BULETINUL INSTITUTULUI POLITEHNIC IAŞI

TOMUL LII (LVI), FASC. 5, 2006

ELECTROTEHNICĂ, ENERGETICĂ, ELECTRONICĂ

PERMANENT MAGNET GENERATORS FOR SMALL WIND

TURBINES REDISIGNED FROM INDUCTION MOTORS
BY
*ION SOBOR and *NICOLAI KOBÎLEAŢKII.

Abstract. The possibility in decreasing the cost for installed kilowatt of stand alone small wind
turbines used for electric energy supplying of unconnected consumers to the electric public
network are presented. The solution consists in redesigned of the induction motors (IM), which
cost on the CIS market is 100-150 $/kW, into permanent magnet generators (PMG). The
recommendations for IM selection, redesigned method of the PMG rotor and some experimental
results for 3,0 kW, 375 rev/min PMG are presented.
.
Keywords: Low – speed permanent magnet generator, small wind turbines.

1. Introduction

The common design for small wind turbines (rated power 1-10 kW) is the
three blade rotor directly coupled with a permanent magnet generator (PMG)
[1]. This design started to be used in the 90s of the previous century [2-4] and is
called Direct Driven Wind Turbine (DDWT). The main advantages of the
DDWT are following:
 The transmission costs, noise and the vibration are decreased;
 Increases the wind energy conversion efficiency, availability and
reliability;
 Decreases the nacelle mass weight and dimensions;
 Decreases the maintenance costs;
 The power characteristics P (V) moves in the moderate speed zone.
This type of the wind turbines have been designed to provide electricity for
remote houses, farms and for batteries charging. The obstacle in small wind
turbines fast implementation in RM is the huge cost of 3500-4000 $ for installed
kilowatt, from which the cost of small speed generator is 1000-1200 $/kW. Such
costs are not acceptable taking into consideration the economical conditions of
RM. There is a possibility in decreasing the PMG cost with 2-3 times through
the redesigning and manufacture of PMG on the IM bases, which costs on CIS
market is 100-150 $/kW. This solution will lead to the integral cost decreasing
of the wind power unit. The recommendations for IM selection, redesigned
method of the PMG rotor and some experimental results of PMG prototype are
presented.
 ION SOBOR and NICOLAI KOBÎLEAŢKII

2. Rated power and rotational speed of the PMG for small

DDWT

Rated power and rotational speed of the PMG should correspond to the
wind turbine power and speed. At the same time, the wind turbine mechanical
power is proportional to the square of rotor diameter and the cube of wind speed
and it can be calculated as:
1
PT  C P D 2V 3 , (1)
8
where ρ = 1,225 kg/m3 is the air density; CP – the power performance or Betz
limit; D - rotor diameter, m; V – wind speed, m/s.
Rotational speed of the turbine rotor is directly proportional with tip
speed ratio λ and wind speed V and inverse proportional with rotor diameter D:
V
n  60 . (2)
D
Rotational speed, rev/min

600 14
Turbine power, kW

12
500
10
400
8
300
6
200 4

100 2

0
0
4 6 8 10 12
4 6 8 10 12
Wind speed, m/s
Wind speed, m/s
2,4 m 3,4 m 4,0 m 2,4 m 3,4 m 4,0 m
5,2 m 7,0 m 5,2 m 7,0 m

Fig. 1.- Wind turbine characteristics for different rotor diameters: left- rotational speed;
right – turbine power
Modern three blade turbines are designed for a tip speed ratio λ between 5
and 12. In this case the power performance CP will have optimal values. The
maximum value of CP is about 0,48, achieved at a tip speed ratio λ=7,5. In figure
1 are presented the aerodynamics characteristics of the modern small three blade
turbines calculated for λ=6 and CP = 0,42 [5]. Taking into consideration the
wind climate on the territory of the RM [6,7] and aerodynamics characteristics
(Figure 1), we can point out that the rated power and rotational speed of the
PMG for the small wind turbines with a rotor diameter between 2,4 and 7 m are
 BUL. INST. POLIT. IAŞI, TOMUL LII (LVI), FASC. 5

the following:
1. At the wind speed 10 m/s the PMG rated power should be between 1,0
and 10,0 kW:
2. The PMG rated rotational speed should be about 500 rev/min for 1 kW
DDWT and about 200 rev/min for 10 kW DDWT;
3. In the RM wind climate condition, at 25 m height above a ground, the
operational wind speed (more than 4,5 m/s) will be about 6500 hour per
year. For example, the 10 kW turbine (rotor diameter – 7 m) will
generate 0,8 - 3,3 kW during a period of 4070 h, and 3,3 – 10 kW -
during 2440 h.

