ECE 788: Electrical Machines

ASSIGNMENT 2

Submitted by

Shamsuddeen N
SNo: 1453319

On
th
24 Nov’2014
Objective:

The aim of this assignment is to design a 3phase, 25W, 15 Vl-l (open circuit emf), fixed speed, rare earth
magnet generator. The generator should supply full-load power to a three phase balanced resistive load
while maintaining a voltage regulation of 10%.

Design input:

Load 0-25 W
Rotor speed 3000rpm
Generated line voltage at 25W 13.5 Vl-l
Generated line voltage at no- 15 Vl-l
load

The main dimensions of the machine are fixed. The machine is three phase star connected. The winding
connection has to be found out to get highest distribution factor. The only variable available is number of
turns, which should be optimized to meet the design requirements.

Design Steps:
The following steps are followed in design.
1. Basic calculation to find design requirements.
2. Calculation of flux linkage from magnetic circuit.
3. Estimation of flux linkage and coil emf from FEM.
4. Find optimal winding scheme to form a balanced three phase winding.
5. Estimation of per phase open circuit emf for a turn and 3000 rpm.
6. Find number of turns to meet OCV requirement.
7. Estimation single coil inductance.
8. Calculation of resistance.
9. Optimization of number of turns to meet voltage regulation.

Part: I

1. Basic calculation:
Per phase load resistance = Per phase rms voltage^2 /Per phase power
= 7.29 Ohm
Per phase load current = Per phase power/per phase voltage
= 1.07 A
Per phase resistance to meet voltage regulation 13.5 Vll
= (Open circuit voltage phase voltage- terminal phase voltage)/load current.
= 0.81 Ohm
 2. Calculation of flux linkage from magnetic circuit:

To find out flux linkage of a single coil, the magnetic circuit in Fig.1 is considered. In the magnetic circuit
the reluctance of core region is considered as zero and the reluctance of air gap and magnet are only
considered. Rg and Rm are air gap and magnet reluctance respectively. ϕr and ϕg are magnet remnant and
air gap flux respectively.

Fig. 1: Magnetic circuit.

From the magnetic circuit the expression for air gap flux is

ϕ
ϕ =
+

In the above equation, the nominator term can be found separately as follows,
ϕr
ϕr =
0

=
μ μ
Where, lm is magnet length, and Br is remnant flux density.

The calculated value of air gap flux is,

= . ×

3. Estimation of coil flux from FEMM:

The given FEMM model is run at two mechanical degrees viz., 0 and 1.5. The zero reference is taken when
tooth 1 is aligned to the magnet as shown in Fig 2. The flux passing through the tooth is the flux which links
the coil wound around tooth. So, this flux information is sufficient to find out induced emf in the coil. After
running the solver, normal value of flux passing through the teeth 1, 2, 3, 4 and 5 are found. This
information and considering half wave and quarter wave symmetry of sinusoidal waveform, the flux
information at each 10o electric step angle is found. Induced emf for a single turn and 1 rad/s is found by
taking differentiation with the radian angle. Table 1 shows these values for one quarter. Fig. 2 and 3 shows
plot of these values for one electric cycle.

Fig. 2: FEMM model showing 5 teeth considered for analysis.

Table I

Elec
angle in Angle in Flux linkage
Degree radian (Wb) emf (V)
0 0 -2.93024E-05 0
10 0.174533 -0.000028929 -2.13942E-06
20 0.349066 -2.77379E-05 -6.8245E-06
30 0.523599 -2.54086E-05 -1.33459E-05
40 0.698132 -2.21409E-05 -1.87225E-05
50 0.872665 -1.80677E-05 -2.33377E-05
60 1.047198 -1.36503E-05 -2.53098E-05
70 1.22173 -9.13675E-06 -2.58607E-05
80 1.396263 -4.58799E-06 -2.60625E-05
90 1.570796 0 -2.62872E-05
Fig. 3: Flux linkage of single turn and corresponding emf for 1 rad/s estimated from FEMM. The calculated
value is also shown which is in good agreement with FEM value.

Part: II

4. Development of optimal 3 phase winding scheme:

The winding scheme can be formulated by first understanding the emf vector of each coil. For this, angle is
parameterized for 50 step with the help of Lua script available in FEMM software. The flux linkage of the
coils wound around teeth 1, 2, and 3 (shown in Fig. 2) are found at each 5 degree step. Fig. 4 shows the flux
linkages of three coils with single turn and Fig. 5 shows the corresponding induced emf for 1 rad/s. It is
clear that. the phase angle of three emf’s are different. The angles of the remaining coils can be found with
the knowledge of angles of these three coils. Table II shows angle of each emf vector. Fig. 6 shows the
vector diagram of emf’s of all coils.
Table II
Coil
no# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Angle 180 340 140 300 100 260 60 220 20 180 340 140 300 100 260 60 220 20
 Fig. 4: Flux linkage of coil wound around teeth 1, 2, and 3 for a turn.

Fig. 5: Induced emf in single turn coil wound around teeth 1, 2, and 3 at 1 rad/s.
 Fig. 6: emf vectors of all coils.

