The

permanent magnet can be positioned inside the rotor or even mounted on the rotorrsquos

surface The maximum efficiency can be achieved by minimizing the air-gap between

rotor and stator

There are various ways for coils to be wound in the stator of the generator Each

of the forms has its own drawbacks and advantages The main purpose of varying the

forms of the coil distribution is to produce three balanced sinusoidal voltages with a little

harmonic voltage and current for three phase machine In other words the output power

is maximized and the losses are minimized with different patterns of coil distribution The

number of slots at the stator can be varied which will affect the manner of the coil

connection and hence different winding patterns can be formed

12 Problem Statement

The PMSG is a part of the wind turbine system Nowadays as the demand for the

electrical energy had increased rapidly around the world the efficiency for the PMSG is

seeking more attention from the researcher With an attempt to increase the performance

of the PMSG the world non-renewable energy consumption can be reduced and the

global warming issue can be minimized or even rectified Moreover the global economy

will also be improved and this will eventually enhance the quality living of life

Furthermore a better performance of PMSG can surely aid in the prevention of climate

change All these advantages come with the energy efficiency Hence various design on

the PMSG had been researched to increase the power output and reduce the losses of the

generator

There is no doubt that the PMSG is well known for its high efficiency and long

lasting performance which can be used in wind turbine However there are various ways

to enhance the performance of the PMSG One of the factors that determine the efficiency

of the PMSG is the winding method In this thesis the winding patterns that are compared

are single layer concentrated winding (SLCW) double layer concentrated winding

(DLCW) single layer distributed winding (SLDW) and double layer distributed winding

(DLDW) In order to improve the efficiency of the PMSG the most suitable winding

pattern has to be chosen

4

13 Objectives

The objectives of this project are

To study and investigate the winding methods for PMSG

To determine the efficiency of PMSG for each type of the windings

To compare the winding methods for the PMSG

To perform analytical analysis and simulation by using Finite Element

Method Magnetics (FEMM) to maximize the efficiency of the PMSG

14 Expected Outcomes

In this project the expected outcomes are listed below

The winding methods of the stator for the PMSG are studied and compared

The simulation of the PMSG is done by using FEMM software

The efficiency of each of the winding methods is analyzed and compared

The winding method that yields the highest performance of the PMSG is

determined

15 Project Outlines

This project contains five chapters These chapters comprised of Introduction

Literature Review Methodology Result and Discussion and Conclusion and

Recommendation These chapters are arranged from Chapter 1 to Chapter 5 respectively

Chapter 1 provides a brief introduction to the electricity generation together with

a short review on the PMSG the problem statement and objectives of this project The

expected outcomes at the end of the project are also included in this chapter

Chapter 2 reviews and compiles all the studies and research that are related to the

project The topologies for the PMSG different winding methods of the stator parameter

that determine the efficiency of the PMSG and analysis approach are discussed in this

chapter

Chapter 3 discusses the methodology that is needed to carry out the project In this

chapter the PMSG model that is used in this project is presented and explained The

5

terminology and the analytical approach by using the FEMM software are depicted in this

section

Chapter 4 computes the performance of the PMSG either through mathematical

calculation or via the 2 dimension simulation of the FEMM The parameters that affect

the efficiency of PMSG is evaluated All the graphical results and the magnetic field maps

are delineated in this chapter

Chapter 5 concludes all the results of the project and summarize the outcomes

The recommendations after carrying out this project are discussed in this chapter Any

limitation of this project is included too

6

CHAPTER 2

LITERATURE REVIEW

21 Permanent Magnet Alternating Current Machine

The Permanent Magnet Synchronous Machine (PMSM) can be divided into two

categories which are axial field and radial field For axial field topology the flux is

moving parallel to the rotor shaft whereas the flux is moving along the machinersquos radius

for the radial field topology [3] The permanent magnet can be placed at a various position

on the rotor The pro and cons of the axial field and radial field topologies are discussed

below [4]

Axial fieldrsquos strengths

A balanced rotor-stator attractive forces with two air-gaps

The grinding to an arc shape is skipped as the permanent magnets have two planar

surfaces

There is an adjustable air-gap

Magnet retainment is not needed

Axial fieldrsquos weakness

There is a poor winding utilization

Restricted size of the end turns at the internal radius

Cogging torque existed

Radial fieldrsquos strengths

There is no radial force on the rotor

Easier removal of heat from the stator winding due to the big surface area of the

stator back iron

7

Skewing is not needed

Radial fieldrsquos weakness

The magnets surface must be arced

Fixed air-gap

An air-gap is formed between rotor magnets with the rotor back iron

Figure 21 and Figure 22 show the axial and radial field structure of PMSM

respectively [5]

