EE466 Power Electronics, Machines and Applications

Assignment
Design of Permanent Magnet Machines

Name: Zhang Yue

Reg. No. : 201215982
Email: yue.zhang.2013@uni.strath.ac.uk
Date: 17th Feb, 2015

EE466 Assignment

Design of PM Machines

Zhang Yue

Abstracts
This report is generated based on tasks of EE466 permanent magnet machine design assignment.
The assignment focuses on a direct-drive permanent magnet machine and permanent magnet
generator design involving magnetic circuit modelling and FEMM simulation. Magnet material
and operating characteristics investigation, flux and flux density calculation and no load voltage
and efficiency calculation are undertook. Some reluctance and reactance, inductance and resistance
are computed as well.

EE466 Assignment

Design of PM Machines

Zhang Yue

Table of Contents
Abstracts............................................................................................................................................................... 1
1 Introduction .................................................................................................................................................. 3
2 Assignment tasks .......................................................................................................................................... 3
2.1 Magnet operating characteristics ............................................................................................................ 3
2.2 Flux per pole and fundamental airgap flux density; magnetic circuit method ....................................... 4
2.3 Flux per pole and fundamental airgap flux density; FEMM .................................................................. 7
2.4 Best use of magnet material ................................................................................................................... 9
2.5 Risk of demagnetisation ....................................................................................................................... 13
2.6 No load voltage .................................................................................................................................... 14
2.7 Resistance and reactance calculation.................................................................................................... 16
2.8 Rated power, losses and efficiencies .................................................................................................... 18
2.9 Forces in the generator ......................................................................................................................... 19
2.10 Recommendations .............................................................................................................................. 19
3 Conclusion.................................................................................................................................................... 21
References .......................................................................................................................................................... 22
Appendix ............................................................................................................................................................ 23

Table of Figures
Figure 1. B-H curve of N40M magnet [2] .................................................................................................... 3
Figure 2. Magnetic circuit method ............................................................................................................... 4
Figure 3. Magnetic circuit of the DD-PM generator .................................................................................... 6
Figure 4. FEMM model of the devised machine (1.Problem definition 2.discretisation into finite elements
3.Field solution and results) ................................................................................................................. 7
Figure 5. Boundary set up ............................................................................................................................ 7
Figure 6. Air-gap Flux and flux density estimation by using FEMM........................................................... 8
Figure 7. Air-gap flux density plot analysis (two poles) .............................................................................. 9
Figure 8. Harmonic analysis of air-gap flux density signal .......................................................................... 9
Figure 9. 3D visualisation of the optimisation problem ............................................................................. 10
Figure 10. Zoom-in short-cut of data selection .......................................................................................... 10
Figure 11. Flux per pole vs. the ratio.......................................................................................................... 12
Figure 12. Air-gap flux density variation ................................................................................................... 12
Figure 13. Harmonic representation of diverse signals .............................................................................. 13
Figure 14. PC determination based on BH-curve ....................................................................................... 13
Figure 15. Estimation of the applied external field .................................................................................... 14
Figure 16. Induced voltage vs. wind speed ................................................................................................ 15
Figure 17. Magnetising inductance measurement ...................................................................................... 16
Figure 18. Air-gap leakage inductance measurement process .................................................................... 17
Figure 19. Slot leakage inductance measurement ...................................................................................... 17
Figure 20. Shear stress and normal stress simulation using FEMM........................................................... 19

Lists of Tables
Table 1. Results comparison between magnetic circuit method and FEMM method .................................. 8
Table 2. Selection of height and width pairs of magnet ............................................................................. 11
Table 3. Results of magnet to pole pitch ratio calculation.......................................................................... 11

EE466 Assignment

Design of PM Machines

Zhang Yue

1 Introduction
With the rapid development of wind turbine industry, some drivetrain configurations are installed
in wind farm such as geared Doubly Fed Induction Generator (DFIG) powertrain, direct-drive
permanent magnet generator powertrain. From James paper [1], it shows that permanent magnet
generator has lower failure rate than DFIG so that to get easier access to the wind farm in aspect
of maintenance, especially for offshore wind farm as harsh environmental condition occurs. Thus,
it is vital that better design of permanent magnet generator leads to higher availability of offshore
wind turbine and therefore lower cost of energy. Thats what this assignment tasks mostly focus
on.

