Design of Wound Rotor Low-Voltage Synchronous Generator
M. osovi, S. Smaka, Š. Maši I. Salihbegovi
Dept. of Electrical Engineering
Faculty of Electrical Engineering Public enterprise Elektroprivreda BiH
Sarajevo, Bosnia and Herzegovina Sarajevo, Bosnia and Herzegovina
mcosovic@etf.unsa.ba
Abstract—Magnetic circuit design of wound rotor low-
voltage three-phase synchronous generator for autonomous
operation is presented in this paper. The Maxwell software
based on two-dimensional finite element method (2D FEM) is
used to study the performance of the synchronous generator in
specified static operating regime. Two machines with different
configurations are analyzed. These machines are characterized
by the same stator and rotor external dimensions and used
materials. Moreover, stators of all machines are exactly the
same while the rotor magnetic circuit structures and excitation
windings are different. Calculated characteristics and their
comparisons are presented and discussed. Some characteristics
of prototype, which is currently under construction, are given.
I. INTRODUCTION
Synchronous generators traditionally operate in large
power grids − with many of them in parallel to provide
voltage and frequency stability to changing load demands −
or they stand-alone. Most synchronous generators are large
machines with rated power per unit up to 1500 MVA and
with rated voltage up to 110 kV. However, in some cases is
suitable to use low-voltage synchronous generators with low
to medium rated power. The low-voltage synchronous
generator is a machine with a rated voltage below 1000 V.
These generators can be used in a variety of applications.
They are becoming more popular for load management
applications since the deregulation and privatization of the
utility industry. Typical applications for the low-voltage
synchronous generators are: home and industrial combined
heat and electricity generation; stand by, peak or continuous
base load operation in stationary power stations; emergency
or backup power units and shaft generator systems in ships or
offshore platforms [1].
The generators are suitable for operation with diesel and
gas engines, gas turbines and steam turbines. Low-voltage
synchronous generator driven by diesel engine is heavily
used in remote locations where it is impractical or
prohibitively expensive to connect to utility
power - autonomous operation.
This generator is typically either a permanent magnet or a
wound rotor machine. In the case of a permanent magnet
generator, the front end consists of a rectifier and a
voltage-source inverter to provide the necessary AC voltage
at the desired frequency. The presence of a power electronics
front end increases the overall cost of the system and
decreases its fault tolerance. However, the presence of the
rectifier and inverter enables variable speed operation of the
diesel engine, which makes it possible to achieve higher
efficiency.
978-1-4577-0746-9/11/$26.00 ©2011 IEEE
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H. Steinhart
Generation Department Dept. of Electronics &
Information Technology
Aalen University
Aalen, Germany
Machines with wound rotor require an exciter and a
voltage regulator to control the AC voltage produced by the
machine. No front end rectifier and inverter are needed since
the machine produces the AC voltage at the desired
frequency provided that the speed of the shaft is held close to
the required fixed value. The reduced cost of the system due
to the absence of the power electronics front end is one of its
major advantages. However, a significant drawback of this
system is that without the power electronics front end, the
dynamics of the diesel engine cannot be decoupled from the
output of the generator [2]. The low-voltage synchronous
generators with DC excitation can have cylindrical or
salient-pole rotor. Typically they are salient-pole machines
with variable air gap reluctance.
Design of wound rotor synchronous generator intended
for the generation of electrical energy within context of
emergency standby operation for feeding in mobile
distribution systems will be presented in this paper. Since the
generator has to be self-excited, there must be an exciter and
power electronic module but their designs are not within the
scope of this paper. In Section II, the basic design properties
of the two generators with different rotors and the same
stators will be presented. Section III will discuss the analysis
approach based on 2D FEM and implemented using software
Ansoft Maxwell 2D. Computed output characteristics of two
machines considered will be shown in Section IV. In Section
V, the comparison of their performances will be given. Main
characteristics of the prototype machine is given in Section
VI. Finally, a conclusion will be drawn in Section VII.
II. BASIC DESIGN PROPERTIES
Synchronous generators are usually tailor-made to match
the customer’s needs [1]. According to desired generator
characteristics, special attention has to be given in the design
to minimize the Total Harmonic Distortion (THD) factor of
output voltage. Generator load with unity or lagging power
factor was expected. As a standard, a low-voltage
synchronous generator is designed to have a rated power
factor of 0.8 overexcited. Other generator’s rated parameters
are: frequency f = 50 Hz; number of poles 2p = 4; speed
n = 1500 rpm; line-to-line RMS voltage V = 400 V; apparent
power S = 45 kVA.
Two machines with different rotor configurations are
analyzed. Rotor outer and inner diameters are fixed for these
generators while rotor laminations have different shapes.
Stator outer diameter, inner diameter, slots cross section and
number of slots is fixed for two analyzed machines.
Consequently, the air gap lengths at the centers of stator and
rotor poles are equal for both generators. Initial designs are
based on analytical calculations described in [3] and [4].
 Stator laminations are made of non-oriented silicon–iron A3 Phase A
electric sheets. In order to reduce production cost, the sheets A1 Phase B
with silicon content of about 1.0 % was chosen. Sheets with Phase C
A2
low silicon content are mechanically robust but they have A4
higher iron loses. The thickness of the sheets is 0.65 mm and
the dissipation power is 8.0 W/kg (M800-65A). This is a
common material used in small machines.
Stator outside and inner diameter are 300.0 mm and
215.0 mm, respectively. Stator active axial length is
340.0 mm. Semi-closed stator slots are adopted in order to
restrain the influence of harmonics. Stator cross section with
Q = 48 slots is shown in Fig. 1.
The stator slots are provided with multiturn coils A8
A6
connected to form a spatially distributed integral single layer
three-phase winding. Diameters of conductors placed within A5 A7
the stator slots are 0.8 mm and 0.85 mm. Stator slot fill factor
is 45.59 %. The average number of slots per pole per phase is
Fig. 2. Schematic layout of stator coils
q = 4, i.e. every phase winding occupies 16 slots. Total
number of coils is 24, thus one phase winding consist of
A. Generator BG200RU
8 coils.
Rotor cross section of this generator is shown in Fig. 3.
Excitation winding consists of 4 serial connected coils, i.e.
one coil per pole. Every coil has 360 turns per pole connected
in series. Conductor’s diameter is 1.12 mm and they are made
of copper. Rotor slot fill factor is 59.3 %.

