Present and Future Trends in Wind Turbine Generator

Designs
Yao Duan and Ronald G. Harley
School of Electrical and Computer Engineering
Georgia Institute of Technology
Atlanta, GA
Abstract- Various wind turbine generators have been designed
and manufactured in recent years, such as the traditional
induction generator, the doubly fed induction generator, the field
excited synchronous generator and the permanent magnet
synchronous generator. Generators are coupled to the turbine by
either a gearbox or without one (so-called direct drive), and there
are four different kinds of interfaces between the generator and
the grid, depending on the type of power electronic converters
used. This paper reviews recent developments in the different
generator topologies and their connections to the turbine. A new
generator design concept without a gear box or any power
electronics is proposed and the feasibility is illustrated in this
paper.
Keywords- Direct Drive, Induction Motor, Wind
I.

A.

Plant Feeders

PF control
Capacitors

Type 1

Slip power as
heat loss

Type 2
Plant Feeders

INTRODUCTION

Electrical energy from the wind is a fast-growing area

worldwide. Various wind turbine and generator topologies
have been developed to maximize the energy conversion
efficiency, the system reliability and minimize the cost. A
challenge with wind turbines is to convert a relatively low and
variable input - the wind impinging on the rotor - into a much
faster and steady alternating current output suitable for grid
connection [1]. This challenge becomes more and more
pronounced with the rapid increase in wind turbine power
ratings. This paper reviews some of the more popular wind
turbine generator concepts and the available commercial
products, with the focus on the generator design and the impact
of the generator topology on the overall wind turbine system.
After summarizing current trends and challenges in the MW
size machines, a new wind turbine concept, which avoids the
gearbox and power electronic converters, is proposed to
improve the system's overall efficiency, the reliability, the
nacelle weight and possibly the system's overall cost.
II.

and the generator. In addition, depending on the means of

connecting the generator to the grid, there are four types, as
shown in Figure 1 [3]:

REVIEW OF CURRENT GENERATOR TECHNOLOGIES

Four Types ofGenerator and Grid Connections

Generally speaking, there are currently four major
generator types used in the utility level wind turbine generators,
namely: Induction Generators (IG), Doubly-fed Induction
Generators (DFIG), Field Excited Synchronous Generators
(FESG) and Permanent Magnet Synchronous Generators
(PMSG) [2]. The wind turbine generators can be also
distinguished by whether there is gear box between the turbine

Type 3

Type 4

Figure 1. Illustration of four types of generator and grid connections

B.

Gearbox and Direct Drive(DD)

A gear box transfers the relatively low rotor speed of the
turbine up to speeds close to the synchronous speed of the
generator, giving a lower generator weight and avoiding a slow
speed generator design with a large number of poles; however,
the gear box has its own weight and a low reliability [2].
Moreover, the power loss in the gear box accounts for a fairly
high proportion of the total system loss, and thus reduces
efficiency [11]. For the above reasons, interest by wind turbine
manufacturers is returning to directly driven generators. Most
direct-drive turbines being sold at the moment are synchronous
generators, either in FESG (No.2 in Table 1) or PMSG (Nos.
9-11 in Table 1) types. The table also shows that the weight of
the direct drive generators are much higher as expected, than
for generators driven through a gear box. For example, the
weight of a 3.8 MW PMSG (No.11 in Table 1) itself is much
higher than the nacelles of Designs 3-7 in Table 1, although the
nacelle contains the generator, the gear box, the shaft, the
brakes and so on. It is also reported in [2] that the direct drive
permanent magnet generators are more expensive, compared to

978-1-4244-4936-1/09/$25.00 2009 IEEE

other types. In spite of the larger weight and higher cost of the
direct drive system, the trend of the wind turbine market shows
that the direct drive generators are becoming a favored choice.
For example, Design 10 in Table 1 is one of the newest
generator designs from Vestas, a major player in the wind
turbine market. This 3 MW PMSG product indicates that
Vestas is switching from their previous IG with gear type
(Design 3, 4 and 5) to the PMSG.

technology by Vestas [6] (Type 2) or doubly-fed configuration

(Type 3). The rotor resistance control is enabled by the wound
rotor and the slip rings. However, there are drawbacks to the
use of slip-ring generators. Additional cost is introduced by the
slip-ring components and the need to maintain the brush-gears
including replacement of the brushes on a regular basis. The
brush-gear related problems are a significant issue in wind
turbine operation and reliability.

