Measurement 69 (2015) 8794

Contents lists available at ScienceDirect

Measurement
journal homepage: www.elsevier.com/locate/measurement

A new axial ux permanent magnet synchronous alternator

autonomously adapted to wind speeds
_
Osman Kalender a,, Yavuz Ege b, mer Eskidere a, Idris
Karen c, Osman Grdal a, Cevat nal a,
a
d
e
Emrah Yrkl , Sedat Nazlbilek , Hakan tak , Mustafa oramk b, Murat Kabaday b
a

Bursa Orhangazi University, Department of ElectricalElectronics Engineering, 16350 Bursa, Turkey

Balikesir University, Necatibey Faculty of Education, Department of Physics, 10100 Balikesir, Turkey
c
Bursa Orhangazi University, Department of Mechanical Engineering, 16350 Bursa, Turkey
d
Atilim University, Faculty of Engineering, Department of Mechatronics Engineering, 06830 Ankara, Turkey
e
Balikesir University, Balikesir Vocational High School, 10100 Balikesir, Turkey
b

a r t i c l e

i n f o

Article history:
Received 12 November 2014
Received in revised form 7 January 2015
Accepted 10 March 2015
Available online 27 March 2015
Keywords:
Renewable energy
Axial ux synchronous alternator
Permanent magnet
Finite element analysis
Power
Efciency

a b s t r a c t
In this study, a new axial ux permanent magnet synchronous generator (PMSA) design
and prototyping procedures are presented. It is composed of a stack of rotorstator blocks
on the same shaft. In other words, it is made up of four alternators based on axial ux permanent magnets that can generate electrical energy within the limits of rotor rotational
speed with varying wind speeds. A control system is also introduced to the generator.
The control system connects or disconnects the stator blocks to the load according to
the changing speeds of the wind. It produces electrical energy with stable voltage, frequency and variable power at the output. The efciency of the generator is tested with different load and speed conditions. It is observed that the efciency is high when the speed is
low in case the load is connected only one stator. The efciency is high when the speed is
above 200 rpm for the case where several stators are connected to the load. It can be seen
that the incremental structure of the generator is suitable for changing speeds of the wind.
It can have high efciency for both low and high speeds with changing the number of stator
blocks connected to the load.
2015 Elsevier Ltd. All rights reserved.

1. Introduction
In this study, a new axial ux permanent magnet synchronous generator (PMSA) design and prototyping procedures are presented. It is composed of a stack of rotor
stator blocks on the same shaft. In other words, it is made
Corresponding author. Tel.: +90 533 317 9579.
E-mail addresses: osman.kalender@bou.edu.tr (O. Kalender),
yavuzege@gmail.com (Y. Ege), omer.eskidere@bou.edu.tr (. Eskidere),
_ Karen), osman.gurdal@bou.edu.tr (O. Grdal),
idris.karen@bou.edu.tr (I.
cevat.unal@bou.edu.tr (C. nal), emrah.yuruklu@bou.edu.tr (E. Yrkl),
snazlibilek@atilim.edu.tr (S. Nazlbilek), hcitak@balikesir.edu.tr (H. tak),
mustafacoramik@hotmail.com (M. oramk), kabadayi_murat89@
hotmail.com (M. Kabaday).
http://dx.doi.org/10.1016/j.measurement.2015.03.013
0263-2241/ 2015 Elsevier Ltd. All rights reserved.

up of four alternators based on axial ux permanent magnets that can generate electrical energy within the limits of
rotor rotational speed with varying wind speeds. The main
problem in producing electrical energy from the wind is
that the wind speed is changing frequently. This in turn
brings difculties in obtaining a constant power, voltage
and frequency at the output of the generator. Normally, a
gear box follows the generator to regulate them even
though the wind speed changes. Since the gear box is a
mechanical device, it gives rise to loss of a lot of power
and reduces the efciency of the generator. In addition,
the gear box is bulky equipment and increases the volume
and weight of the generator system. The main aim of our
study is to eliminate the gear box from the generator

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O. Kalender et al. / Measurement 69 (2015) 8794

Fig. 1. Slotted alternator structure developed in this study.

system and increase the efciency of the generator

together with reducing the volume and the weight of the
overall system. We replace the gear box with an electronic
unit. We introduce a new approach to regulate the
power, voltage and the frequency of the output by means

of electronic control of alternator blocks autonomously.