Fig. 1. Stator magnetic circuit cross section

Schematic layout of stator coils is shown in Fig. 2. Only

phase A coils are labeled (A1 – A8). Coils labeled A1 – A4
are connected in parallel as well as coils A5 – A8. Resulting
two groups of coils are then connected in series to form
one-phase winding. Phases B and C are formed in the same
way. Stator phases A, B and C are star connected to form
three-phase armature winding. Due to the manufacturing
constraints, the parallel-connected coils have two different
coil pitches. As a consequence, the voltages induced in the
coils are different and there is a small amount of circulating
currents between them.
Two generators with different rotor configurations will be
presented in following Subsections. Rotor design of generator
BG200RU is based on the design of salient two-pole rotor of
generator BG132 described in [5]. Ansoft RMxprt software is
used to develop preliminary rotor design of generator BG200.
The input for this program includes basic electrical
parameters and geometrical dimensions of the machine and
specifications of the materials properties.
Rotor laminations are made of the same material as the
stator laminations. Rotor inner and outer diameter for both
generators are 212.6 mm and 75.0 mm, respectively.
Fig. 3. Rotor magnetic circuit cross section of generator BG200RU
Every rotor pole has five bars in the slots at the surfaces
of pole shoes. Those copper bars create the damper windings.
The copper end plates are connected with a suitable copper
connector to form a ring for the damper currents. Damper
windings improve the performance characteristics of
synchronous generators especially during transients.
B. Generator BG200
Rotor cross section of generator BG 200 is shown in Fig.
4.
Every pole has five damper copper bars. Also, there are
eight bars distributed around shaft. Those bars are filled of
brass and improve rotor mechanical characteristics. Every
coil has 168 turns per pole and four coils are series connected
thus forming rotor excitation winding. Rotor fill factor is
44.4 % and this is considerably lower value than that of
BG200RU. Therefore, manufacturing cost of BG200 can be
reduced due to simpler rotor winding production.