Figure 21 Axial Flux PMSMrsquos Structure [5]

Figure 22 Radial Flux PMSMrsquos Structure [5]

8

Figure 23 24 25 and 26 show the radial field of the PMSM with different

positions of permanent magnets [3]

Figure 23 Surface PMSM [3] Figure 24 Surface Inset PMSM [3]

Figure 25 Interior PMSM [3] Figure 26 Interior PMSM with

Circumferential Orientation [3]

The permanent magnets of the surface PMSM are directly mounted on the rotorrsquos

surface as shown in Figure 23 Figure 24 shows that the permanent magnets of the

surface inset PMSM are fixed at the rotor inner surface The Figure 25 depicts that the

permanent magnets of the PMSM are implanted inside the rotor meanwhile the permanent

magnets are aligned in a circular orientation inside the rotor of the PMSM as shown in

Figure 26

Page 17: COMPARISON ON WINDING METHOD FOR ELECTRICAL …

1

CHAPTER 1

INTRODUCTION

11 Overview

Electricity is one of our essential needs especially in our daily life as most of the

appliances in the home office or even factories depend on electricity to function Almost

all the electricity produced in the world is generated by the electric machine Electricity

exists in nature as a form of lightning It also can be generated from the electrical power

generator Electricity can be produced through various ways such as wind water nuclear

or even combustion of coal and oil Figure 11 below depicts that the wind energy is the

second highest of the renewable energy in the electricity generation which is 37 [1]

Figure 11 Global Electricity Production of Renewable Energy Share 2015 [1]

2

A synchronous machine is an alternating current rotating machine that its speed

is proportional to the frequency of the current in its armature under steady state condition

This means that the magnetic field of the armature currents will rotate at the same

synchronous speed as the permanent magnets (PM) or the field current on the rotor Due

to the characteristic of the synchronous speed the synchronous generator is applied to the

constant speed drive

Figure 12 Global Capacity of Wind Power in the year 2005-2015 [1]

Figure 12 shows that the wind power global capacity had increased continuously

for each year from the year 2005 until 2015 In the year 2015 the global capacity for wind

power had reached 433 Gigawatts [1] This concluded that the demand for the electricity

from wind energy had risen In wind turbine industry permanent magnet synchronous

generator (PMSG) is widely used to produce electricity Permanent magnet is used for

the synchronous generator instead of the coil for excitation field PMSG does not require

slip rings to operate There is no direct current supply that is needed for excitation circuit

Without the need of slip rings PMSG is easier to be constructed and lower maintenance

cost The permanent magnet minimizes the rotor losses and this indirectly improves the

efficiency of the generator

PMSG offers a great privilege due to its stable operation [2] However the

construction fee for PMSG is costly due to its rare earth material permanent magnet

3

Despite the high cost of the permanent magnet the PMSG is widely used in the concern

of the environmental conservation The air-gap magnetic flux density also increased with

the use of permanent magnet PMSG has a smaller volume and lower density The

permanent magnet can be positioned inside the rotor or even mounted on the rotorrsquos

surface The maximum efficiency can be achieved by minimizing the air-gap between

rotor and stator

There are various ways for coils to be wound in the stator of the generator Each

of the forms has its own drawbacks and advantages The main purpose of varying the

forms of the coil distribution is to produce three balanced sinusoidal voltages with a little

harmonic voltage and current for three phase machine In other words the output power

is maximized and the losses are minimized with different patterns of coil distribution The

number of slots at the stator can be varied which will affect the manner of the coil

connection and hence different winding patterns can be formed

12 Problem Statement

The PMSG is a part of the wind turbine system Nowadays as the demand for the

electrical energy had increased rapidly around the world the efficiency for the PMSG is

seeking more attention from the researcher With an attempt to increase the performance

of the PMSG the world non-renewable energy consumption can be reduced and the

global warming issue can be minimized or even rectified Moreover the global economy

will also be improved and this will eventually enhance the quality living of life

Furthermore a better performance of PMSG can surely aid in the prevention of climate

change All these advantages come with the energy efficiency Hence various design on

the PMSG had been researched to increase the power output and reduce the losses of the

generator

There is no doubt that the PMSG is well known for its high efficiency and long

lasting performance which can be used in wind turbine However there are various ways

to enhance the performance of the PMSG One of the factors that determine the efficiency

of the PMSG is the winding method In this thesis the winding patterns that are compared

are single layer concentrated winding (SLCW) double layer concentrated winding

(DLCW) single layer distributed winding (SLDW) and double layer distributed winding