Our approach is such that each of the synchronous alternators consists of a rotor with permanent magnets on it and a
stator with windings. All the rotors of the alternators are
mounted on the same shaft. Hence, all the rotors rotate
with the same speed and induce voltages across the coils
of the stators. The voltage of the rst alternator is selected
as the reference voltage. When this voltage reaches the target value, this alternator output is connected to the load.
When the reference voltage decreases below the desired
level, it is removed from the load. Based on the increase
(decrease) in the reference voltage, second, third and
fourth alternators are connected (disconnected) to the
load. Hence, a block of alternators are obtained that can
operate with varying wind speeds. This structure can give
an opportunity to be operated with varying wind speeds
without any gear boxes and big losses in power and can
produce energy with high efciency compared to traditional wind turbines. Unlike the traditional high power
systems, it is possible to produce electric energy for the
wind speeds of 23 m/s by means of our system. For

Fig. 2. The behavior of the magnetic ux of the permanent magnets by use of the AnsysMaxwell simulation software.

O. Kalender et al. / Measurement 69 (2015) 8794

89

Fig. 3. Magnets on a compact laminate plate.

excessive wind speeds, slots of alternators are externally

loaded or made short-circuits, the system can be damped
or broken. The structure of the designed generator is
shown in Fig. 1.
Axial Flux Permanent Magnet Synchronous Alternators
are widely used in wind turbines in recent years because
of their simple structures and low costs. They can be operated at different powers and speeds. They do not need any
gear boxes. Several different structures may be used in the
design of the PMSAs. In some designs, single rotor and stator are used. In others, a single rotor is placed between
double stators or two rotors are mounted at both sides of
double sided stators. There are a lot of studies on the
geometric structure, number of poles and phases, and
materials used in the construction [122]. Also, studies
can be found on mechanical stress resulting from the
electromagnetic attraction between rotor and stator [21],
low power [23], and thermal analysis [24]. There are applications such as vertical and horizontal wind turbines, and
hybrid electric vehicles [2527], and micro-scale
generators with output powers of 2.5 W and 8 W, and
open-circuit output voltages of 3.3 V [2830]. The system
described in [31] has stator windings in stages and incrementally increased or decreased to satisfy different power
requirements. A design and modeling procedure are
described in [32]. A structural analysis is explained in
[33]. In [34], again a high speed and with low harmonics
PMSA design procedures are explained. An analytical

method for the calculation of inductance is developed

[35]. Some design procedures and performance analysis
methods are explained in the studies in [3548].
In this study, we did not aim to produce different
powers. We aimed to design a generator structure that
utilize the wind speeds effectively and eliminate bulky
gear boxes and external brake systems in high efciency
and cost effective manner.
In this study, AnsysMaxwell software was used to
determine most suitable magnet lengths and power levels.
Based on the simulation results, we developed a prototype
system. We also developed an electronic control system.
During the experiments, we used an external electric
motor to simulate the wind speeds. The alternator performance was tested for different wind speeds.
2. Material and method
The behavior of the magnetic ux of the permanent
magnets is determined by use of the AnsysMaxwell simulation software (Fig. 2). The required magnet lengths and
attraction forces are determined from the simulation
results.
The most suitable magnet dimensions are determined
to be 5  5 cm. These magnets are located on a compact
laminate having a diameter of 30 cm as seen in Fig. 3.
Then this structure is covered by a mix of ber glass and
polyester.

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O. Kalender et al. / Measurement 69 (2015) 8794

Fig. 4. Placement of coils and a block of alternator.