C. Connection to the grid

D. Fixed speed or variable speed

The selection of variable speed or fixed speed wind
generators for a specific site is determined by several factors:
the wind speed distribution of the site, the reliability and
maintenance concerns, the system cost, and the profit by the
electricity generation. At present, the variable speed generators
generally have much higher cost than the fixed speed ones,
either due to the larger size of the Direct Drive (DD) generators
and the power electronics converters, or the slip rings on
wound rotor induction generators. On the other hand, more
electricity is produced on average by the variable speed
generator because of the maximum power point tracking. In the
long term, which type of wind generator is more profitable
depends on the wind distribution of the site where the generator
is installed.

Table 1 also shows that most direct drive generators use

power electronic converters to connect to the grid (Type 4 in
Fig. 1). This configuration has a full range variable shaft speed
operation and thus allows maximum power point tracking of
the wind velocity. Moreover, these generators can be designed
with a lower pole count and produce around 16 to 20 Hz
instead of around 60 Hz. However, the downside of this
configuration is also significant compared to the other three
types of Figure 1. In Type 4, the converter is rated at the full
power of the generator while in Type 3 the converter is rated at
the slip power, which is about 30% of the generator rated
power. The large power rating of the power electronic
converters reduces the system reliability and increases the cost
[11]. Moreover, the voltage and power capability of the power
electronic devices limit the voltage level of the generators. A
higher rated voltage is preferred for the generator design
because it reduces the winding current and thus reduces the
losses.

According to [15], the distribution of wind speed for a

specific site generally follows a Weibull distribution, which is
defmed as follows in (1):

The Type 2 and Type 3 allow a certain range of rotor speed

variations by rotor resistance control, such as the OptiSlip

TABLE

No

Generator
Type

FESG

FESG

IG

IG

IG

DFIG

DFIG

DFIG

PMSG

10

PMSG

11

PMSG

12

PMSG

I.

(1)

LIST OF TYPICAL WIND TURBINE GENERATORS DEVELOPED IN THE RECENT YEARS

Gearbox

Manufacture

Power
Rating

Turbine
Rotor
Speed Range

Generator
Voltage
Rating

Yes
direct
drive

DeWind [4]

11.1 - 20.7 rpm

13.8 kV

N/A

N/A

Yes

Vestas[6]

2MW
4.5
MW
850
kW

26 rpm

690V

Yes

Vestas[6]

2MW

16.7 rpm

690V

Yes

Vestas[6]

N/A

1000 V

Yes

Gamesa[7]

3MW
850
kW

16.2 - 30.8 rpm

690 V

Yes

DeWind[4]

2MW

11.1 to 2.7 rpm

690V

Yes
Direct
drive
Direct
drive
Direct
drive

Gamesa[7]

9-19 rpm

690V

Zephyros[8]

2MW
1.5
MW

18 rpm

3000 V

Vestas[6]
The
Switch[9]
The
Switch[9]

3MW
3.8
MW
950
kW

N/A

N/A

21 rpm

690V

N/A

690 V

Yes

Enercon[5]

Grid
Connection
Type
4
2
2
2
3
3
3
4
4
4
4
4

Nacelle
Weight

Generator
Weight

62,000 kg

N/A

N/A

220,000 kg

38,000 kg

N/A

67,000 kg

N/A

70,000kg

N/A

33,000 kg

N/A

62,000 kg
107,000
kg

N/A
N/A

N/A

47,200 kg

70,000 kg

N/A

N/A

81,000 kg

N/A

3,400 kg

where:

paper for a direct drive, grid connected wind generator

application.

V o = wind velocity
h=

A.

lim

{Fraction of time wind speed is between Va and (va +~va)}

I1V~Q

~va

k, I are site-specific shape factors.

Different sites have different wind distributions and thus

different shape factors. Figure 2 [16] shows the effect of the
shape factor k on the Weibull distribution of the wind speed.
Generally, wind site data tend towards a k value of 2, but site
with values as low as 1.5 and as high as 3 have been observed
[17] [18]. As seen in Figure 2, at sites with a low k, the
distribution of the wind speed is more "flat" and the variable
speed generators will have more advantage than the fixed speed
generators in terms of the electricity generated. On the other
hand, at sites with a higher k, the distribution of the wind speed
centers closely around a certain value and thus the fixed speed
generator is sufficient to have good wind power conversion for
most of the time.
VVe/bull D i s t r i b u t i o n s

_ _.-. ""1.-.<1

/~-

s ~

7_26 r n / s

-,...p

A
B
C

_k=" 5
_k=2
_k=3

D_ k

/~/

Vo (mI_)

Figure 2. Effect of shape factor k on the Weibull distribution [16]

E. Future Trend
From the above analysis of the commercially available
wind turbine generators, it is concluded that direct drive, grid
connected generators indicate a future trend in the wind
generation. The elimination of the gear boxes and the power
electronic converters will significantly increase the system
reliability. The overall system efficiency will increase because
the losses in the gear box and power electronic converters are
eliminated. In addition, the other disadvantages introduced by
the gear boxes and converters discussed above are also no
longer a concern.
III.

