WP3 – Development of innovative solutions for electrical generators

//WP3 – Development of innovative solutions for electrical generators
WP3 – Development of innovative solutions for electrical generators 2017-05-29T07:17:11+00:00

Main Objective:

To design an innovative and low cost wind generator (between 1 and 100 kW) which could be adapted to different types of wind turbines deployments depending on its final emplacement. Two configurations of permanent magnet generator will be developed, one for direct drive connection and a second one for a gearbox connection.

SWIP will develop magnets with low content of Neodymium and RE free, maintaining the performance that market magnets nowadays have.

Furthermore, a magnetic gearbox capable to transfer kinetic energy between a low and high speed shafts without any physical contact between them will be designed. The magnetic gearbox must have a higher efficiency and lower costs than conventional mechanic and/or magnetic gear boxes.

The performance of the entire wind turbine system will be improved:

  • Reducing generator cost by a factor of 10
  • Maintenance cost and improving its reliability.


Specific objectives:

· To reduce production and maintenance costs of electrical generators.

· To select and optimise the final design of the PM generator by using 2D and 3D FEM studies from different preliminary designs in order to optimise stator topologies for permanent magnet machine, which minimize the peak values of cogging torque allowing lower cut-in wind speeds and optimize the efficiency.

· To reduce costs of the generator assembly. The generator design proposed will be modular and a new assembly technique for inserting the electrical coils in the stator slots will be developed.

· To develop a post-assembly magnetizing technique in order to reduce costs of the generator assembly.

· To design, simulate and construct a prototype-lab of a magnetic gearbox, using finite element methods (FEM) and RSCAD.

· To develop a high-coercivity Nd2Fe14B-based material with zero or drastically-reduced heavy-rare-earth content (Dy or Tb). By using sophisticated methods of microstructure modification, the need of using HREs for Nd-Fe-B magnets production will be reduced or completely eliminated without to affect the magnet characteristics (e.g. hysteresis) at high operating temperatures.

· To develop of oriented, dense magnets with intermediate properties that can fill the gap between sintered ferrite and sintered Nd-Fe-B magnets. Such new material combining a suitable coercivity Hc, Curie temperature (TC) and remanence magnetisation (Br), has a huge potential to be widely used in different commercial applications and is highly needed on the market. A new appropriate magnetic material has been sought by scientists for years, as all currently known materials meet only two of the three requirements.

· To construct prototypes of the generators and the magnetic gearbox.