Once emf vectors of all coils are available, they can be added to form a balanced three phase with high
winding factor. In this design, the best two winding schemes (Scheme 1 and 2), are analyzed. Fig. 7 shows
the vector diagram for scheme 1 and Fig. 8 shows that of scheme 2. In scheme 2, coils, 1, 10, 7, 16, 4 and 13
are inverted. The physical meaning of the inversion here is the corresponding coils should be wound in anti-
clock wise direction compared to other coils. Table III presents the winding factor for each schemes and it
is shown that scheme 2 has highest winding factor, hence it is chosen for the design. Fig. 9 shows the
stator diagram with the winding scheme 2.

Fig. 7: Vector diagram for winding scheme 1.

Fig. 8: Vector diagram for winding scheme 2.

Table: III
Winding Schemes
Scheme I Scheme II
Coil No# Angle Coil No# Angle
17 220 18 20
1 180 1 180
3 140 2 340
8 220 9 20
10 180 10 180
12 140 11 340

Distribution
factor 0.8444 0.95979
 Fig. 8: Final winding (Scheme 2).

5. Estimation of phase emf (OCV) and speed scaling:

Once the coil connections to form a three phase balanced winding is established, the emf of each phase can
be found by taking vector sum of corresponding coil emf’s. Fig. 10 shows the per phase flux linkage and
emf, and speed scaled value of emf for a single turn.
Fig. 10: (a) Per phase flux linkage for single turn coils, (b) Per phase emf for single turn coils at 1 rad/s, (c)
Per phase emf for single turn coils at 3000 rpm.
 6. Estimation of number of turns to get required OCV:
The value of emf in Fig. 10 (c) is scaled with number of turns and it is found that 30 turns are required per
phase to get 14.42 Vl-l open circuit voltage. The next possible number of turns by considering equal number
of turns in each coil is 36 which give line-line voltage 17.3 V, which is on higher side. So, number 30 is
chosen. The number of turns per coil is 5. Fig. 11 shows the phase voltage for 30 turns.

Fig. 11: Phase voltage for 30 turns.

7. Estimation inductance of a coil:

FEMM software is used to estimate inductance of a coil with 5 turns. With the knowledge of this value, the
per phase inductance can be found by using appropriate scaling. The mutual coupling of phases is studied.
Fig. 12 shows the flux plot while three coils of a phase are excited together. It is clear that; negligible
amount of flux is only linking with the coils in other phases. Fig. 13 shows the flux linkage vs current of a
! "
coil. The estimated value of inductance for each coil is × H. Phase inductance is . × H.
8. Calculation of resistance:
First, single turn resistance is calculated for active length of 6.9mmm and overhang radius of 4mm. The area
available for a conductor in slot is found by considering fill factor 0.3. From the area, the wire diameter is
decided. The conductor size SWG 19 (1 mm diameter) is chosen. The resistance value of single turn is 0.85
mΩ. The phase resistance for 30 turns is 25.5 mΩ. The current density of a conductor is . " #/%% ,
which is in the safer limit.
9. Optimization of number of turns:
Number of turns per phase is varied to find optimum turns which satisfy voltage regulation (10%). The
number of turns is varied in steps of 6, so that each coil in a phase gets equal number of turns. Table IV
shows the phase values of open circuit rms voltage, resistance, inductance, rms phase current and rms load
voltage, 3 phase load, and rms line to line voltage across load. It is shown from the table that, number of
turns per phase considered in earlier section to meet open circuit voltage requirement is optimal. The line-
line voltage is 14.37 V. Hence, the voltage regulation achieved is 0.2%. Fig. 14 shows the line-line terminal
voltage and phase current vs load.

Fig. 12: Flux plot while exciting three coils of a phase together to understand phase coupling.

Fig. 13: Single turn coil flux and inductance for various current.
 Table IV
Line- line
No of Phase rms
turns Open circuit Phase Phase Phase voltage voltage
per voltage per resistance inductance current across load 3 Phase across
phase phase rms (V) (Ohm) (H) rms (A) rms (V) load (W) load (V)
6 1.67E+00 5.10E-03 4.80E-08 2.28E-01 1.66E+00 1.14E+00 2.8823
12 3.33E+00 1.02E-02 1.92E-07 4.56E-01 3.33E+00 4.55E+00 5.7605
18 5.00E+00 1.53E-02 4.32E-07 6.84E-01 4.99E+00 1.02E+01 8.6347
24 6.66E+00 2.04E-02 7.68E-07 9.11E-01 6.64E+00 1.82E+01 11.5049
30 8.33E+00 2.55E-02 1.20E-06 1.14E+00 8.30E+00 2.83E+01 14.3711
36 9.99E+00 3.06E-02 1.73E-06 1.36E+00 9.95E+00 4.07E+01 17.2333

Fig. 14: Terminal line voltage vs load.

 10. Design output:
Number of turns per phase 30
Conductor diameter SWG 19, 1 mm
Current density 1.36 A/mm+
Phase resistance 25.5 mΩ
Phase inductance -
1.2 × 10 H
Open circuit voltage (line-line) 14.4 V
Line-line terminal voltage at full load 14.37 V
Load regulation 0.2%

11.Conclusion:

The optimal number of turns and conductor diameter are chosen for the rare earth magnet, three phase
generator of given dimensions. The design meets all the requirements with superior load regulation.