DIRECT DRIVE, GRID CONNECTED GENERATOR

DESIGN

Based on the commercial availability of generators in MW

size applications, three candidate generator types are
considered in this paper for direct drive, grid connected
applications: the field excited synchronous generator (FESG),
the permanent magnet synchronous generator and the induction
generator. However, [12] [13] claim benefits for permanent
magnet excitation, which eliminates the excitation losses of a
FESG. The synchronous generators and squirrel cage induction
generators are usually run with fixed speed wind turbines,
which are especially suitable for sites with a higher k of the
wind speed Weibull distribution. An induction machine and a
permanent magnet machine are designed and compared in this

Squirrel cage induction generator design

A squirrel cage induction generator is first designed to
illustrate the feasibility of a direct drive, grid connected wind
generator in MW applications; the ratings are 5 MW, 13.8 kV
(line-line voltage) and 400-pole, 60 Hz for the base case design.
The rated speed of the wind turbine is chosen as 18 rpm,
which is a typical value for MW level wind turbines seen from
Table 1. Then if 3 slots/pole/phase are chosen, the stator will
have 3600 slots. The stator winding is short pitched by 1 slot in
order to reduce the harmonics in the generator. For this type of
winding configuration, the winding factor k; of the
fundamental turns out to be 0.9452.

The base case design of the induction generator starts with

the classical sizing equation [14]:

S == 11kw * B * ac * D

*L *n

(2)

where S is the motor rating in W, B is the specific magnetic

loading in Tesla, ac is the specific electrical loading in A/m, D
is the stator bore diameter in meter, L is the generator active
length in meter, and n is the rated speed in rps (revolutions per
second). If typical values are chosen, for example, efficiency

eff= 0.84, power factor pf= 0.84, k;

40000, then D2L is calculated as:

0.9659,

0.5 T, ac

D 2L=

~utleffl pi =112.5 m 3

11kw * B*ac**n

where Pout is the rated output power, which is 5 MW.

The pole pitch-to-length ratio kp l is defmed as:

k =Y=JrDlp
pI
L
L

(3)

where Y is the pole pitch in meters and p is the number of the

poles. If a square pole profile is chosen, hence kol = 1 and the
stator bore diameter is found as 24.3 m, and the stator length is
0.191 m. This significantly large stator bore diameter is a great
challenge to the manufacturing, transportation and installation
of the generator and thus needs to be reduced, which means the
value of kol needs to be decreased. On the other hand, because a
square pole leads to the shortest coil length for the same pole
area, the kol cannot be too small in order to keep the stator
resistance low.
The airgap length is large for the base design motor with this
size because of the manufacturing capability, structural
stiffness and the bearing. According to [19], an airgap length of
10 mm is a possible value for this base design. This large
airgap length will increase the mmf drop across the airgap
significantly, which leads to lower airgap flux density. As a
result, the specific magnetic loading
decreased to be 0.25 T.

B in the base design is

With the kol chosen to be 1/10, the stator bore diameter is

found as 15.245 m and the axial length is 1.197 m. The largest
stator bore diameter ever reported for the wind generator is 10
m [5], which indicates the feasibility of this base design with
the 15.245 m stator bore diameter. The 10 m diameter
generator is manufactured by Enercon and the structure of this
generator is illustrated below in Figure 3:
Stator
winding
Stator
ring

~
~
Figure 3. Illustration of the 10m airgap diameter wind generator - Enercon

El12 [5]

standard induction motors and this base design is thus feasible

to be connected to the grid as a generator.
B.

Surface Mounted Permanent Magnet(SMPM) generator

design
The SMPM motors have been designed for the direct-drive
wind generators by several companies, as shown in Table 1. In
the present designs in Table 1, the generator output has a lower
frequency (17.5 Hz for the Switch 3.8 kW design) in order to
have a lower number of poles. In this paper, as the PM
generator is designed to be directly connected to the grid with
60 Hz frequency, the pole number is much higher. For the base
design with 18 rpm, the pole number is 400.

