Optimal design and verification of interior permanent magnet synchronous generator based onFEAand Taguchi method

Background Permanent magnet machines can be used for many applications, due to their high power density, high efficiency, observable torque-to-current ratio, and low maintenance cost. As such, the generator design in wind turbine systems is highly dependent on improvement of efficiency and generator performance. Thus, in order to improve the quality of manufactured electrical machines, a robust and precise optimization model should be developed to substitute the traditional deterministic models. Purpose This paper investigated the optimization design process of an interior permanent magnet synchronous generator (IPMSG) for wind power systems using the finite element analysis (FEA) based on a prototype IPMSG. To that end, a multi-objective optimization design of a permanent magnet generator (PMG) based on Taguchi method was proposed. Design/Method The influence of the pole arc angle, magnet inset, magnet thickness, magnet width, and stator tooth width as well as slot depth were considered as the design parameters. The main characteristics of generator efficiency, total harmonic distortion (THD) and the amplitude of induction electromotive force (EMF) were taken as the optimization objectives, as well. The orthogonal matrix was established based on the number of the selected variables and the level factor of each variable, and finite element method (FEM) was, in turn, applied to solve the experimental matrix. As a result, an improved generator with higher maximum efficiency and EMF and lower THD was designed. Conclusions Finally, the prototype IPMSG which was manufactured based on the analysis results and Taguchi method was tested. The experimental tests were then performed to confirm the validity of the proposed design process and the generator efficiency. The prototype experiments and the finite element simulation results verified the efficacy of the optimization method.