3. Induction motor selection and PMG redesign

Selection criteria

The IM selection is done taking into consideration the following

criteria:
 The environmental class protection must be no less than IP44;
 The rated speed must be as low as possible. Thus, for IM type 4A, 4AM or
AIR rated speed will be 750 or 600 rev/min;
 IM rated power (PIM) should be equal or higher than the PMG rated power
(PPMG). The ratio PIM/PPMG is proportional to the speed ratio nIM/nPMG;
 The number of the slot per pole and phase for all PMG, q=1, so the number
stator slot Z1 for 3 phase windings must be equal to 6p, where p is the pair
pole number.
PMG redesigned from induction motors

Only the rotor and stator winding are redesigned. All the geometrical
characteristics are known. In addition, the main formulas for PMG calculation
will be presented.
1. The PMG rated power. The power of any electric machine with known
geometrical dimensions and electromagnetic stress can be calculated using the
machine constant C or Arnold constant [8]:
DI2 l  2
CA   , (3)
P '
 K B KW AB
where DI – inner stator diameter; lδ – length of the stator core; Ω=πn/30 -
PMG rated speed; P` - calculating power; αδ – ratio of the magnet width per
pole pitch; KB=1,08 – 1,11 – shape coefficient; KW =1 – winding factor; A=250-
350 A/cm – current loading and not exceed that for IM; Bδ=0,8-0,9 T – air gap
flux density.
 ION SOBOR and NICOLAI KOBÎLEAŢKII

By using (3) PMG rated power can be expressed as:

P `Cos 1
Pn    K B KW AB DI2 l Cos , (4)
KE 2K E
where power factor Cosυ = 0,8; KE = 1,08;
2. The magnet width bMP must be equal to an integer number of the stator
slot pitch tz1. In this case the cogging torque has a minimal value [2,3]. At the
same time, the αδ should frame in (0,65-0,80)τ values, were τ is the pole pitch.
In this case magnet width can be calculated by expression:
ntz ( DI   )
bMP  , ntz  1,2,3... (5)
Z1
3. The thickness of the mounted surface magnet is directly proportional to
air gap length δ and can be expressed as:
BM
hM  0,6  10 6 K , (6)
H M Fe
where δ, for analyzed GMP, varies between 10-3 and 2·10-3 m; BM and HM
are coordinates of the operational point on the NdFeB magnet demagnetized
curve; KFe = 1,25 – 1,35 is the factor taking into account core reluctance; σ =
1,1 – 1,15 is the magnet leakage factor.
4. The stator phase turn number
(1,1  1,15)U n
Wf  , (7)
4,44 fKW   B l
where Un is the rated phase tension, for all analyzed PMG Un = 220 V.
260 100
Efficiency, %
Phase tension, V

240 90
220
80
200
180 70
160 60
140
50
120
100 40
80 30
60
20
40
20 10
0 0
0 300 500 1000 1515 2310 2820
Generated power, W
Phase tension, V Efficiency, %

Fig. 2- PMG prototype, rated power 3,0 kW, rotational speed – 375 rev/min and it experimental
 BUL. INST. POLIT. IAŞI, TOMUL LII (LVI), FASC. 5

characteristics
Other geometrical and electrical rotor and stator data are calculated by
using the classical methodology described in [8]. The main data of the selected
IM and redesigned PMG are presented in the table 1. In figure 2 are presented a
PMG prototype redesigned from IM type 4AM132S8, rated power 4,0 kW,
rotational speed 750 rev/min. The PMG rated power is 3,0 kW and speed - 375
rev/min.
Table 1
Main data of the induction motors and redesigned PMG
Redesigned
Induction motor
PMG
Rated power, kW 1,1 1,1
Type Rated speed, rev/min/Pole number 750/8 500/12
4A90LB8 1
Slots number per pole & phase, q 1 1
or 2
AIR90L8 Winding factor, KW 0,96 1,0
Efficiency, % 70,0 82,0
Rated power, kW 3,0 2,0
Type
Rated speed, rev/min/Pole number 750/8 375/16
4A112MB8
Slots number per pole & phase, q 2 1
or
Winding factor, KW 0,96 1,0
AIR112MB8
Efficiency, % 79,5 85,0
Rated power, kW 5,5 3,0
Type Rated speed, rev/min/Pole number 750/8 333,3/18
4A132M8/6 1
Slots number per pole & phase, q 2 1
or 4
AIR132M8/6 Winding factor, KW 0,94 1,0
Efficiency, % 83,0 88,0
Rated power, kW 15,0 5,1
Type
Rated speed, rev/min/Pole number 750/8 250/24
4A180M8
Slots number per pole & phase, q 3 1
or
Winding factor, KW 0,902 1,0
AIR180M8
Efficiency, % 87,0 91,0
Rated power, kW 30,0 10,1
Type
Rated speed, rev/min/Pole number 600/10 200/30
4A250S10
Slots number per pole & phase, q 3 1
or
Winding factor, KW 0,902 1
AIR250S10
Efficiency, % 88,0 94,0

