Design and Modeling of Low-Speed Axial Flux Permanent

Magnet Generator for Wind Based Micro-Generation

Systems
Daniyal Ahmed*, Fazal Karim** and Aftab Ahmad**
*Centres of Excellence in Science & Applied Technologies (CESAT),
H-11/4, Islamabad, Pakistan
daniyal.ahmed@uettaxila.edu.pk
**Department of Electrical Engineering, University of Engineering & Technology,
Taxila, Punjab Province, Pakistan
karim.npcc@yahoo.com
aftab.ahmad@uettaxila.edu.pk
Abstract - Pakistan is currently hit by severe energy crisis. In
both its urban and rural areas, the shortfall of electricity is so
intense that it can cause power shut-down for as long as ten
hours a day. In order to cope with this situation, harnessing
renewable energy resources is crucial. Therefore, in this work
an efficient, low-speed gearless wind based micro-generation
system is proposed. Such a system can exploit wind energy in
urban and rural parts of the country and can convert it to
electrical energy to meet daily domestic energy requirements. A
1.5 kW low speed direct driven axial flux permanent magnet
(AFPM) generator is designed for this system using analytical
techniques. The generator comprises of modular structure
having non-ferromagnetic core and offers special features as
light weight, low wind speed operation capability and low
maintenance cost. Such features make it superior to the
available types of energy systems such as those utilizing
Induction Generators (IG) and Synchronous Generators (SG).
The design is implemented using dynamic modeling in
MATLAB (Simulink) and validated through performance
comparison with available state-of-the-art wind energy system
models.

Index Terms Axial flux permanent magnet (AFPM), building
augmented wind turbine (BAWT), coreless, direct-driven, micro-
generation.

I. INTRODUCTION
The high dependability on oil and other fossil fuels by
South Asian countries has developed a severe energy crisis in
the region, especially Pakistan. The share of furnace oil and
gas in total derated capacity of Pakistan is about 65 percent
according to figures obtained from department of National
Power Control Centre, Islamabad. Keeping in view the scarce
indigenous fossil fuel resources, Pakistan needs to harness its
abundant alternate energy resources like wind, solar, hydel and
their hybrid forms [1]. The total wind power potential of the
country is 346 GW. In order to exploit this potential, Govt. of
Pakistan is working on installing large-scale wind generation
systems in different areas of Sindh [2].
Renewable energy based small-scale or micro-generation
systems are being utilized in different countries for electricity
production such as building mounted wind turbine systems,
solar panels and mini hydro-generation plants [3]. In urban and
rural areas of Pakistan, solar and hydel energy based micro-
generation systems are being utilized to overcome the shortfall
of electricity however electricity production using wind-based
micro-generation systems is still in its early stages. Therefore
the main focus of this research work is on wind based micro-
generation systems.
Extensive work has been carried out in this area worldwide
especially in Europe where different projects of small scale
wind generation have been installed on buildings [4-5].
Different types of wind turbines currently being used in urban
environment are ducted wind turbines [6] and building
augmented wind turbines (BAWT) [7]. Populated urban areas
generally have lower wind speeds as compared to those of
open areas. However, it has been analyzed in Ref. [7] that in
urban areas, the concentration effect of buildings and
corresponding wind flows can increase the wind speed locally,
resulting in increased energy yield in comparison to open
areas. In [8], the authors have analyzed that the optimal value
of energy production depends upon the installation point of
the wind turbines in buildings. This is due to the fact that the
distance between buildings significantly alters the highest
wind speed occurrence position. There is no significant
change in maximum value of wind speed in-between the
buildings with change in height; however on roof tops, this
value increases with increase in height.
Performance of wind based generation system mainly
depends upon the type of generator coupled with wind turbine
to generate electrical energy [9]. Therefore extensive work has
been done so far in the field of generator design for such
51
2014 International Conference on Robotics and
Emerging Allied Technologies in Engineering (iCREATE)
Islamabad, Pakistan, April 22-24, 2014
978-1-4799-5132-1/14/$31.00 2014 IEEE

