Design and optimization of a large-scale permanent magnet synchronous generator

Direct drive permanent magnet synchronous generators have numerous advantages such as improved reliability, low maintenance, long life, and developed performance characteristics. Focus of this paper is on the development of a step-by-step method for the design of a permanent magnet synchronous generator. Then the winding function method is used to model the generator and to analytically calculate its output characteristics. The analytical results of the designed generator are evaluated with the finite element analysis (FEA) results and it is demonstrated that the achieved results from both methods are well matched with the experimental measurements of the Northern Power direct-drive generator. The sensitivity analysis and the optimization based on the genetic algorithm are used to achieve an optimum generator. The optimization goal is obtaining higher efficiency and power factor with lower required permanent magnet (PM) volume and voltage regulation for the optimum machine compared to the initial design. In addition, the calculation of the voltage total harmonic distortion (THD) is presented and the optimum skew angle for the optimum generator is computed to reduce the voltage THD.