(DLDW) In order to improve the efficiency of the PMSG the most suitable winding

pattern has to be chosen

4

13 Objectives

The objectives of this project are

To study and investigate the winding methods for PMSG

To determine the efficiency of PMSG for each type of the windings

To compare the winding methods for the PMSG

To perform analytical analysis and simulation by using Finite Element

Method Magnetics (FEMM) to maximize the efficiency of the PMSG

14 Expected Outcomes

In this project the expected outcomes are listed below

The winding methods of the stator for the PMSG are studied and compared

The simulation of the PMSG is done by using FEMM software

The efficiency of each of the winding methods is analyzed and compared

The winding method that yields the highest performance of the PMSG is

determined

15 Project Outlines

This project contains five chapters These chapters comprised of Introduction

Literature Review Methodology Result and Discussion and Conclusion and

Recommendation These chapters are arranged from Chapter 1 to Chapter 5 respectively

Chapter 1 provides a brief introduction to the electricity generation together with

a short review on the PMSG the problem statement and objectives of this project The

expected outcomes at the end of the project are also included in this chapter

Chapter 2 reviews and compiles all the studies and research that are related to the

project The topologies for the PMSG different winding methods of the stator parameter

that determine the efficiency of the PMSG and analysis approach are discussed in this

chapter

Chapter 3 discusses the methodology that is needed to carry out the project In this

chapter the PMSG model that is used in this project is presented and explained The

5

terminology and the analytical approach by using the FEMM software are depicted in this

section

Chapter 4 computes the performance of the PMSG either through mathematical

calculation or via the 2 dimension simulation of the FEMM The parameters that affect

the efficiency of PMSG is evaluated All the graphical results and the magnetic field maps

are delineated in this chapter

Chapter 5 concludes all the results of the project and summarize the outcomes

The recommendations after carrying out this project are discussed in this chapter Any

limitation of this project is included too

6

CHAPTER 2

LITERATURE REVIEW

21 Permanent Magnet Alternating Current Machine

The Permanent Magnet Synchronous Machine (PMSM) can be divided into two

categories which are axial field and radial field For axial field topology the flux is

moving parallel to the rotor shaft whereas the flux is moving along the machinersquos radius

for the radial field topology [3] The permanent magnet can be placed at a various position

on the rotor The pro and cons of the axial field and radial field topologies are discussed

below [4]

Axial fieldrsquos strengths

A balanced rotor-stator attractive forces with two air-gaps

The grinding to an arc shape is skipped as the permanent magnets have two planar

surfaces

There is an adjustable air-gap

Magnet retainment is not needed

Axial fieldrsquos weakness

There is a poor winding utilization

Restricted size of the end turns at the internal radius

Cogging torque existed

Radial fieldrsquos strengths

There is no radial force on the rotor

Easier removal of heat from the stator winding due to the big surface area of the

stator back iron

7

Skewing is not needed

Radial fieldrsquos weakness

The magnets surface must be arced

Fixed air-gap

An air-gap is formed between rotor magnets with the rotor back iron

Figure 21 and Figure 22 show the axial and radial field structure of PMSM

respectively [5]

Figure 21 Axial Flux PMSMrsquos Structure [5]

Figure 22 Radial Flux PMSMrsquos Structure [5]

8

Figure 23 24 25 and 26 show the radial field of the PMSM with different

positions of permanent magnets [3]

Figure 23 Surface PMSM [3] Figure 24 Surface Inset PMSM [3]

Figure 25 Interior PMSM [3] Figure 26 Interior PMSM with

Circumferential Orientation [3]

The permanent magnets of the surface PMSM are directly mounted on the rotorrsquos

surface as shown in Figure 23 Figure 24 shows that the permanent magnets of the

surface inset PMSM are fixed at the rotor inner surface The Figure 25 depicts that the

permanent magnets of the PMSM are implanted inside the rotor meanwhile the permanent

magnets are aligned in a circular orientation inside the rotor of the PMSM as shown in

Figure 26

Page 18: COMPARISON ON WINDING METHOD FOR ELECTRICAL …

2

A synchronous machine is an alternating current rotating machine that its speed

is proportional to the frequency of the current in its armature under steady state condition

This means that the magnetic field of the armature currents will rotate at the same

synchronous speed as the permanent magnets (PM) or the field current on the rotor Due

to the characteristic of the synchronous speed the synchronous generator is applied to the

constant speed drive

Figure 12 Global Capacity of Wind Power in the year 2005-2015 [1]

