FEM Analysis of a Synchronous Generator

with Inset Permanent Magnet Rotor

Constantin Dobrean1, Marian Greconici1, Gheorghe Madescu2, Martian Mot1, Marius Biriescu1
1
Politehnica University Timisoara, Romania; 2 Romanian Academy – Timisoara Branch, Romania
martian.mot@upt.ro

The paper [14] state that the rotor with surface inset
Abstract- The paper analyses the performances of a three-phase magnets “develops reluctance torque, improves mechanical
synchronous generator with an inset neodymium-iron-boron robustness, possesses better field weakening capability and
permanent magnet rotor. This rotor structure produces an has lower PM eddy current losses compared to those of
inverse saliency effect meaning the quadrature-axis reactance is
greater than the direct-axis reactance. As a result of this effect, surface mounted magnet topologies”.
the generator presents itself a voltage compensation capability The present paper analyses an inverse saliency
for maintaining almost constant output voltage at different synchronous generator with inset PM rotor that present itself
loads. The paper presents some characteristics and a voltage compensation capability to keep almost constant the
performances computed with FEM and highlight the benefits of generator voltage at different load. This analysis with finite
this kind of generator for the applications when the generator
need to keep almost constant output voltage irrespective of load element method was performed.
current. II. GENERATOR TOPOLOGY
I. INTRODUCTION A simple four-pole PM generator with inset magnets in the
rotor core is illustrated in Fig. 1.
Permanent magnet (PM) machines have many attractive The stator has a classical three-phase winding, star
characteristics as high efficiency and high torque/power connected, with integer number of slots per pole per phase
density. Consequently, the use of PM machines has increased (q=3) and single layer: 6 coils series connected per phase
significantly last two decades in different industrial with 42 turn per coil. Cross-section area of conductor: 1.1
applications, mainly due to diminishing cost of the PMs. mm2.
The replacement of the excitation winding with PM is the
best solution to remove the weaknesses of synchronous
machine. The absence of excitation currents and the high
power factor make the PM machine a winner solution in
many cases [1-3]. That is why many papers deal with the
design and optimization of such kind of electrical machines
using analytical and numerical methods [4-9].
There are several structure [10] of such generators with
different rotor topologies: surface-mounted, circumferential
interior (buried), radial interior (spoke), V-shape PM rotor,
etc. The drawback of such PM generators is that the
excitation (PM) cannot be changed and, consequently, the
output voltage, at constant speed, still varies with load.
However, there is a rotor topology as a solution that
removes this drawback, namely: rotor with surface inset
permanent magnet. Such a rotor construction gives rise to an
inverse saliency effect [11] that means the direct-axis
synchronous reactance is less than the quadrature-axis
reactance improving the output voltage regulation
characteristics. Other recent papers [12-15] analyses the Fig. 1. Cross section of synchronous generator with inset PM rotor.
performances of such kind of synchronous generators with
inset PM rotors. The permanent magnets on the rotor surface are mounted;
An advantage of the permanent magnet machines with whole the interpolar spaces by soft-iron pieces are occupied.
saliency is highlight in [12]: “there is a possibility of However, between the PMs and the soft-iron pieces there are
generating a reluctance torque in addition to the magnet field equal air-spaces of 2° (mechanical degree) in all the cases
torque, so it is possible to take advantage of it to reduce the below analyzed.
current load”. The main specifications of the generator in Table I are
presented.
 TABLE I
GENERATOR SPECIFICATIONS
Power [kW] 4
Phase number 3
Poles number 4
Stator slots number 36
Stator inner diameter [mm] 100
Stator length [mm] 120
Stator outer diameter [mm] 160
Air-gap thickness [mm] 1
Permanent magnet thickness [mm] 5
Permanent magnet material NdFeB