systems. The type of generator being used in the system
varies depending upon the system power ratings, air dynamics
and the location where it is to be installed like open area or
urban environment. Most common type of generators used in
large scale wind based generation systems installed in open
area, are induction generators (IG), doubly fed induction
generators (DFIG), electrically excited synchronous generators
(EESG) and permanent magnet synchronous generators
(PMSG) [9-11]. Features of these machines like fixed speed
operation (in case of IG) and partially variable speed (in case of
DFIG), low efficiency at lower wind speed and high weight due
to gear system restrict usage usually to larger wind farms
installed at open areas [12]. The issue of fixed speed has been
addressed in EESG but most attractive generator currently
being used for wind based generation systems is PMSG. This
generator can be used both for small scale and large scale
generation systems [13-17]. Its wide area of applications
include battery charging applications, human power
applications, marine current generation system, portable hand
crank generating system, induction heating and defense usage
[18-23]. PMSGs are further categorized into axial flux permanent
magnet (AFPM) and radial flux permanent magnet (RFPM)
generators. AFPM generator has an advantage over RFPM
generator in terms of power density, low speed efficiency and
volume [9]. Therefore, this paper presents the design and
modeling of 1.5kW low-speed direct-driven AFPM generator
with modular structure having non-ferromagnetic cores for
application to wind based micro-generation systems. Fig. 1
shows configuration of the proposed BAWT system prepared
using Trimble SketchUp software [24]. The design/model is
validated through performance comparison with micro-
generation systems incorporating IG, DFIG and EESG. The
comparison is carried out through simulations using the
software MATLAB (Simulink) [25].
Fig. 1 Proposed Wind Based Micro-Generat ion Syst em for buildings;
1 BAWT, 2 Shaft direct ly coupled t o BAWT, 3 Designed AFPM
Generat or, 4 Generat or 3-phase Out put , 5 AC/ DC Power Elect ronic
Convert er, 6 DC feed t o Bat t ery Bank, 7 Bat t ery Bank (Energy
St orage).
II. GENERATOR DESIGN
A. Topology
In literature, the AFPM generator is categorized under
different topologies based on its design. On the basis of its
rotor/stator configuration, it is categorized as single/dual-
stator and single/dual-rotor based single-stage or multi-stage
(two or more modules) generator. It is further categorized as
coreless or cored and slot-less or slotted generator depending
on its material.
The designed generator in this proposed research
consists of a three-staged structure. The structure of each
stage or module consists of single-rotor in-between twin-
stators. The two stators in each stage have identical structure
and are electrically connected in series. Furthermore, the three
stages are then electrically connected in parallel increasing the
overall electrical power output of the generator. Both the twin-
stators and the single-rotor in each stage have non-
ferromagnetic cores. The stators which are stationary part of
the generator are fixed with the frame whereas the rotors that
constitute the rotating part are attached to the shaft of the
generator. Fig. 2 shows the 2D model of this design topology.
The non-ferromagnetic three-staged structure reduces losses,
stator/rotor axial attractive forces, cogging torque and the
overall weight of the generator. Hence this design results in
increased wind energy utilization and efficiency.
Fig. 2 Designed AFPM Generat or 2D Model; 1 Dot t ed envelop
showing Single St age/Module, 2 Twin-St at ors, 3 Single-Rot or, 4
Shaft ,
5 Bearing, 6 Frame.
B. Rotor and Stator Design
The stator core consists of non-ferromagnetic material
(resin) in which the stator coil is embedded. This coil consists
of 3-phase dual-layered toroidal winding. The rotor placed in-
between the dual stators in each stage consists of circular non-
ferromagnetic material (aluminium) based disc supporting the
neodymium permanent magnets (sintered NdFeB with 0% Co
having magnetic strength of 40 MGOe).
The neodymium magnets on the rotor are arranged in such
a way that the magnetic field vector of each piece makes an
1
2
3
4
5
6
1
2
4
3
5 7
Inside View (Nacelle)
Building Rooft op
6 6
52

angle of 90 with its neighboring pieces. This arrangement of
magnets, called the Halbach Array [26], increases the magnetic
flux density in the air-gap between the stator and rotor in
comparison to the basic arrangement of magnets in typical
permanent magnet machines where this angle is 0. The
increase in density is because the flux lines of each magnet
reinforce each other in the air-gap whereas they cancel out
each others effect on the side where the non-ferromagnetic
core is present. This arrangement has been verified with the
help of finite element analysis techniques by designing a part
of the rotor in the Finite Element Method magnetic (FEMM)
software [27] as shown in Fig. 3 and Fig. 4. The peak value of
magnetic flux density in the air-gap depends on characteristics
of the permanent magnets and increases exponentially with the
increase in height of the magnets.
Fig. 3 Flux Dist ribut ion & Densit y Plot of NdFeB Magnet s wit h 0 angle
bet ween flux-lines of adjacent pieces.