Figure 12 shows that the wind power global capacity had increased continuously

for each year from the year 2005 until 2015 In the year 2015 the global capacity for wind

power had reached 433 Gigawatts [1] This concluded that the demand for the electricity

from wind energy had risen In wind turbine industry permanent magnet synchronous

generator (PMSG) is widely used to produce electricity Permanent magnet is used for

the synchronous generator instead of the coil for excitation field PMSG does not require

slip rings to operate There is no direct current supply that is needed for excitation circuit

Without the need of slip rings PMSG is easier to be constructed and lower maintenance

cost The permanent magnet minimizes the rotor losses and this indirectly improves the

efficiency of the generator

PMSG offers a great privilege due to its stable operation [2] However the

construction fee for PMSG is costly due to its rare earth material permanent magnet

3

Despite the high cost of the permanent magnet the PMSG is widely used in the concern

of the environmental conservation The air-gap magnetic flux density also increased with

the use of permanent magnet PMSG has a smaller volume and lower density The

permanent magnet can be positioned inside the rotor or even mounted on the rotorrsquos

surface The maximum efficiency can be achieved by minimizing the air-gap between

rotor and stator

There are various ways for coils to be wound in the stator of the generator Each

of the forms has its own drawbacks and advantages The main purpose of varying the

forms of the coil distribution is to produce three balanced sinusoidal voltages with a little

harmonic voltage and current for three phase machine In other words the output power

is maximized and the losses are minimized with different patterns of coil distribution The

number of slots at the stator can be varied which will affect the manner of the coil

connection and hence different winding patterns can be formed

12 Problem Statement

The PMSG is a part of the wind turbine system Nowadays as the demand for the

electrical energy had increased rapidly around the world the efficiency for the PMSG is

seeking more attention from the researcher With an attempt to increase the performance

of the PMSG the world non-renewable energy consumption can be reduced and the

global warming issue can be minimized or even rectified Moreover the global economy

will also be improved and this will eventually enhance the quality living of life

Furthermore a better performance of PMSG can surely aid in the prevention of climate

change All these advantages come with the energy efficiency Hence various design on

the PMSG had been researched to increase the power output and reduce the losses of the

generator

There is no doubt that the PMSG is well known for its high efficiency and long

lasting performance which can be used in wind turbine However there are various ways

to enhance the performance of the PMSG One of the factors that determine the efficiency

of the PMSG is the winding method In this thesis the winding patterns that are compared

are single layer concentrated winding (SLCW) double layer concentrated winding

(DLCW) single layer distributed winding (SLDW) and double layer distributed winding

(DLDW) In order to improve the efficiency of the PMSG the most suitable winding

pattern has to be chosen

4

13 Objectives

The objectives of this project are

To study and investigate the winding methods for PMSG

To determine the efficiency of PMSG for each type of the windings

To compare the winding methods for the PMSG

To perform analytical analysis and simulation by using Finite Element

Method Magnetics (FEMM) to maximize the efficiency of the PMSG

14 Expected Outcomes

In this project the expected outcomes are listed below

The winding methods of the stator for the PMSG are studied and compared

The simulation of the PMSG is done by using FEMM software

The efficiency of each of the winding methods is analyzed and compared

The winding method that yields the highest performance of the PMSG is

determined

15 Project Outlines

This project contains five chapters These chapters comprised of Introduction

Literature Review Methodology Result and Discussion and Conclusion and

Recommendation These chapters are arranged from Chapter 1 to Chapter 5 respectively

Chapter 1 provides a brief introduction to the electricity generation together with

a short review on the PMSG the problem statement and objectives of this project The

expected outcomes at the end of the project are also included in this chapter

Chapter 2 reviews and compiles all the studies and research that are related to the

project The topologies for the PMSG different winding methods of the stator parameter

that determine the efficiency of the PMSG and analysis approach are discussed in this

chapter

Chapter 3 discusses the methodology that is needed to carry out the project In this

chapter the PMSG model that is used in this project is presented and explained The

5

terminology and the analytical approach by using the FEMM software are depicted in this

section

Chapter 4 computes the performance of the PMSG either through mathematical

calculation or via the 2 dimension simulation of the FEMM The parameters that affect

the efficiency of PMSG is evaluated All the graphical results and the magnetic field maps

are delineated in this chapter

Chapter 5 concludes all the results of the project and summarize the outcomes

The recommendations after carrying out this project are discussed in this chapter Any

limitation of this project is included too

6

CHAPTER 2

LITERATURE REVIEW

21 Permanent Magnet Alternating Current Machine

The Permanent Magnet Synchronous Machine (PMSM) can be divided into two

categories which are axial field and radial field For axial field topology the flux is

moving parallel to the rotor shaft whereas the flux is moving along the machinersquos radius

for the radial field topology [3] The permanent magnet can be placed at a various position

on the rotor The pro and cons of the axial field and radial field topologies are discussed

below [4]