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 for loaded generators with determined excitation currents was
performed. The three-phase symmetrical load with unity
power factor and Rl = 3.5 Ω phase resistance was assumed in
all cases. The generators were driven at fixed rated speed.
Stator winding resistance and leakage inductance were 0.1 Ω
and 0.4552 mH, respectively.
A. Generator BG200RU
Generator output characteristic is a plot of the line-to-line
voltage RMS value against the excitation current, when the
generator is driven at fixed rated speed and with constant
load. Output characteristic of the generator is shown in Fig. 5.
The normal range of operation is at the knee of the output
characteristic for economy of design. It can be seen that knee
Fig. 4. Rotor magnetic circuit cross section of generator BG200
point is obtained for field excitation current If = 6.0 A. Line
III. 2D FEM ANALYSIS voltage and phase current waveforms calculated for this
excitation current are shown in Fig. 6 and Fig. 7.
For structures with moving parts the time-dependent field THD factor of the line-to-line voltages is calculated as:
equation in xyz plane is [6]:
JG 40
JG JG
∇ × ν∇ × A = J s − σ
∂A G JG
− σ∇V + σv ×∇ × A (1) ¦V n
2
(3)
⋅ 100 ( % )
∂t n =2
THD =
V1
where:
JG ∇ is the Nabla operator, ν is the magnetic reluctivity,
A is the magnetic vector potential, Js is the source current where: n is the order of the harmonic (2 ≤ n ≤ 40), Vn is the
density, σ is the electric conductivity, t is the time, V is the line-to-line voltage RMS value of the harmonic with the
scalar electric potential and v is the velocity of moving parts. order n, V1 is the line-to-line voltage RMS value of the
harmonic with the order 1.
Electrical machines present complex geometries and a
two-dimensional approximation of the electromagnetic 600

phenomena must be often made. The magnetic induction is Knee point

defined only in the xy plane and consequently the magnetic 500

vector potential and the current density have only z

LL RMS voltage (V)

400
component. For this two-dimensional case, (1) can be written
as [7], [8]: 300

∂ § ∂A · ∂ § ∂A ·
ν + ¨ν ¸=
200

∂x ¨© ∂x ¸¹ ∂y © ∂y ¹
100

∂A ∂A ∂A
= −Js + σ + σgradV + σ vx + σ v y (2)
∂t ∂x ∂y
0
0 2 4 6 8 10 12 14 16
Excitation current (A)

where: vx and vy are velocity components. Fig. 5. Output characteristic − BG200RU

Ansoft Maxwell 2D software is used to create generator Line voltage THD factor of this generator is 5.7 %.
transient model and to determine instantaneous solutions Maximum permissible stator conductor current density is
corresponding to given excitation currents and rotational within the range from 8.0 A/mm2 to 9.0 A/mm2. In this case,
speed. Rotor movement is considered by using two reference phase current RMS value is 72.6 A, and stator conductor
frames: the first one related to the fixed part and the second current density is 6.7 A/mm2.
one to the moving part. The field equation is applied to both Ansoft LLC Linijski
Line napon
to line voltages Maxwell2DDesign1
800
800.00
parts in their own reference frame in which velocity is always VBC VCA VAB
zero. Because the moving components have now been fixed 600
600.00

to their own coordinate system, the partial time derivative in 400.00

400

(1) and (2) becomes the total time derivative of A. The 200.00
200
Napon [V](V)

coupling between the fixed and the mobile part is made by

Voltage

0.00
0

finite elements placed in the air gap using moving band −200
-200.00

technique.
−400
-400.00

IV. CALCULATED CHARACTERISTICS −600

-600.00

In order to determine optimal excitation currents, the −800

-800.00
0.00
0.0
5.00
5.0
10.00
10.0
15.00
15.0 Vrijeme [ms]
20.00
20.0
25.00
25.0
30.00
30.0
35.00
35.0
output characteristics for loaded generators are calculated at Time (ms)

first. Then, calculation of time varying voltages and currents Fig. 6. Line-to-line voltage waveforms − BG200RU

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 Ansoft LLC Struja
Phase currents Maxwell2DDesign1 Ansoft LLC Linijski
Line napon
to line voltages Maxwell2DDesign1
150.00
150 800.00
800

IC IB IA VAB VBC VCA

600.00
600
100.00
100
400.00
400

50.00
50
200.00
200

(V)
(A)

Napon [V]
Struja [A]