4. Conclusions
1. The PMG rated power for direct driven small wind turbines (rotor
diameter between 2,4-7,0 m, calculating wind speed - 10 m/s) varies
from 1,0 still 10,0 kW. Respectively, PMG rotational rated speed
should be 500 – 200 rev/min.
2. For facilitating the implementation of the small wind turbines in the
 ION SOBOR and NICOLAI KOBÎLEAŢKII

Republic of Moldova the PMG can be redesigned from IM. In this

case the PMG cost can be significantly decreased.
3. The rated power of the selected IM for 1,0-10,0 kW PMG varies
between 1,1 and 30 kW. The rated rotational speed is 750 or 600
rev/min.

Acknowledgments
The work has been performed with the fanatical support of the Supreme Council for
Science and Technological Development, project number 095 “Electrical Generators for Non-
conventional Energy Sources”.

*Technical University of Moldova, Power Engineering Faculty, Electromechanically

Department, Chisinau, Republic of Moldova;

REFERENCES
1. Wind Energy. The facts. European Wind Energy Association. Luxembourg, 1999.
2. Andreas Grauers. Design of Direct-diven Permanent-magnet Generators for Wind Turbines.
Technical Report nr. 292, Chalmers University of Technology. Sweden, Goteborg, 1996.
3. Petri Lampola. Directly Driven, Low-Speed Permanent-Magnet Generators for Wind Power
Applications. Acta Polytechnica Scandinavica, Electrical Engineering Series, nr. 101, Espoo,
2000.
4. Godfrey Boyle. Renewable Energy: power for a sustainable future, Oxford University Press,
Oxford, 2004.
5. Tony Barton, David Sharpe, Nick Jenkins, Ervin Bossanyi. Wind Energy Handbook, John
Wiley and Sons, LTD, New York, 2001.
6. Petru Todos, Ion Sobor, Andrei Chiciuc. Processing Results of Wind Raw data on the territory
of the Republic of Moldova. Bul. Inst. Polit., Iaşi. Elecrtotehnica, Energetica, Electronica,
XLVIII (LII), fasc. 5C, 301-306, (2002).
7. Petru Todos, Ion Sobor, Andrei Chiciuc, Mihai Grosu. Prefeasibility study for wind power
production in Republic of Moldova. Bul. Inst. Polit., Iaşi. Electrotehnica, Energetica,
Electronica, L(LIV), Fasc. 5A, 240- 245, (2004)
8. Проектирование электрических машин: Учеб. Пособие для вузов/ И. П. Копылов и др.
Энергия, Москва, 1980

GENERATORE CU MAGNEŢI PERMANENŢI PENTRU

TURBINE EOLIENE DE MICĂ PUTERE REPROIECTATE PE BAZA MOTOARELOR DE
INDUCŢIE
(Rezumat)

Se prezintă o posibilitate de micşorare a costului unui kilowatt instalat a turbinelor

eoliene de mică putere utilizate în regim autonom pentru alimentarea cu energie electrică a
consumatorilor neconectaţi la reţeaua electrică publică. Soluţia constă în reproiectarea
motoarelor de inducţie (MI), costul cărora pe piaţa CSI este de 100-150 $/kW, în generatoare cu
magneţi permanenţi (GMP). Sunt prezentate recomandări pentru selectarea tipului MI, metodica
de reproiectare a rotorului cu magneţi permanenţi şi rezultatele studiilor experimentale a GMP
cu puterea de 3,0 kW, viteza de rotaţie 375 tur/min.