Axial fieldrsquos strengths

A balanced rotor-stator attractive forces with two air-gaps

The grinding to an arc shape is skipped as the permanent magnets have two planar

surfaces

There is an adjustable air-gap

Magnet retainment is not needed

Axial fieldrsquos weakness

There is a poor winding utilization

Restricted size of the end turns at the internal radius

Cogging torque existed

Radial fieldrsquos strengths

There is no radial force on the rotor

Easier removal of heat from the stator winding due to the big surface area of the

stator back iron

7

Skewing is not needed

Radial fieldrsquos weakness

The magnets surface must be arced

Fixed air-gap

An air-gap is formed between rotor magnets with the rotor back iron

Figure 21 and Figure 22 show the axial and radial field structure of PMSM

respectively [5]

Figure 21 Axial Flux PMSMrsquos Structure [5]

Figure 22 Radial Flux PMSMrsquos Structure [5]

8

Figure 23 24 25 and 26 show the radial field of the PMSM with different

positions of permanent magnets [3]

Figure 23 Surface PMSM [3] Figure 24 Surface Inset PMSM [3]

Figure 25 Interior PMSM [3] Figure 26 Interior PMSM with

Circumferential Orientation [3]

The permanent magnets of the surface PMSM are directly mounted on the rotorrsquos

surface as shown in Figure 23 Figure 24 shows that the permanent magnets of the

surface inset PMSM are fixed at the rotor inner surface The Figure 25 depicts that the

permanent magnets of the PMSM are implanted inside the rotor meanwhile the permanent

magnets are aligned in a circular orientation inside the rotor of the PMSM as shown in

Figure 26

Page 19: COMPARISON ON WINDING METHOD FOR ELECTRICAL …

3

Despite the high cost of the permanent magnet the PMSG is widely used in the concern

of the environmental conservation The air-gap magnetic flux density also increased with

the use of permanent magnet PMSG has a smaller volume and lower density The

permanent magnet can be positioned inside the rotor or even mounted on the rotorrsquos

surface The maximum efficiency can be achieved by minimizing the air-gap between

rotor and stator

There are various ways for coils to be wound in the stator of the generator Each

of the forms has its own drawbacks and advantages The main purpose of varying the

forms of the coil distribution is to produce three balanced sinusoidal voltages with a little

harmonic voltage and current for three phase machine In other words the output power

is maximized and the losses are minimized with different patterns of coil distribution The

number of slots at the stator can be varied which will affect the manner of the coil

connection and hence different winding patterns can be formed

12 Problem Statement

The PMSG is a part of the wind turbine system Nowadays as the demand for the

electrical energy had increased rapidly around the world the efficiency for the PMSG is

seeking more attention from the researcher With an attempt to increase the performance

of the PMSG the world non-renewable energy consumption can be reduced and the

global warming issue can be minimized or even rectified Moreover the global economy

will also be improved and this will eventually enhance the quality living of life

Furthermore a better performance of PMSG can surely aid in the prevention of climate

change All these advantages come with the energy efficiency Hence various design on

the PMSG had been researched to increase the power output and reduce the losses of the

generator

There is no doubt that the PMSG is well known for its high efficiency and long

lasting performance which can be used in wind turbine However there are various ways

to enhance the performance of the PMSG One of the factors that determine the efficiency

of the PMSG is the winding method In this thesis the winding patterns that are compared

are single layer concentrated winding (SLCW) double layer concentrated winding

(DLCW) single layer distributed winding (SLDW) and double layer distributed winding

(DLDW) In order to improve the efficiency of the PMSG the most suitable winding

pattern has to be chosen

4

13 Objectives

The objectives of this project are

To study and investigate the winding methods for PMSG

To determine the efficiency of PMSG for each type of the windings

To compare the winding methods for the PMSG

To perform analytical analysis and simulation by using Finite Element

Method Magnetics (FEMM) to maximize the efficiency of the PMSG

14 Expected Outcomes

In this project the expected outcomes are listed below

The winding methods of the stator for the PMSG are studied and compared

The simulation of the PMSG is done by using FEMM software

The efficiency of each of the winding methods is analyzed and compared

The winding method that yields the highest performance of the PMSG is

determined

15 Project Outlines

This project contains five chapters These chapters comprised of Introduction

Literature Review Methodology Result and Discussion and Conclusion and

Recommendation These chapters are arranged from Chapter 1 to Chapter 5 respectively

