Axial Flux Permanent Magnet Generator Design for Low Cost Manufacturing of Small Wind Turbines

In this paper the design and manufacturing processes for coreless axial flux permanent magnet generators are described for low cost rural electrification applications, where local production of small wind turbines is considered. The process is based on already existing open source design and construction manuals, while a systematic approach to designing generators of varying nominal power and for grid connection or direct battery charging schemes is described. The manufacturing process of a 3 kW small wind turbine generator for grid connection is used as a case study. Emphasis is given to the use of simple tools and techniques to achieve a lower cost, while intricate steps in the manufacturing process are described in more detail. The generator design is simulated and the constructed machine is tested in the laboratory.