Voltage
0.00
0
Current

0.00
0

−200
-200.00

-50.00
−50
−400
-400.00

−100
-100.00
−600
-600.00

−800
-800.00
−150
-150.00 0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00
0.0 5.0 10.0 15.0 Vrijeme [ms ] 20.0 25.0 30.0 35.0
0.0 5.0 10.0 15.0 Vrijeme [ms] 20.0 25.0 30.0 35.0 Time (ms)
Time (ms)

Fig. 7. Phase current waveforms − BG200RU Fig. 10. Line to line voltage waveforms − BG200
Ansoft LLC Phase Struja
currents Maxwell2DDesign1

Fig. 8 shows the results of harmonic analysis of the 100.00

100
IA IC IB
output voltage of the generator BG200RU.
Ansoft LLC Fourier-ova analiza
Fourier analysis Maxwell2DDesign1
700.00
700 50
50.00
Name X
Name X Y Y
m1 m1 50.00
m1 50.0000 622.87
622.8782
m1 m4 200.0000 22.8551
m4 200.00 22.85

Struja(A)
600.00
600 m5 250.0000 27.6441

[A]
m5 250.00 27.64

Current
0.000

500
500.00
Napon [V] (V)

400
400.00 −50
-50.00
Voltage

300.00
300
−100
-100.00
0.00
0.0 5.00
5.0 10.00 15.00 20.00 25.00 30.00 35.00
10.0 15.0 Vrijeme [ms ] 20.0 25.0 30.0 35.0
200
200.00 Time (ms)

Fig. 11. Phase current waveforms − BG200

100.00
100

m5
0.00
0
m4
m4 m5
Spectral analysis of voltage waveforms shown in Fig. 10
0.00
0.0 100.00
100.0 200.00
200.0 300.00
300.0 400.00
400.0 500.00
500.0 600.00
600.0
Frekvencija [Hz]
Frequency (Hz) is performed using Fast Fourier Transformation and results
Fig. 8. Voltage harmonic contents – BG200RU are shown in Fig. 12. This analysis shows that fundamental
component of line voltage has amplitude equal to 608.4 V
The value of the first harmonic is 662.87 V. The fourth while content of higher harmonics component was
harmonic has a value of 22.85 V and its contents in relation negligible. Therefore, line-to-line voltage THD factor of this
to the first harmonic is 3.4 %, which is more than the generator, calculated according to (3), is 0 %.
permitted limit of 1.0 %. The fifth harmonic has a value of
Fourier-ova analiza
27.64 V, which is 4.2 % compared to the first harmonic. Ansoft LLC
700.00
700
Fourier analysis
Name
Maxwell2DDesign1

X Y
Name X Y608.4174
B. Generator BG200
m1 50.0000
m1 50.00 608.40
m1
m1
600.00
600

Output characteristic of generator BG200 is shown in Fig.

9. Optimal excitation field current is If = 12.0 A and this is
500.00
500

much higher value than that of generator BG200RU due to

Napon [V] (V)

400.00
400
Voltage

decreased number of rotor winding turns. 300

300.00

500
200
200.00

450
100
100.00
400
Knee point
350
LL RMS voltage (V)

0
0.00
0.00 100.00 200.00 300.00 400.00 500.00 600.00
0.0 100.0 200.0 300.0
Frekvencija [Hz] 400.0 500.0 600.0
300 Frequency (Hz)

250
Fig. 12. Voltage harmonic contents – BG200
200

150
V. COMPARISON OF GENERATORS CHARACTERISTICS
100

50
Generators main characteristics are summarized in Table
0
1. Also, initial distributions of magnetic flux density
0 2 4 6 8 10 12 14 16
Excitation current (A)
calculated for two generators are shown in Fig. 13.
Presented results clearly demonstrate advantages of
Fig.9. Output characteristic − BG200
generator BG200 regarding lower THD factor.
Line-to-line voltage and phase current waveforms calculated Disadvantages of the BG200 are higher rotor excitation
for excitation current intensity 12.0 A are shown in Fig. 10 current and higher rotor current density.
and Fig. 11. Phase current RMS value is 71.1 A, and stator
conductor current density is 6.6 A/mm2.