Fig. 4 Flux Dist ribut ion & Densit y Plot of NdFeB Magnet s wit h 90
angle bet ween flux-lines of adjacent pieces.
C. Design Equations
The peak value of flux density Bpeak in the air-gap as a
result of the arrangement of magnets mentioned above is:
( )
62.83
0.9 1
magnet
h
peak rem
-
= B B e . (1)
In (1), hmagnet is axial height of the magnets and Brem is the
remanent magnetic flux density. The electro-motive force Einduce
induced in a single side of the dual-stator is:
0.4467
induce pair magnet turn elec
p | e = E N . (2)
In (2), ppair is the pole-pair number of a single stage, |magnet
is the flux, Nturn is the coil-turns per phase per stator side
and eelec is the angular-speed in electrical degrees. The electro-
magnetic torque Telec and power Selec of a single stage of the
generator is:
0.679
elec p pair magnet turn p
n p | = T N I . (3)
(2 )
elec p induce p
n = S E I . (4)
In (3) and (4), Ip is phase current in the winding of the
single-stage stator and np is phase number. The sizing
equations to calculate diameter of the generator are:
1
3
1,
,
1.204
stage nom
o
rpm nom peak
e
| |
= |
|

\ .
P
D
B
. (5)
0.577
i o
= D D . (6)
In (5) and (6), Do is the outer diameter, Di is the inner
diameter of the generator, Pstage1,nom is the nominal output power
of a single stage and erpm,nom is the nominal mechanical speed
of the generator.
D. Design Parameters
The parameters of single stage of the designed
1.5kW AFPM generator have been shown in Table I.
TABLE I
DESIGN PARAMETERS OF 1.5KWAFPMGENERATOR (SINGLE STAGE)
Paramet er Value Unit
Nominal power out put 0.5 kW
Nominal mechanical speed of rot or
25 rpm
2.618 rad/sec
Nominal line volt age (st ar connect ion) 435 V
Phase number 3 -
Resist ance of st at or 0.01 m
Induct ance of st at or 1.2 mH
Pole pairs number 120 -
Pole pit ch 0.05 m
Dimensions of permanent magnet s
Axial height 0.0254 m
Axial widt h 0.0191 m
Axial lengt h 0.0191 m
Peak flux densit y in air gap
(calculat ed analyt ically and from
FEMM)
1.041 T
Dimensions of Generat or
Out er diamet er 0.285 m
Inner diamet er 0.165 m
Average diamet er 0.225 m
Elect romot ive force (EMF) const ant 0.302 V.sec
Moment of inert ia 0.387 Kg.m
2
III. PROPOSED SYSTEM MODEL
The complete wind based micro-generation system for a
building, already shown in Fig. 1, consists of the designed
1.5kW AFPM generator directly coupled to the BAWT without
any gearbox using a simple shaft. The output of the generator
is converted to DC via AC/DC power electronic converter and
then stored in a battery bank of the building. The mathematical
models of the BAWT, its drive-train and the designed AFPM
generator have been presented. The scope of this research
work is the designing and modeling of 1.5 kW AFPM generator
for BAWT only, therefore, the modeling of AC/DC converter
has not been covered.
Magnet ic Flux Vect or Orient at ion
(shown by arrows)
Magnet ic Flux Vect or Orient at ion
(shown by arrows)
53

A. BAWT
The site selected for the design and modeling of BAWT in
Pakistan is Karachi that has a number of tall buildings where
this micro-generation system can be installed. Moreover, the
average wind speed available in Karachi is quite suitable for
small-scale wind turbines. For validation of the designed
system, 12 m/sec, 10 m/sec, 7 m/sec and 4 m/sec wind speeds
have been selected as input to the system models. The BAWT
chosen for the designed system is a three-bladed horizontal-
axis wind turbine. The output mechanical power Po,turbine and
output torque To,turbine of the BAWT being extracted from the
wind Vw upstream to the blades is:
2 3
, ,
1
2 4
o turbine b turbine karachi p w
P D C V
t
= . (7)
,
,
o turbine
o turbine
turbine
P
T
e
= . (8)
In (7) and (8), Db,turbine is diameter of the turbine blades,
karachi is air density at Karachi site, Cp is performance
coefficient and eturbine is rotating speed of BAWT. The
maximum value of Cp which can be obtained theoretically is
0.59 [28]. The air density at Karachi site can be calculated
using:
-4
0
1.194 10 ( )
karachi karachi building
E E = + . (9)
In (9), o is the sea level air density (1.225 kg.m
-3
), Ekarachi
and Ebuilding are the elevation of Karachi site and building
rooftop from sea level. For variable-speed wind turbines, Cp
depends on pitch angle oo and tip speed ratio , of the blades.
Cp according to variable-speed turbine characteristics of [29],
can be calculated as:
18.4
2.2
0 0
110
0.4 0.002 9.6
i
p
i
C e
,
o o
,