Chapter 1 provides a brief introduction to the electricity generation together with

a short review on the PMSG the problem statement and objectives of this project The

expected outcomes at the end of the project are also included in this chapter

Chapter 2 reviews and compiles all the studies and research that are related to the

project The topologies for the PMSG different winding methods of the stator parameter

that determine the efficiency of the PMSG and analysis approach are discussed in this

chapter

Chapter 3 discusses the methodology that is needed to carry out the project In this

chapter the PMSG model that is used in this project is presented and explained The

5

terminology and the analytical approach by using the FEMM software are depicted in this

section

Chapter 4 computes the performance of the PMSG either through mathematical

calculation or via the 2 dimension simulation of the FEMM The parameters that affect

the efficiency of PMSG is evaluated All the graphical results and the magnetic field maps

are delineated in this chapter

Chapter 5 concludes all the results of the project and summarize the outcomes

The recommendations after carrying out this project are discussed in this chapter Any

limitation of this project is included too

6

CHAPTER 2

LITERATURE REVIEW

21 Permanent Magnet Alternating Current Machine

The Permanent Magnet Synchronous Machine (PMSM) can be divided into two

categories which are axial field and radial field For axial field topology the flux is

moving parallel to the rotor shaft whereas the flux is moving along the machinersquos radius

for the radial field topology [3] The permanent magnet can be placed at a various position

on the rotor The pro and cons of the axial field and radial field topologies are discussed

below [4]

Axial fieldrsquos strengths

A balanced rotor-stator attractive forces with two air-gaps

The grinding to an arc shape is skipped as the permanent magnets have two planar

surfaces

There is an adjustable air-gap

Magnet retainment is not needed

Axial fieldrsquos weakness

There is a poor winding utilization

Restricted size of the end turns at the internal radius

Cogging torque existed

Radial fieldrsquos strengths

There is no radial force on the rotor

Easier removal of heat from the stator winding due to the big surface area of the

stator back iron

7

Skewing is not needed

Radial fieldrsquos weakness

The magnets surface must be arced

Fixed air-gap

An air-gap is formed between rotor magnets with the rotor back iron

Figure 21 and Figure 22 show the axial and radial field structure of PMSM

respectively [5]

Figure 21 Axial Flux PMSMrsquos Structure [5]

Figure 22 Radial Flux PMSMrsquos Structure [5]

8

Figure 23 24 25 and 26 show the radial field of the PMSM with different

positions of permanent magnets [3]

Figure 23 Surface PMSM [3] Figure 24 Surface Inset PMSM [3]

Figure 25 Interior PMSM [3] Figure 26 Interior PMSM with

Circumferential Orientation [3]

The permanent magnets of the surface PMSM are directly mounted on the rotorrsquos

surface as shown in Figure 23 Figure 24 shows that the permanent magnets of the

surface inset PMSM are fixed at the rotor inner surface The Figure 25 depicts that the

permanent magnets of the PMSM are implanted inside the rotor meanwhile the permanent

magnets are aligned in a circular orientation inside the rotor of the PMSM as shown in

Figure 26

Page 20: COMPARISON ON WINDING METHOD FOR ELECTRICAL …

4

13 Objectives

The objectives of this project are

To study and investigate the winding methods for PMSG

To determine the efficiency of PMSG for each type of the windings

To compare the winding methods for the PMSG

To perform analytical analysis and simulation by using Finite Element

Method Magnetics (FEMM) to maximize the efficiency of the PMSG

14 Expected Outcomes

In this project the expected outcomes are listed below

The winding methods of the stator for the PMSG are studied and compared

The simulation of the PMSG is done by using FEMM software

The efficiency of each of the winding methods is analyzed and compared

The winding method that yields the highest performance of the PMSG is

determined

15 Project Outlines

This project contains five chapters These chapters comprised of Introduction

Literature Review Methodology Result and Discussion and Conclusion and

Recommendation These chapters are arranged from Chapter 1 to Chapter 5 respectively

Chapter 1 provides a brief introduction to the electricity generation together with

a short review on the PMSG the problem statement and objectives of this project The

expected outcomes at the end of the project are also included in this chapter

Chapter 2 reviews and compiles all the studies and research that are related to the

project The topologies for the PMSG different winding methods of the stator parameter

that determine the efficiency of the PMSG and analysis approach are discussed in this

chapter

Chapter 3 discusses the methodology that is needed to carry out the project In this

chapter the PMSG model that is used in this project is presented and explained The