This report is based on the sequence of assignment instructions and tasks are underdone in order.
A short conclusion is generated at the end.
2 Assignment tasks
2.1 Magnet operating characteristics

Figure 1. B-H curve of N40M magnet [2]

As shown the red curve (magnet temperature of 100C) on Figure 1, the normal curve and
intrinsic curve of the magnet. To calculate remanent flux density,

EE466 Assignment

Design of PM Machines

r = 11.6 kG = 1.16 Tesla

Zhang Yue

(1)

Below compute the coercivity,

cB = 7.3 kOe = 580.91 kA/m

(2)

As shown the blue curve (magnet temperature of 20C) on Figure 1, remanent flux density and
coercivity are computed as follows,
cB,20 = 12.25 kOe = 974.82 kA/m

(3)

r,20 = 12.8 kG = 1.28 Tesla

(4)

Using the fact that all of normal curves are parallel when in their linear sections which means
they have the same permeability. Thus, the permanent magnet recoil permeability is determined
in Equation (5).
r,PM =

r,20
1.28 Tesla
=
= 1.045
0 cB,20
4 107 974.82 kA/m

(5)

2.2 Flux per pole and fundamental airgap flux density; magnetic circuit method
As shown on Figure 2, the magnetic circuit of the permanent magnet machine is generated based
on a cross section sketch of a PM machine from Polinders paper [3]. Relevant reluctances,
fluxes and the magnet MMFs are labelled accordingly.

Figure 2. Magnetic circuit method

Calculate tooth reluctance,
Rt=

30 r,Fe

30 r,Fe t

(6)

where refers to stack length in meters, is pole pitch in m, is stator radius in m, p is

number of pole pairs, is height of tooth in m, 0 is the permeability, r,Fe is steel relative
permeability, A is the cross sectional area.
4

EE466 Assignment

Design of PM Machines

Rt =

80103
34107 7700.0181.2

= 1276 /

Zhang Yue

(7)

As for the calculation of air-gap reluctance,

Rg=

(8)

where is the effective air-gap, is the width of magnet in m. From Equation (9) to (13),
effective air-gap is calculated.
= 1
=

(9)

(10)

= + t = (15 + 18) 103 = 0.033

1 = +

15 103
= 5 103 +
= 0.0194
r,PM
1.045

2
(
arctan (
) ln 1 + (
) ) = 0.0933
21
21
21

(11)

(12)

(13)

Thus, the air-gap reluctance can be calculated.

Rg=

1
0

1
1

0.0330.0194
0.0330.01940.0933
4107 0.0791.2

= 171870 /

(14)

As for the calculation of stator yoke reluctance,

R sy =

0 r,Fe

2
2

0 r,Fe

(15)

where is the height of stator yoke in m,

R sy =

2
2

0 r,Fe

22.5
280

4107 77040103 1.2

= 2114 /

(16)

Compute rotor yoke reluctance

R ry =

0 r,Fe

2
2

0 r,Fe

(17)

where is the height of rotor yoke in m,

R ry =

2
2

0 r,Fe

22.5
280

4107 77040103 1.2

= 2114 /

(18)

Below, calculate MMF,

FM=

r
0 r,PM

1.16
4107 1.045

15 103 = 13250

(19)

EE466 Assignment

Design of PM Machines

Zhang Yue

Figure 3. Magnetic circuit of the DD-PM generator

As shown on Figure 3, it can be deduced that = 2 and = 2 from node A
and node B respectively. As for loop C, according to KVL,
2F M 2 R g 2 R t R ry R sy = 0

(20)

Therefore, flux per pole can be calculated using Equation (21).

1

= 2F M / ( 2R g + 2R t + 2R ry + 2R sy)
=

213250
1
2

1
2

( 2171870+21276+ 2114+ 2114)

(21)

= 0.076 Wb
(22)

Fundamental air-gap flux is computed using Equation (23),

4

sin(
)

4 0.076
0.079
sin(
57.3) = 0.092

2 22.5
2 80

(23)

(24)

The air-gap flux density is calculated,

=

0.076
=
=
= 0.802
A

0.079 1.2

(25)

As for the fundamental flux density,

=

= 0.802

4

sin(
)

4
0.079
sin(
57.3) = 0.973

2 22.5
2 80

(26)

(27)

EE466 Assignment

Design of PM Machines

Zhang Yue

2.3 Flux per pole and fundamental airgap flux density; FEMM

Figure 4. FEMM model of the devised machine (1.Problem definition 2.discretisation into
finite elements 3.Field solution and results)
Figure 4 displays the FEMM model of the permanent magnet machine design. As shown on
Figure 5, seven boundary pairs are defined to depict the repeated elements.