| |
|
|
\ .
= . (10)
In (10),
3
0 0
1
1 0.03
0.02 1
i
,
, o o
=

+ +
| |
|
\ .
and
,
2
turbine b turbine
w
D
V
e
,
-
=

.
Equations (7) to (10) have been implemented in MATLAB
(Simulink) to develop the model shown in Fig. 5.

Fig. 5 BAWT (1.5kW) Model.
The design parameters of 1.5kW BAWT are given in Table
II.
TABLE II
PARAMETERS OF 1.5 KWBAWT
Paramet er Value Unit
Nominal power out put 1.5 kW
Nominal wind speed 12 m/sec
Diamet er of t urbine blades 4 m
Sit e (Karachi) air densit y 1.2094 Kg/m
3
Sit e (Karachi) elevat ion 11 m
Height of building 120 m
B. Drive Train
The drive train model represents the transfer of wind
energy extracted by the blades of the turbine to the generator
in the form of torque and speed. A single-mass drive system
has been used to model the BAWT micro-generation system in
MATLAB (Simulink) as shown in Fig. 6.

Fig. 6 Drive-Train Model.
The dynamic equation used to implement the drive-train in
Simulink is:
, ,
=
gen
s em gen o turbine s gen
d
T T F
dt
e
e J . (11)
In (11), Js is the moment of inertia of the BAWT including
the AFPM generator, Fs is the friction factor of the complete
system, Tem,gen is the electromagnetic generator torque and egen
is the mechanical rotational speed of the drive train. The
friction factor of the system is close to zero since there is no
use of gear-box in the system. The lumped mechanical
parameters of the complete system are shown in Table III. The
mechanical parameters for the designed BAWT have been
analytically calculated using the variable-speed turbine
characteristics of [29] and [30].
TABLE III
DRIVE TRAIN PARAMETERS
Paramet er Value Unit
Moment of inert ia of BAWT including
AFPM generat or (lumped)
10.176+0.38
7
Kg.m
2
Frict ion fact or of BAWT including
AFPM generat or (lumped)
0.001 N.m.sec
C. 1.5kW AFPM Generator
The dynamic model of the designed 1.5kW AFPM
generator consists of three identical sub-models each
representing a single stage connected in parallel. The model
has been implemented by transforming the three-phase system
to synchronous or direct-quadrature-zero (dq0) reference frame
system using Parks transformation [31] as follows:
0 dq s abc
k = v v . (12)
54

2 2
3 3
2 2 2
where,
3 3 3
1 1 1
2 2 2
elec elec elec
s elec elec elec
k
t t
u u u
t t
u u u
( | | | |
+
| | (
\ . \ .
(
(
| | | |
= +
( | |
\ . \ .
(
(
(