Next, 12 rectangular coils with 50 windings are placed

between two 30 cm compact laminates as seen in
Fig. 4a and b. Then the discs are xed as shown in
Fig. 4d. The rotors are placed between the stators.

The parameters of the generator designed, analyzed and

manufactured as a prototype are given in Table 1.
A 3-phase synchronous motor is connected to the shaft
of the generator and the motor is excited by the motion

Fig. 5. The prototype permanent magnet generator and control diagram.

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O. Kalender et al. / Measurement 69 (2015) 8794

control system of SIEMENS SINAMICS V20. Hence the rotor

can be rotated with the desired speed. In Fig. 5, the axial
ux synchronous generator developed in this study and
the control ow diagram are seen.
The motor used has a self induction coefcient of
L = 0.1888 H and a resistance of R = 79.074 X. An increase
in rotational speed of the excitation motor will
increase its total impedance and hence the power factor
will change in decreasing direction. The power factor in
our study is

1.00

0.98
0.97
0.96
0.95
0.94
700

It is plotted in Fig. 6. Then the reactive power can be

determined based on the rotation speed. The total power
of the motor is determined by the active power that is
measured by an electric counter and the reactive power
together. Hence the efciency can be determined.
Blocks of alternators in the electronic part of the
generator, the outputs of the alternator blocks are rectied
and connected to the load circuit. The switching action is
performed by the electronic control unit. The breaking
action by short-circuiting the outputs of the blocks is
achieved by this unit as well. Control unit is a PIC controlled circuit. The block diagram of the electronic unit is
given in Fig. 7.
As seen from Fig. 7, each group of stator coil outputs is
rectied and the voltage value is read by the DAQ card.
When the output voltage of the 1st stator exceeds 24 V,
the DAQ sends a Logical-1 to the PIC and the switch is
closed. If the stator output voltage is still above 24 V while
the R1 is in circuit, the DAQ sends a second logical signal

Fig. 6. The relation between angular velocity and power factor.

Table 1
Parameters of PMSA.
Value

Stator diameter
Stator material
Number of windings
Coil thickness
Number of magnets
Magnet material
Rotor diameter
Magnet thickness
Rotor material

300 mm
Fiber glass and polyester
12
30 mm
10
N35
30 cm
12 mm
Fiber glass and polyester

Stator
Coils

Parameters

Rectifier

R1

Fig. 7. The block diagram of the electronic control unit.

Stator
Coils

600

Rectifier

500

R4

400

Angular velocity (rpm)

Stator
Coils

300

Rectifier

200

R3

100

Stator
Coils

Rectifier

0.93

R
cos u q
2
2pfL R2

R2

Power factor

0.99

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O. Kalender et al. / Measurement 69 (2015) 8794

55

Resistances: 10 Ohm

50
45
40

60

35

50

30
25
20
15

R1
R1,R2
R1,R2,R3
R1,R2,R3,R4

40
30
20

10

10

5
0

Resistances: 20 Ohm

70

Efficiency

Efficiency

80

R1
R1,R2
R1,R2,R3
R1,R2,R3,R4

200

400

600

800

Angular velocity(rpm)
Resistance: 20 Ohm

12

(a)

Resisance: 30 Ohm

80

600

800

(b)

R1
R1,R2
R1,R2,R3
R1,R2,R3,R4

70
60

Efficiency

Efficiency

400

Angular velocity (rpm)

R1
R1,R2
R1,R2,R3
R1,R2,R3,R4

10

200

6
4

50
40
30
20

10

60

80

100 120 140 160 180 200 220

400

600

(c)

(d)
90

R1
R1,R2
R1,R2,R3
R1,R2,R3,R4

R1
R1,R2
R1,R2,R3
R1,R2,R3,R4

70

60
40

800

Resistance: 50 Ohm

80

Efficiency

Efficiency

200

Angular velocity (rpm)

Resistances: 40 Ohm

80

Angular velocity (rpm)

60
50
40
30
20

20

10
0

200

400

600

800

200

400

600

Angular velocity (rpm)

Angular velocity (rpm)

(e)

(f)

800

Fig. 8. SpeedEfciency plots.

and the 2nd switch is also closed. Similarly, the other

switches may change their positions according to the value
of the output voltage of the 1st stator. As soon as the speed
of motor decreases, the stator output voltage decreases
and the switches are opened sequentially. In this study,
four alternators of 250 VA have been used. For this scale
of alternators, air cooling is sufcient.