5

terminology and the analytical approach by using the FEMM software are depicted in this

section

Chapter 4 computes the performance of the PMSG either through mathematical

calculation or via the 2 dimension simulation of the FEMM The parameters that affect

the efficiency of PMSG is evaluated All the graphical results and the magnetic field maps

are delineated in this chapter

Chapter 5 concludes all the results of the project and summarize the outcomes

The recommendations after carrying out this project are discussed in this chapter Any

limitation of this project is included too

6

CHAPTER 2

LITERATURE REVIEW

21 Permanent Magnet Alternating Current Machine

The Permanent Magnet Synchronous Machine (PMSM) can be divided into two

categories which are axial field and radial field For axial field topology the flux is

moving parallel to the rotor shaft whereas the flux is moving along the machinersquos radius

for the radial field topology [3] The permanent magnet can be placed at a various position

on the rotor The pro and cons of the axial field and radial field topologies are discussed

below [4]

Axial fieldrsquos strengths

A balanced rotor-stator attractive forces with two air-gaps

The grinding to an arc shape is skipped as the permanent magnets have two planar

surfaces

There is an adjustable air-gap

Magnet retainment is not needed

Axial fieldrsquos weakness

There is a poor winding utilization

Restricted size of the end turns at the internal radius

Cogging torque existed

Radial fieldrsquos strengths

There is no radial force on the rotor

Easier removal of heat from the stator winding due to the big surface area of the

stator back iron

7

Skewing is not needed

Radial fieldrsquos weakness

The magnets surface must be arced

Fixed air-gap

An air-gap is formed between rotor magnets with the rotor back iron

Figure 21 and Figure 22 show the axial and radial field structure of PMSM

respectively [5]

Figure 21 Axial Flux PMSMrsquos Structure [5]

Figure 22 Radial Flux PMSMrsquos Structure [5]

8

Figure 23 24 25 and 26 show the radial field of the PMSM with different

positions of permanent magnets [3]

Figure 23 Surface PMSM [3] Figure 24 Surface Inset PMSM [3]

Figure 25 Interior PMSM [3] Figure 26 Interior PMSM with

Circumferential Orientation [3]

The permanent magnets of the surface PMSM are directly mounted on the rotorrsquos

surface as shown in Figure 23 Figure 24 shows that the permanent magnets of the

surface inset PMSM are fixed at the rotor inner surface The Figure 25 depicts that the

permanent magnets of the PMSM are implanted inside the rotor meanwhile the permanent

magnets are aligned in a circular orientation inside the rotor of the PMSM as shown in

Figure 26

Page 21: COMPARISON ON WINDING METHOD FOR ELECTRICAL …

5

terminology and the analytical approach by using the FEMM software are depicted in this

section

Chapter 4 computes the performance of the PMSG either through mathematical

calculation or via the 2 dimension simulation of the FEMM The parameters that affect

the efficiency of PMSG is evaluated All the graphical results and the magnetic field maps

are delineated in this chapter

Chapter 5 concludes all the results of the project and summarize the outcomes

The recommendations after carrying out this project are discussed in this chapter Any

limitation of this project is included too

6

CHAPTER 2

LITERATURE REVIEW

21 Permanent Magnet Alternating Current Machine

The Permanent Magnet Synchronous Machine (PMSM) can be divided into two

categories which are axial field and radial field For axial field topology the flux is

moving parallel to the rotor shaft whereas the flux is moving along the machinersquos radius

for the radial field topology [3] The permanent magnet can be placed at a various position

on the rotor The pro and cons of the axial field and radial field topologies are discussed

below [4]

Axial fieldrsquos strengths

A balanced rotor-stator attractive forces with two air-gaps

The grinding to an arc shape is skipped as the permanent magnets have two planar

surfaces

There is an adjustable air-gap

Magnet retainment is not needed

Axial fieldrsquos weakness

There is a poor winding utilization

Restricted size of the end turns at the internal radius

Cogging torque existed

Radial fieldrsquos strengths

There is no radial force on the rotor

Easier removal of heat from the stator winding due to the big surface area of the

stator back iron

7

Skewing is not needed

Radial fieldrsquos weakness

The magnets surface must be arced

Fixed air-gap

An air-gap is formed between rotor magnets with the rotor back iron

Figure 21 and Figure 22 show the axial and radial field structure of PMSM

respectively [5]

Figure 21 Axial Flux PMSMrsquos Structure [5]

Figure 22 Radial Flux PMSMrsquos Structure [5]

8

Figure 23 24 25 and 26 show the radial field of the PMSM with different

positions of permanent magnets [3]

Figure 23 Surface PMSM [3] Figure 24 Surface Inset PMSM [3]

Figure 25 Interior PMSM [3] Figure 26 Interior PMSM with

Circumferential Orientation [3]