According to the sizing equation (2), the stator bore diameter

of the SMPM machine is expected to be similar to the previous
induction machine design, also around 10m. As a result, the
airgap length for this SMPM is chosen to be 10 mm, the same
value as the induction motor.
In the SMPM machine, the airgap flux density can be
increased by increasing the thickness of the magnets. Suppose
that the NdFeB is used, the airgap flux density in the SMPM
machine is approximated by the following equation [20]:

After the sizing of the machine, this ring-type induction

machine is further designed with the classical induction
machine design methods as in [14]. The other design
parameters and performance indexes are highlighted in Table 2
below:
TABLE II.

B ==
m

Br *kleak
1+ JLr * g * k carter
hm

(4)

where
DESIGN OF THE DIRECT DRIVE, GRID CONNECTED INDUCTION
GENERATOR

Stator bore
diameter

15310 mm

Rated
voltage

13.8 kV

Stator outer
diameter

15245 mm

Slip at rated
load

0.064

Rotor outer
diameter

15185 mm

Efficiency at
rated load

85.5 %

Rotor inner
diameter

15225 mm

Power factor
at rated load

0.6

Stator
current
density

5.1 Azrnm?

Break-down
slip

0.21

Rotor
bar
current
density

5.2A/mm 2

Break-down
torque ratio

1.72 pu

Airgap flux
density

0.25 T

Active mass

18.6 tons

In spite of the large airgap length, Table 2 shows that this

base design has a relatively high efficiency (85.5 %). Although
the power factor (0.6) is relatively low due to the large airgap,
this low power factor can be corrected by the power factor
control capacitors. The performance is comparable to the

hm : magnet thickness in mm
B r : the residual flux density. For NdFe35, it's 1.23 T.
g: the airgap length, which is 10 mm for the base design
JLr

relative recoil permeability. For NdFe35, it's

1.09981.

k 1eak: leakage factor. Typically in the range of 0.9 to 1.0

for SMPM machine
kcarter: Carter coefficient. Typically in the range of 1.0
to 1.1 for surface mount PM machine

Based on equation (4), a magnet thickness of 13.5 mm is

chosen and the resulting airgap flux is 0.7 T. According to the
analytical design model of SMPM machine as proposed in [20],
the other design parameters of this 5 MW, 60 Hz and 18 rpm
ring-type SMPM machine can be determined. Some key design
parameters and performance indexes are shown in Table 3.
Although the PM machine can achieve a larger airgap flux
density and the stator bore diameter is smaller, Table 3 shows
that the active mass of the machine is not significantly less than
the induction generator. However, the advantage of the PM
machine design is that it has a much higher efficiency (97.3 %)
than the induction machine (85.5 %).

TABLE III.

DESIGN OF THE DIRECT DRIVE, GRID CONNECTED

GENERATOR

SMPM

Stator bore
diameter

11634 mm

Rated
voltage

13.8 kV

Stator outer
diameter

11734 mm

Efficiency at
rated load

97.3 %

Rotor outer
diameter

11614 mm

Power factor
at rated load

0.98

Rotor inner
diameter

11550 mm

Stator
current
density

4.9A/mm2

Active
length

913mm

Active mass

16.4 tons

C. Discussion

ofthe direct drive, grid connected generator

designs

1) Structure and Total Mass

For the ring type generator designed above with a large
stator bore diameter, the structure is different from the ordinary
machine. Support needs to be provided to enable the torque
transfer and prevent the cylindrical ring structure from
deflection. As shown in Figure 3, the machine has rotor radial
arms and the stator is a cylinder for structural support.
Depending on different designs and configurations of the
structure support, the structural mass is different. However, [21]
provides a method to model and estimate the structure mass of
the ring type generators. According to [21], the structural mass
is mainly determined by the power rating and the generator
aspect ratio (LID) for a well designed direct drive generator.
The mass of a 5 MW direct drive generator for different aspect
ratios is shown below in Figure 3.