Figure 5. Boundary set up

EE466 Assignment

Design of PM Machines

Zhang Yue

Figure 6. Air-gap Flux and flux density estimation by using FEMM

As shown on the result box of FEMM on Figure 6, the normal flux is 0.079 Webers and the
average flux density is about 0.812 Tesla. Table 1 describes the results comparison between two
methods. The reason of the difference occurs is that there are some flux leakage which are not
took into account while using magnetic circuit method. In addition, a linearized version is
generated using FEMM yet true geometry of the modelled element should be a sector which is
used in the calculation of pole pitch. This is another reason for the difference of the results
between magnetic circuit method and FEMM method.
Table 1. Results comparison between magnetic circuit method and FEMM method
Magnetic circuit

FEMM method

method
Air-gap flux (Wb)

0.076

0.079

Air-gap flux density (T)

0.802

0.812

As shown on Figure 7, fundamental flux density and flux density are marked. Magnet width and
pole pitch are also depicted and from the curve it can be conform that this PM machine is middle
of magnet and tooth aligned.

EE466 Assignment

Design of PM Machines

Zhang Yue

Figure 7. Air-gap flux density plot analysis (two poles)

Figure 8 illustrates the harmonic analysis of the air-gap flux density signal generated in the middle
of the PM machine air-gap. From the 1st harmonic, it shows that the magnitude of normal flux
density at the fundamental frequency of the signal. The magnitude of fundamental flux density if
about 1.05T.

Figure 8. Harmonic analysis of air-gap flux density signal

2.4 Best use of magnet material
As shown on Figure 9, points along the intersection line of two curved surfaces satisfies the
conditions declaimed in the question and the values of points in 3D plot become larger from blue
to red. The curved surface which is perpendiculars to x-y surface depicts the condition of fixed
area of 1185 mm2. It is a half of the inverse proportion curves in 3D. The other curved surface
illustrates the relationship between height, width of the magnet and normal flux density.
9

EE466 Assignment

Design of PM Machines

Zhang Yue

Figure 9. 3D visualisation of the optimisation problem

From Figure 10, five points are selected and marked as cursors. It can be seen that the optimised
magnet height and width pair is closed to the top cursor. Note that the colourful parallel lines
described as the curved surface which is perpendicular to the x-y surface results in a good
estimate of selection. Code is attached in appendix.

Figure 10. Zoom-in short-cut of data selection

Table 2 describes the data of cursors, air-gap flux per pole and fundamental flux.

10

EE466 Assignment

Design of PM Machines

Zhang Yue

Table 2. Selection of height and width pairs of magnet

No. Height of

Width of magnet

Flux per pole (Wb)

Fundamental flux (Wb)

magnet (m)

(m)

--- referred to Eq.23

0.0125

0.0948

0.085

0.1032

0.0129

0.09186

0.083

0.1007

0.0143

0.08287

0.077

0.0935

0.0174

0.0681

0.066

0.0801

0.0198

0.05985

0.058

0.0704

Table 3 shows the results of width of magnet and pole pitch ratio calculation and Figure 11
demonstrates the relationship between flux per pole and the ratio.
Table 3. Results of magnet to pole pitch ratio calculation
No.

Pole pitch (m)

Width of magnet (m)

Ratio (wm/p)

0.09817

0.0948

0.9657

0.09817

0.09186

0.9357

0.09817

0.08287

0.8441

0.09817

0.0681

0.6937

0.09817

0.05985

0.6097

11

EE466 Assignment

Design of PM Machines

Zhang Yue

Figure 11. Flux per pole vs. the ratio

As shown on Figure 12 and Figure 13, it can be found that with the width of magnet and pole pitch
ratio decreases, the magnitude of fundemantal flux density increases.

Figure 12. Air-gap flux density variation

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EE466 Assignment

Design of PM Machines

Zhang Yue

Figure 13. Harmonic representation of diverse signals

2.5 Risk of demagnetisation

Figure 14. PC determination based on BH-curve

As shown on Figure 14, the pink line has an approximate crossing point with the normal curve of
permanent magnet at the knee point (magnet temperature at 100C). Due to going beyond the
knee point causes irreversible demagnetisation, the PC = 0.75 line is the line a knee point
coincided with and the permeance coefficient is 0.75.
13

EE466 Assignment

Design of PM Machines

Zhang Yue

(28)