III. FEM ANALYSIS

The finite element method (OPERA 13-Vector Field-
software) to analyze the performances of synchronous
generator with inset PM rotor (Fig.1) was used. Many
simulations with different values of PM pole arc and different
values of arc of interpolar soft-iron pole pieces was
performed. Some aspects of these results in the next
paragraphs are presented and discussed.
A. Magnetic flux lines
Fig. 2 and Fig. 3 presents the magnetic flux lines in follow
conditions:
- Pole arc of magnets: 58° (mechanical degree);
- Arc of interpolar soft-iron pole pieces: 28° (mech.);
- The rotor moving at 1500 rot/min;
- Generator on full load with three-phase symmetrical
resistive load (50Ω).
Fig. 3. Magnetic flux lines distribution in presence of soft-iron pieces
(inset PM-rotor).
Fig. 2 corresponds to the case without soft-iron pole pieces
that means air-gap with thickness of 5 mm in the spaces
between the magnets; this is the case of surface-mounted PM
rotor.
Fig. 3 shows the magnetic flux lines in presence of soft-
iron pieces with smaller air-gap (1 mm) in the q-axes; this is
the case of inset PM rotor.
Under load, between the axis F corresponding to resulting
magnetic field and the axis M corresponding to PM there is
the angle θ (load angle). As effect of saliency rotor, the angle
θ of inset PM rotor (Fig. 3) is larger than the angle θ of
surface-mounted PM rotor (Fig. 2), at the same load current.
A lot of magnetic field lines, highlighted in Fig. 4, passes
through soft-iron pieces placed in the q-axes because of
smaller air gap.

Fig. 2. Magnetic flux lines distribution without interpolar

soft-iron pole pieces (surface mounted PM-rotor).
Fig. 4. Magnetic flux lines through soft-iron pieces.
 B. Flux density distribution
In the same conditions as in previous paragraph, the Fig. 5
to Fig. 8 show the air-gap flux density distribution. In Fig. 5
the air-gap flux density due to rotor magnets (only) is
represent (without armature reaction).
Fig. 5. Air-gap flux density distribution due to rotor magnets
(zero current in the stator).
The flux density in Fig. 5 is provided only by PM with
rotor at standstill (without stator current). It is interesting to
note here the same flux density distribution is obtained
irrespective of the material placed in the spaces between the
PM poles (soft-iron or air). In zone A (Fig. 5) corresponding
to the q-axis the flux density is zero.
To understand different phenomenon inside the generator,
in Fig. 6 the air-gap flux density due to just the armature
reaction (without soft-iron pieces and without magnets) is
represented. The magnetic permeability of the magnets is
nearly to air-permeability and, consequently, the air-gap is of
5 mm everywhere. That is why the flux density has little
values in Fig. 6.
Fig. 6. Air-gap flux density distribution due to stator current (6A),
without soft-iron pieces.
To show the rotor saliency effect on the air-gap flux
density characteristics, the generator is simulated also with
soft-iron pieces. In this conditions, in generator air-gap arise a
four-pole distribution of flux density with considerable
values, as can be seen in Fig. 7.
Fig. 7. Air-gap flux density distribution due to stator current (6A),
with soft-iron pieces.
Further, Fig. 8 and Fig. 9 presents the resultant air-gap flux
distribution under load (excitation and reaction).
Without interpolar soft-iron pieces, if the rotor moving at
1500 rot/min, at full load current, the flux density distribution
is shown in Fig. 8. In these conditions, in zone A arise a flux
density, but insignificantly because of large air-gap here in q-
axis (5 mm). If soft-iron pieces are placed in these interpolar
spaces, the air-gap thickness becomes of 1 mm and,
consequently, the flux density increases in zone A, as can be
seen in Fig. 9. Consequently, as effect of this rotor saliency
arise a reluctance torque produced by stator current reaction.
At zero stator current, this reluctance torque becomes zero.
Fig. 8. Air-gap flux density distribution without soft-iron pieces,
at 1500 rot/min under load.
 Fig. 11. Phase-voltage waveforms at 1500 rot/min in presence of interpolar
Fig. 9. Air-gap flux density distribution in presence of interpolar soft-iron soft iron pieces with different PM pole arc: 1-78°; 2- 66°; 3-58°.
pieces at 1500 rot/min under load.