Cos Cos Cos
Sin Sin Sin
,
and,
elec elec
dt u e =
}
.
In (12), elec is the electrical angular displacement of the
generator. Since the designed AFPM generator is electrically
balanced, therefore, the zero-sequence quantities can be
ignored. Moreover, EMF induced in d-axis of the dual-stator is
zero since d-axis is always aligned with permanent magnet flux
position. Hence, the dq-axis equations of a single stage of the
generator implemented in MATLAB (Simulink), as shown in
Fig. 7, in simplified formare:
1 1
L L
1
L
q
s
E elec q elec d q
s s s
d s
d elec q d
s s
d
dt
d
dt
e e
e
=
=
i
R
K i i v
L
i R
i i v
L
. (13)
In (13), udq and idq are the dq-axis voltages and currents,
KE is the EMF constant, Rs is stator resistance and Ls is the
stator inductance of a single stage of the designed generator.
In addition to the above, the electromagnetic generator torque
Tem,gen has been implemented in MATLAB (Simulink), as shown
in Fig.7, using the following equation:
,
0.453
em gen pair q
T p i = . (14)
The design parameters of single-stage of the designed
AFPM generator have been given already in Table I.
IV. RESULTS AND DISCUSSION
In this section, simulation results and performance of t he
designed 1.5kW low-speed direct-driven AFPM generator
directly coupled to the BAWT under different wind speeds
have been shown using MATLAB (Simulink). The designed
system dynamic model has been compared with similar 1.5kW
BAWT systems utilizing available state-of-the-art generators.
These generators include IG, DFIG and EESG whose standard
models, available at [25] have been used for simulation work.
The results reported in this work include comparison of the
simulated output active and reactive power, angular
mechanical speed, performance factor and efficiency of these
standard generators with the designed AFPM generator. The
studies are carried out under similar operating conditions using
the same 1.5kW BAWT.
Fig. 7 Elect rical model of single-st age AFPM generat or.
A. Designed Generator Performance in BAWT
The designed generator has a nominal speed of 25rpm
(2.618 rad/sec) as mentioned in Table 1 which makes it highly
suitable for locations where wind speed is comparatively low
such as rooftops of buildings. The simulation results of the
generator mechanical speed and active power have been
recorded and shown in Fig. 8 and Fig. 9. The wind speed in
these simulations has been varied from a peak value of 12m/sec
to a value of 4 m/sec.
B. Designed Generator Performance Comparison
The results of performance comparison of the designed
generator with standard generator models with respect to
changing wind speeds have been shown in Fig. 10 to Fig. 13.
Percentage performance factor Pfactor (efficiency) of each
generator, as shown in Fig. 13, has been defined as follows:
100
actual
factor
nom
P
P
P
= . (15)
In (15), Pactual and Pnom are the actual and nominal output
powers of a generator at a given wind speed. Pnom for all the
generators under study is 1.5kW.
The maximum efficiency of each generator under rated
operating conditions has been shown in Table IV. In this table,
the efficiency of coreless-stator AFPM generator with iron-
cored-rotor, designed by R. J. Wang et. al in [32], has also been
mentioned for the purpose of validation of the proposed
design.
55

Fig. 8 Mechanical rot at ional speed under variable wind speeds.
Fig. 9 Act ive power delivered under variable wind speeds.
Fig. 10 Mechanical rot at ional speed Vs Wind speed.
Fig. 11 Act ive power Vs Wind speed.
Fig. 12 React ive power Vs Wind speed.
Fig. 13 Performance fact or Vs Wind speed.
TABLE IV
GENERATOR EFFICIENCIES UNDER RATER OPERATING CONDITIONS
Generat or Operat ing Speed
Efficiency
(%)
Proposed coreless low-speed
direct -driven AFPM generat or
Variable 96.0
Coreless-st at or AFPM
generat or proposed in Ref. [32]
Variable 95.7
EESG Variable 73.67
DFIG
Part ially
variable
70.8
IG Fixed 61.48
From the results shown in Fig. 10 to Fig. 13 and in
Table IV, it can be seen that at any wind speed the designed
AFPM generator is operating at a very low angular speed with
negligible losses, highest wind power utilization, maximum
efficiency and no reactive power requirements from the
buildings power system to which it is being connected. In
addition to the above, the designed generator also has
coreless stator and rotor with gearless wind turbine operation
making it the lightest generator among all under study.
V. CONCLUSION
In this research work, the design of low-speed three-
staged direct-driven coreless AFPM generator based BAWT
micro-generation system is proposed. The simulated results
after comparison of the designed AFPM generator BAWT
model with existing state-of-the-art generators based BWAT
models prove that the designed generator has a very low
angular speed with negligible losses, highest wind power
utilization, maximum efficiency at all wind speeds, no reactive
power consumption, coreless structure, gearless operation and
lighter weight making the designed AFPM generator, the most
Vw: 12 m/sec
Vw: 10 m/sec
Vw: 7 m/sec
Vw: 4 m/sec
Vw: 12 m/sec
Vw: 7 m/sec
Vw: 4 m/sec
Vw: 10 m/sec
56

suitable and highly feasible generator for small-scale wind
energy conversion systems, especially BAWT based micro-
generation systems.
ACKNOWLEDGMENT
The authors thank Mr. Rizwan Masood for his valued
contribution in preparation of this manuscript.
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