Since all the wind energy cannot be transformed into

the mechanical energy, efciency is calculated for the
mechanical power obtained from the wind kinetic energy.
The actual power for rotor is the difference between the air
ows of channel input and the channel output. Maximum
theoretical efciency that can be obtained from a wind is
expressed as Betz Limit. The system developed in this

O. Kalender et al. / Measurement 69 (2015) 8794

study is a laboratory prototype. Therefore, it is excited by a

motor instead of wind. For this reason, the maximum Betz
limit of Cp = 0.5926 is selected and the efciency is
assumed to be 59.26%. However, we assumed the maximum efciency as 100% instead of 59.26% for simplicity.
The efciency graphics shown in the experiments section
have been plotted based on an efciency of 100%.
Furthermore, high speed is considered to be the speed
above 200 rpm and low speed is below 200 rpm.

93

speed is low in case the load is connected only one stator.

The efciency is high when the speed is above 200 rpm for
the case where several stators are connected to the load.
It can be seen that the incremental structure of the
generator is suitable for changing speeds of the wind. It
can have high efciency for both low and high speeds with
changing the number of stator blocks connected to the
load.

Acknowledgment
3. Experiments
The alternator blocks are connected to the resistors of
10 X and the rotor shaft is permitted to rotate at low angular velocities. The blocks are incrementally connected to
load resistors and the energies are determined. The same
procedure is repeated by the resistors of 20 X, 30 X,
40 X and 50 X keeping the angular velocity as before.
Then the same procedures are repeated by 25 different
angular velocities. The efciencies versus angular velocities for each resistance are plotted as seen in Fig. 8.
In Fig. 8, the curve R1 represents that it is the efciency
when only the Stator-1 is connected to the load. Similarly,
the curve R1, R2 represents that it is the efciency when
both the Stator-1 and Stator-2 are connected to the load.
This reasoning applies to the other curves. A seen the efciency is high when only Stator-1 is connected to the load
at low speeds. However, as the number of stator increases,
the efciency becomes high when the speed is higher than
200 rpm.
Furthermore, the range of 0220 rpm of the graphics
seen in Fig. 8b (that is, Fig. 8c) shows that efciency will
be about 4.2, even though all four stages of the alternator
are feeding the load. However, the efciency will be 6.8 if
only the rst stage is in circuit. The advantage of this system is that the efciency of a single stage obtained at low
speeds (about 150 rpm) with appropriate resistance (that
is R = 20 X) is higher than the multi-stage case.
However, the maximum efciencies for all load resistors are obtained at about 600 rpm (Fig. 8). The produce
power is high at high efciency. Since the maximum power
obtained by this system is 250 W, the maximum torque
that is to be obtained will be s = P/x  4 N m.
4. Conclusion and discussion
In this study, a new axial ux permanent magnet
synchronous generator (PMSA) design and prototyping
procedures are presented. It is composed of a stack of
rotorstator blocks on the same shaft. In other words, it
is made up of four alternators based on axial ux permanent magnets that can generate electrical energy within
the limits of rotor rotational speed with varying wind
speeds. A control system is also introduced to the generator. The control system connects or disconnects the stator
blocks to the load according to the changing speeds of the
wind. It produces electrical energy with stable voltage, frequency and variable power at the output. The efciency of
the generator is tested with different load and speed conditions. It is observed that the efciency is high when the

This study is supported by the Council of Scientic

Research of Turkey called TUBITAK under the number of
113E281.

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