The permanent magnets of the surface PMSM are directly mounted on the rotorrsquos

surface as shown in Figure 23 Figure 24 shows that the permanent magnets of the

surface inset PMSM are fixed at the rotor inner surface The Figure 25 depicts that the

permanent magnets of the PMSM are implanted inside the rotor meanwhile the permanent

magnets are aligned in a circular orientation inside the rotor of the PMSM as shown in

Figure 26

Page 22: COMPARISON ON WINDING METHOD FOR ELECTRICAL …

6

CHAPTER 2

LITERATURE REVIEW

21 Permanent Magnet Alternating Current Machine

The Permanent Magnet Synchronous Machine (PMSM) can be divided into two

categories which are axial field and radial field For axial field topology the flux is

moving parallel to the rotor shaft whereas the flux is moving along the machinersquos radius

for the radial field topology [3] The permanent magnet can be placed at a various position

on the rotor The pro and cons of the axial field and radial field topologies are discussed

below [4]

Axial fieldrsquos strengths

A balanced rotor-stator attractive forces with two air-gaps

The grinding to an arc shape is skipped as the permanent magnets have two planar

surfaces

There is an adjustable air-gap

Magnet retainment is not needed

Axial fieldrsquos weakness

There is a poor winding utilization

Restricted size of the end turns at the internal radius

Cogging torque existed

Radial fieldrsquos strengths

There is no radial force on the rotor

Easier removal of heat from the stator winding due to the big surface area of the

stator back iron

7

Skewing is not needed

Radial fieldrsquos weakness

The magnets surface must be arced

Fixed air-gap

An air-gap is formed between rotor magnets with the rotor back iron

Figure 21 and Figure 22 show the axial and radial field structure of PMSM

respectively [5]

Figure 21 Axial Flux PMSMrsquos Structure [5]

Figure 22 Radial Flux PMSMrsquos Structure [5]

8

Figure 23 24 25 and 26 show the radial field of the PMSM with different

positions of permanent magnets [3]

Figure 23 Surface PMSM [3] Figure 24 Surface Inset PMSM [3]

Figure 25 Interior PMSM [3] Figure 26 Interior PMSM with

Circumferential Orientation [3]

The permanent magnets of the surface PMSM are directly mounted on the rotorrsquos

surface as shown in Figure 23 Figure 24 shows that the permanent magnets of the

surface inset PMSM are fixed at the rotor inner surface The Figure 25 depicts that the

permanent magnets of the PMSM are implanted inside the rotor meanwhile the permanent

magnets are aligned in a circular orientation inside the rotor of the PMSM as shown in

Figure 26

Page 23: COMPARISON ON WINDING METHOD FOR ELECTRICAL …

7

Skewing is not needed

Radial fieldrsquos weakness

The magnets surface must be arced

Fixed air-gap

An air-gap is formed between rotor magnets with the rotor back iron

Figure 21 and Figure 22 show the axial and radial field structure of PMSM

respectively [5]

Figure 21 Axial Flux PMSMrsquos Structure [5]

Figure 22 Radial Flux PMSMrsquos Structure [5]

8

Figure 23 24 25 and 26 show the radial field of the PMSM with different

positions of permanent magnets [3]

Figure 23 Surface PMSM [3] Figure 24 Surface Inset PMSM [3]

Figure 25 Interior PMSM [3] Figure 26 Interior PMSM with

Circumferential Orientation [3]

The permanent magnets of the surface PMSM are directly mounted on the rotorrsquos

surface as shown in Figure 23 Figure 24 shows that the permanent magnets of the

surface inset PMSM are fixed at the rotor inner surface The Figure 25 depicts that the

permanent magnets of the PMSM are implanted inside the rotor meanwhile the permanent

magnets are aligned in a circular orientation inside the rotor of the PMSM as shown in

Figure 26

Page 24: COMPARISON ON WINDING METHOD FOR ELECTRICAL …

8

Figure 23 24 25 and 26 show the radial field of the PMSM with different

positions of permanent magnets [3]

Figure 23 Surface PMSM [3] Figure 24 Surface Inset PMSM [3]

Figure 25 Interior PMSM [3] Figure 26 Interior PMSM with

Circumferential Orientation [3]

The permanent magnets of the surface PMSM are directly mounted on the rotorrsquos

surface as shown in Figure 23 Figure 24 shows that the permanent magnets of the

surface inset PMSM are fixed at the rotor inner surface The Figure 25 depicts that the

permanent magnets of the PMSM are implanted inside the rotor meanwhile the permanent

magnets are aligned in a circular orientation inside the rotor of the PMSM as shown in

Figure 26