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 TABLE I regulates the supplied generator voltage. The output
GENERATORS MAIN CHARACTERISTICS frequency constancy depends on the speed constancy of the
Generator Type prime mover.
Parameter Unit
BG200RU BG200
Excitation Current A 6.0 12.0
Number of Turns per Rotor Pole 360 168
Rotor Slot Fill Factor % 59.3 44.4
Line to Line Voltage RMS Value V 442.4 429.4 Induction motor

Generator
Phase Current RMS Value A 72.6 71.1 Exciter

Stator Conductor Current Density A/mm2 6.7 6.6

2
Rotor Conductor Current Density A/mm 3.0 6.1
Total Harmonic Distortion % 5.7 0

Fig. 14. Test setup for the BG200 prototype

a. BG200 b. BG200RU
Fig. 13. Magnetic flux density distribution for t = 0
Red colored regions shown in Fig. 13 are characterized
with highest value of magnetic flux density equal to 2.0 T. It
can be seen that magnetic circuit of the generator BG200RU
is locally saturated (especially the interpolar areas). On the
other hand, very small areas of stator and rotor of BG200 is
saturated. Saturation seriously affects the waveforms of the
output voltages but also the overall performance of the
generator.
Rotor of the BG200 has 31.0 % more iron and about
36.0 % less copper than rotor of the BG200RU. Rotor
winding of the BG200 has lower slot fill factor and this is
preferable due to some manufacturing constraints.
VI. PROTOTYPE PROPERTIES
A prototype based on above design BG200 has been built
and some preliminary tests are running but more work need
to be done. Therefore, the experimental results are not
presented in this paper. Fig. 14 shows some parts of the
experimental test setup for measuring the prototype
characteristics.
The brushless exciter of the prototype is an inverted
synchronous machine with a DC stator winding and AC
windings on the rotor. The rotor windings are single-phase to
reduce cost. The AC voltage is rectified into DC using a
diode bridge that is integrated into the rotor shaft. Hence,
adjusting the input voltage to the brushless exciter can control
the main field voltage. The rating of the brushless exciter is
about 10.0 % of the rating of the main generator, and these
machines typically operate unsaturated.
Rotating direction-independent self-ventilation performs
cooling of the prototype. The electronic generator governor
VII. CONCLUSION
Magnetic circuit design of wound rotor low-voltage three-
phase synchronous generator for autonomous operation is
presented in this paper. Two machines with different rotor
and same stator configuration are analyzed using two-
dimensional finite element method (2D FEM).
Obtained results clearly underline advantages of generator
BG200 regarding lower THD factor and disadvantages
regarding higher rotor excitation current and higher rotor
current density.
Analysis also shows that magnetic circuit of the generator
BG200RU is locally saturated. On the other side very small
areas of BG200 stator and rotor are saturated.
Optimal magnetic circuit of the generator is choosen and
prototype based on above design BG200 has been built and
some preliminary tests are running.
ACKNOWLEDGMENT
Calculations of synchronous generators characteristics are
made in laboratory for electrical drives and power
electronics of HTW–Aalen, Germany. The authors gratefully
acknowledge the contributions of company GTS–
Mögglingen, Germany, for their help in characterizing
analyzed generators and for manufacturing the prototype
machine.
REFERENCES
[1] P. Rasilo, “Low-voltage Synchronous Generator Excitation
Optimization and Design”, Helsinki University of Technology, 2007,
pp. 9.
[2] S. Krishnamurthy, T. M. Jahns, R. H. Lasseter, “The operation of
diesel gensets in a CERTS microgrid”, US DOE, 2007.
[3] I. Boldea, “Electrical generator handbook: Synchronous generators”,
vol. I, CRC Press Taylor & Francis Group, 2006, pp. 7.1–7.32.
[4] J. Pyrhonen, T. Jokinen, V. Hrabovcová, “Design of rotating electrical
machines,” John Wiley and Sons Ltd, 2008, pp. 47–150.
[5] Generator-Technik Schwäbisch Gmünd GmbH, “Synchronous
generators - series DGG, DWG and WG - size BG 132 and BG 160”,
2002.
[6] “Transient Problem”, Ansoft Corporation, 2008.
[7] “Maxwell 2D Magnetostatic Problem”, Ansoft Corporation, 2002.
[8] J. P. A. Bastos, N. Sadowski, “Electromagnetic modeling by finite
element methods”, Marcel Dekker Inc, 2003, chapter 5 and 6.

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