Where --- height of magnet,

g --- airgap length,
airgap cross section area
magnet cross section area
5
1.2
0.0125
=
160
= 2.6
0.005 0.0948 1.2

(29)

Figure 15. Estimation of the applied external field

As shown on Figure 15, the yellow lines illustrates the process of estimating applied external
field and it can be found that a value of 379.89 kA/m for the applied field.
2.6 No load voltage
The induced EMF can be calculated as follows,
= 21 1

(30)

Where 1 is stator turns per phase, f is the frequency, 1 is winding factor: pitch, distribution
and skew and is the fundamental flux.
These unknowns are defined as follows,

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EE466 Assignment

Design of PM Machines

=
=

60

Zhang Yue

(31)

15 80
= 20
60

(32)

1 = 2 10 = 1600

(33)

1 = 0.866

(34)

2
22.5
0.076
4
0.095
= 1.2

sin(
) = 0.0636

160
0.095 1.2
2 22.5
160

(35)

(36)

Thus, the induced EMF,

= 2 20 1600 0.866 0.0636 = 7830.52

(37)

From Equation (30), the value of the induced EMF can be determined.
= 2

15 80
1600 0.866 0.0636 = 870.04
9 60

(38)

Where U is the upcoming wind speed in m/s.

From Polinders paper [3], the rotor speed is assumed to be proportional to the wind speed at low
wind speed and equal to the rated rotor speed at higher wind speeds (above 9m/s). Thus, by
applying Equation (30) it can be seen the relationship of induced voltage and wind speed in
Figure 16.

Figure 16. Induced voltage vs. wind speed

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EE466 Assignment

Design of PM Machines

Zhang Yue

2.7 Resistance and reactance calculation

the resistance can be calculated using Equation (39),
R=

(39)

Where is the resistivity of the material at relevant temperature in , is the length of

conductor in m and A is the cross-sectional area of the conductor in m2.
To calculate the resistivity at 120C, the length of conductor and cross-sectional area.
120 = 20 (1 + ( 0 )) = 1.72 108 (1 + 3.93 103 100) = 0.024
= 1600 2 (1.2 + 2

5
) = 4468.32
160

0.6 80 15 106
A=
=
= 1.35 105 m2
160

(40)

(41)

Thus, the resistance can be determined in Equation (42).

R=

0.024 106 4468.32

=
= 7.94

1.35 105

(42)

The definition of inductance is defined as follows. By using FEMM, different kinds of inductance
can be calculated by dividing the relevant flux by pre-defined current (in this case as 1 A).

(43)
L=

Figure 17. Magnetising inductance measurement

From Figure 17, the normal flux calculated as 4.29 105 Webers and the magnetising
inductance is about 4.29 105 Webers.
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EE466 Assignment

Design of PM Machines

Zhang Yue

Figure 18. Air-gap leakage inductance measurement process

From Figure 18, the normal flux calculated as 7.13 105 Webers. Thus, the air-gap leakage
inductance is
L=

7.13 105 4.29 105

= 2.84 105
1
1

(44)

Figure 19. Slot leakage inductance measurement

From Figure 19, the normal flux calculated as 3.28 105 Webers. Thus, the slot leakage
inductance can be computed
L= 2

3.28 105
= 6.56 105
1

17

(45)

EE466 Assignment

Design of PM Machines

Zhang Yue

2.8 Rated power, losses and efficiencies

Below shows the reactance calculation, note that the end winding inductance is neglected.
= =

(46)

= = 1.57 80 (6.56 + 2.84 + 4.29) 105 = 0.0172

(47)

Equation (48) to (50) describes the calculation of joule loss

P = 3 2

(48)

P
= 127.7
3E . .

(49)

P = 3 127.72 7.94 = 388

(50)

As for the calculation of iron losses.

First of all, calculate the flux densities of teeth and stator yoke.
=

0.076
=
= 1.17 1.2
3
3 1.2 0.018

0.076
=
= 0.645 0.6
5

1.2 160

(51)

(52)

From SURA data sheet [3], losses of teeth and yoke can be found as 1.5 W/kg and 0.45W/kg
respectively.
As for the masses of teeth and yoke, 7650 kg/m3 of the lamination density is assumed.
= 2 160 7650

(53)

= 2 480 7650 0.018 0.08 1.2 = 12690 kg

(53)

= 2 160 7650

(54)

= 2 160 7650

5
0.04 1.2 = 11536 kg
160

(55)