IV. VOLTAGE COMPENSATION CAPABILITY

C. Generator phase-voltage waveforms
For each voltage waveform previously simulated, the
The following two figures present the phase-voltage
RMS-value was calculated in order to prove the voltage
waveforms at different conditions.
compensation capability of this PM generator.
Thus, Fig. 10 shows the time-variation of output voltage
Thus, in Fig. 12 can be see how the generator voltage
when the pole arc of PM is 66° (mech.) in the presence of
decrease if the load current increases.
interpolar soft-iron pieces with the rotor moving at 1500
The solid lines means the cases with interpolar soft-iron
rot/min.
pieces for different pole arcs of magnets: 74° (mech.); 66°
Curve 1 denotes the no-load voltage waveform and curve 2
(mech.); 58° (mech.). Dashed line denotes the cases in which
is the voltage wave at full load condition.
the soft-iron pieces are missing. The solid line in this figure,
clearly highlight (in all cases) the effect of soft-iron pieces
that are placed in the interpolar spaces (between PM). But
this effect depends on the PM pole arc: the smaller the PM
pole arc, the larger the arc of interpolar soft-iron piece is.
However, as is known, the PM pole arc must be larger than
60% of pole pitch, that means more than 54° (mech.) in this
case.

Fig. 10. Phase-voltage waveforms at 1500 rot/min in presence of interpolar

soft iron pieces: 1-no-load; 2-under load current.

In Fig. 11 one can be see three voltage waveforms at 1500

rot/min, in presence of interpolar soft-iron pieces,
corresponding to three values of PM pole arc:
- curve 1 corresponds to a pole arc of 78° (mech.);
- curve 2 corresponds to a pole arc of 66° (mech.);
- curve 3 corresponds to a pole arc of 58° (mech.).

Fig. 12. Generator phase-voltage (RMS) versus load current at 1500 rot/min:
PM74 means 74° pole arc of magnet; PM66 means 66°; PM58 means 58°.
 Quantitatively, the effect of PM-pole arc in Fig. 13 is
shown. To see the voltage compensation capability, in Fig. 13
with dashed line the voltage variation without soft-iron pieces
is represented.
Fig. 13. Generator phase-voltage (p.u.) versus load current at 1500 rot/min.
Finally, from Fig. 14 the optimal ration between the PM-
pole arc and arc of soft-iron piece can be obtained: the better
values of PM-pole arc between 58° (mech.) and 62° (mech.)
are placed.
In these optimal conditions, at any load current (between
zero and full load) the decrease of output generator voltage is
less than 3%.
Fig. 14. Generator voltage (p.u.) versus PM pole arc at 1500 rot/min
and full load current (5.25 A).
These results proves that the synchronous generator with
inset PM rotor present itself a voltage compensation
capability. Such performance is a significant advantage of the
generator in stand-alone applications because provide better
field weakening capability of the generator.
Many other simulations in the case of low speed
applications with direct drive synchronous generators with
inset PM-rotor were performed. Based on these results, the
authors state that in the case of generator with high pole
number (with fractional-slot concentrated windings, q<1) the
effect of saliency is missing. Consequently, this kind of
generators [16, 17, 18] has not a voltage compensation
capability, according with the results of ours FEM
simulations.
V. CONCLUSIONS
In the paper some performances of a synchronous generator
with an inset PM-rotor are presented. This kind of PM-
generator produces an inverse saliency effect that provides a
voltage compensation capability for maintaining almost
constant the output generator voltage at different loads. This
performance is very useful if the generator supplies an
isolated load in stand-alone applications.
But, this effect of inverse saliency in the case of generators
with inset PM-rotor becomes significantly only for the
generator with low number of poles (distributed stator
windings with number of slot per pole per phase q>1).
Thus, the synchronous generator with inset PM-rotor is a
suitable and economical solution in stand-alone power system,
especially with unity-power-factor load, because no need an
additional voltage regulation system.
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