holds true for a converter based direct drive generator with a

relatively low pole number. With the high number of poles for
the direct drive grid connected generator, however, the larger
aspect ratio introduces machine designs with small diameters
and large lengths. For example, an aspect ratio of 0.3 leads to a
design with 0.3 m in stator bore diameter and 9 m in length. It
will be difficult to fit the large number of slots (at least 1200
slots needed for integer winding) into the small stator inner
circumference of only 1 m. In addition, this irregular long
machine will also possibly need a special support structure and
bearing, which may increase the inactive mass.
For comparison purposes, an induction generator with a
gear box is also designed. The generator has the rating of 5
MW, 13.8 kV and 1800 rpm. Because of the much higher rated
speed, the D2L is significantly decreased and the stator bore
diameter in this design is about 1 m, which means the airgap
length can be reduced to 1 mm. The resultant generator has an
efficiency of around 97 %, a power factor of 0.9, and the active
mass of this generator is 10 tons (which is similar to the direct
drive base design). However, because of the much smaller
stator bore diameter, the structural mass is reduced
significantly and can be simply estimated as equal to the active
mass. On the other hand, the gearbox contributes significantly
to the total mass of the generator system. According to [22], the
mass for a wind generator gearbox rated at 2.3 - 2.9 MW and
14-18 rpm is 21 tons. Due to the unavailability of larger
gearbox data, it is assumed that two such 2.3- 2.9 MW
gearboxes are used in parallel for the 5 MW generators. As a
result, the total mass of the geared generator system is
10+10+21 *2 = 62 tons. The mass for the three generator
designs is compared below in Figure 5.

Mass comparison
Acti ve Mass 0 Structure Mass 181 Gearbox Mass
'U)

.s

300

<::

--r---------------.....,

100
50

'b

150

200

a --+------+-----11----+-----11---.. .

100

---......&.---------.. .

O...........l.....- -.......
o
0.1
0.3

DD
Induction
Generator

DD SMPM
generator

Induction
generator
with gear
box

0.5

Aspect Ratio, K rad

Figure 5. Comparison of the mass for different generator designs

Figure 4. Mass of a 5 MW direct drive generator for different aspect ratios
[21]

The induction generator base design has an aspect ratio of

1.197/15.245 = 0.08 and the PM generator base design has an
aspect ratio of913/11634 = 0.08. From Figure 3, it is estimated
that the structure mass is about 100 tons for both generator
designs. The total mass is then 118.6 tons for the induction
generator base design and 116.4 tons for the SMPM generator
base design. Larger aspect ratios, as seen from Figure 4, could
reduce the inactive mass of the machine. However, this only

Figure 5 shows that structural mass is the dominant factor

for the larger mass of direct drive generators. However, the
success of the direct drive generators in the present market
indicates that the problem of the larger mass design can be
overcome. With better material and designs of the supporting
structure of the direct drive generators in the future, the total
mass can be further reduced, which makes the direct drive
generators even more promising.

2) Applicability in wind generation

Both the direct drive, grid connected induction generators
and SMPM generators are intended for fixed speed operations.
When the SMPM generator is connected to the grid, the speed
is determined by the grid frequency and is constant. If the
torque to the generator is increased, the generator will produce
electromagnetic force to resist an increase in speed. As a result,
a gust of wind will cause large stresses on the wind turbine's
drive train. On the other hand, the induction generator allows a
small change of speed with the change of torque going to the
generator, which reduces the wear and tear of the drive train.
From the cost point of view, because both the induction
machine and the SMPM machine have similar stator topologies,
the cost difference is mainly in the rotor. The PM's have a
much higher price than the aluminum. As a result, the cost of
the induction generator is expected to be much lower than the
SMPM generators for the same power rating. On the other hand,
the SMPM generators have higher efficiencies. The higher
material cost can be partly compensated for the extra electricity
generated. Due to inductive power factor of the induction
generators, capacitors are needed for power factor correction,
which also increases the overall cost of the induction generator.
Cost trade-off studies are therefore needed for every site.
IV.

CONCLUSION

Commercially available MW size wind generator systems

are summarized and reviewed. The gear boxes and the full
scale power electronic converters have a reduced reliability and
one of the technology trends is to eliminate them. For this
purpose, a non-traditional induction generator and SMPM
generator with a high pole number is designed. The feasibility
and the advantage of the designed direct drive, grid connected
wind generators are explained and illustrated. The main
challenges with the direct drive generators are their large size
and structure mass, but the E-112 generator by Enercon has
shown that this challenge has been overcome. The advantages
and disadvantages of fixed speed and variable speed generators
are also discussed and choice has to be based on the wind
distribution of the specific site. The designed induction
generator and SMPM generator are also compared in terms of
the system cost, the efficiency and the impact to the grid and
the drive train.
ACKNOWLEDGMENT

Financial support for this work from the Office of Naval

Research is gratefully acknowledged.
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