According to Equation (32), the frequency is 20 Hz. In addition, the teeth additional loss factor
and yoke additional loss factor are defined as 1.85 and 3.2 respectively based on A. McDonalds
[5]. Thus, the total iron loss can be calculated.
18

EE466 Assignment

Design of PM Machines

Zhang Yue

3
= 1,50 ( ) ( 2 + 2 ) = 11536 kg
50

(56)

20 3
= 1.07 ( ) (1.85 1.22 12690 + 3.2 0.62 11536) = 14852 W
50

(57)

As for the calculation of efficiency of the generator at rated speed and rated power, assume that
only iron loss and joule loss make contribute to the total loss.
Thus, the efficiency can be approximately defined in Equation (58)

3 106 388 103 163.35

= 87.06%
3 106

(58)

2.9 Forces in the generator

Figure 20. Shear stress and normal stress simulation using FEMM
From Figure 20, it can be found that the normal stress is 1000 times bigger than the shear stress.
2.10 Recommendations
When it comes to improve the cost, it is good to get cheap materials i.e. rare earth, iron and copper
from China and Chile. Apart from the costs of materials, masses of generator components could
be optimised so as to reduce the total mass and therefore decrease the total cost.

As to improve efficiency of Permanent magnet generator, the main purpose is to minimise various
kinds of losses. Firstly, reducing winding area or increasing number of turns of winding result in
19

EE466 Assignment

Design of PM Machines

Zhang Yue

reducing joule loss. In addition, keeping a larger value of power factor and induced EMF leads
decreasing current and then reducing joule loss. Next, to decrease iron loss by cutting down the
masses of generator components i.e. stator yoke, teeth. Whats more, getting better design of
dimensions of generator components, such as magnet, teeth and slot will increase the induced EMF
and then improve the efficiency. Some angle of tweaks for teeth, winding and even permanent
magnet help to improve the design in dynamic aspect. Finally, improving rated power which leads
to new design of PM generator results in better efficiency.

20

EE466 Assignment

Design of PM Machines

Zhang Yue

Conclusion

The results from each section are undertook based on the assignment instructions. A linearized
version of PM generator element is used in FEMM simulation. As for the best selection of magnet
width and height with respect to maximised air-gap flux, even if five random selections are asked
an improved model become further consideration. The efficiency calculation is based on the
assumption that only joule loss and iron loss are being considered. Recommendations of improving
efficiency and cost are given in engineering aspect.

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EE466 Assignment

Design of PM Machines

Zhang Yue

References
[1] J. Carroll, A. McDonald, Reliability comparison of DFIG drive train configuration with PMG
drive train configuration in the first 5 years of operation, 3rd Reneable Power Generation Conf.
(RPG 2014), Naples, Italy, 2014.
[2] Sintered Neodymium-Iron-Boron Magnets data sheet, ARNOLD MAGNET
TECHNOLOGIES.
[3] H. Polinder, F. F. A. Van Der Pijl, G. De Vilder, and P. J. Tavner, Comparison of Direct-Drive
and Geared Generator Concepts for Wind Turbines, IEEE Trans. on Energy Convers., vol. 21, no.
3, pp. 725-733, 2006.
[4] M270-50A steel data sheet, SURA
[5] A. McDonald, EE466 Permanent magnet machine design slides (2014-2015), 2014.

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EE466 Assignment

Design of PM Machines

Zhang Yue

Appendix
% H = 0.015;
% W = 0.079;
%sys H W fi
w_m = 0.05:0.001:0.098;
h_m = (1185*10^(-6))./w_m;
[H,W] = meshgrid(h_m,w_m);
pai = 3.14159165358980;
b_so = 0.015;
g = 0.005;
mu_rm = 1.045;
p = 80;
g1 = g + H/mu_rm;
gamma = 4/pai.*(b_so./(2*g1).*atan(b_so./(2*g1))-log(sqrt(1+(b_so./(2*g1)).^2)));
w_s = b_so;
w_t = 0.018;
tau_s = w_s+w_t;
k_C = tau_s./(tau_s-gamma.*g);
g_eff = k_C.*g1;
mu_0 = 4*pai*10^(-7);
l_s = 1.2;
r_g = g_eff./(mu_0*W*l_s);
B_r = 1.16;
MMF = B_r.*H./(mu_0.*mu_rm);
fi = MMF./(2333+r_g);
figure,
surf(H,W,fi);
hold on
z = 0.04:0.001:0.095;
x = 0:0.001:0.04;
[z,x] = meshgrid(z,x);
y = 1185*10^(-6)./x;
surf(x,y,z);

23