Outer Rotor Flux Reversal Machine for Rooftop

Wind Generator
D . S . More, Hari Kalluru and B . G . Fernandes
Department of Electrical Engineering, Indian Institute of Technology Bombay,
Powai, Mumbai - 400 076, INDIA.
Email: dsmore@ee.iitb.ac.in khari@iitb.ac.in bgf@ee.iitb.ac.in

TABLE I
Abstract— In this paper outer rotor flux reversal machine
VARIOUS FRM CONFIGURATIONS
(FRM) topology is proposed for rooftop wind generator ap-
plication. The prototype design of 3-phase, 2.4 kW, 214 rpm, Sr. No. Machine No. of Gear Speed No. of Flux
50 Hz, 6/14 pole outer rotor FRM is presented. Finite element type magnets ratio for 50 pattern
analysis is carried out to evaluate the self and mutual inductance, Hz poles
regulation and efficiency of the machine. Outer rotor and inner 1 6/8 pole 12 8 375 2
rotor configurations of FRM with same outer dimensions are 2 12/16 pole 24 8 187.5 4
compared. The results show that outer rotor FRM has 1.25 times 3 6/14 pole 24 14 214.28 2
higher power density than inner rotor FRM. 4 12/28 pole 48 14 107.14 4
5 12/40 pole 60 20 75 4
I. I NTRODUCTION
Single-phase flux reversal machine (FRM) was first intro-
applications. The most low-speed applications are handled
duced in 1997 by R. P. Deodhar and et al for automobile
through conventional high speed motor and reduction gear.
application to replace the standard claw pole alternator [1].
The main benefits deriving from direct drive (i.e. eliminating
It has numerous advantages such as simple construction, low
the mechanical gear) are
inertia, high power density and is suitable for high speed appli-
• Lower plant engineering and installation costs due to
cation due to stationary permanent magnets (PM) and stator
windings. This single phase configuration is fully explored fewer mechanical drive components.
• Better positional accuracy as backlash is absent.
as a high speed automotive generator. Three phase FRM was
• Higher availability of the machine due to fewer mechan-
introduced by C. Wang and et al in 1999 [2]. The design of the
machine was optimized to ensure (i) high PM flux linkage in ical components.
• Lower maintenance costs as a result of a simpler system
the winding, (ii) low cogging torque and PM weight. The basic
machine configuration is 8 salient pole rotor and 6 pole stator with fewer components and spares.
• Lower energy costs due to lower over-all losses.
with concentrated windings. PMs are fixed to stator pole and
rotor is similar to switched reluctance machine (SRM). It has with these advantages, the low-speed machine will have
advantages of both brushless dc machine (BLDC) and SRM. competitive edge over the high-speed machine with reduction
FRM for low-speed servo drive application was introduced gear.
by Ion Boldea and et al in 2002 [3]. This low speed machine This paper proposes the outer rotor FRM topology
has 28 rotor poles and 12 stator poles with two permanent for rooftop wind power generation. Section II describes
magnet pairs on each stator pole. This machine is designed for the importance and requirements for rooftop wind power
128 rpm at 60 Hz. Using vector control high torque density generator. Design details of 6/14 pole outer rotor FRM
with less than 3% torque pulsation was achieved. In order to is discussed in section III. Generator performance of the
reduce the cogging torque, rotor teeth pairing method has been machine is evaluated with FEM in section IV. Comparison
proposed [4]. Attempts were made to reduce the leakage flux with inner rotor is made in section V and finally conclusions
by providing flux barrier on the rotor poles at its edges [5]. are drawn.
Power density comparison of doubly salient permanent magnet
electrical machines has been made. It is concluded that FRM
has higher power density in comparison with other machines in II. ROOFTOP W IND G ENERATOR
the same class [6]. Attempts were made to improve the power The need for increased use of renewable energy is well
density of FRM by introducing full pitch winding arrangement established. Small-scale wind turbines (rooftop) have the
[7]. potential to provide electricity to domestic and commercial
Various configurations of FRM are shown in the Table I. applications. Rooftop wind power generation has acquired
From this table it is observed that FRM topology is suitable importance due to environmental concerns. Rooftop wind
for low-speed application. Conventional induction and syn- generators should be direct driven. Cogging torque can be
chronous machines are not suitable for low-speed, low power reduced by proper skewing of the rotor. Hence, overall noise

978-1-4244-2279-1/08/$25.00 © 2008 IEEE 1

 TABLE II
S PECIFICATIONS OF 6/14 POLE OUTER ROTOR FRM
Sr. No. Description Symbol Value
1 Rated phase voltage (V) Vph 85
2 Rated speed (rpm) N 214
3 Rated current (A) I 9.5
4 Frequency (Hz) f 50
5 Torque (Nm) Te 122.5

III. D ESIGN D ETAILS OF O UTER ROTOR FRM

A. Design Procedure
A procedure for sizing of FRM is given in [3]. Specific elec-
trical and magnetic loading determines the specific tangential
Fig. 1. Cross-section of 6/14 pole outer rotor FRM. force ft . Relationship between machine dimensions and torque
Te is given by
D
Te = ft πDlsk (2)
generated will be less which is required for rooftop wind 2
power generating system. where, D = airgap diameter.
Depending upon the output power, the variation in the rated lsk = stack length of the machine.
speed of the rooftop wind turbine is 140 rpm to 500 rpm. In The ratio of stack length to airgap diameter λ is defined as
wind turbine generators, as capacity increases, the speed of
the machine decreases. Rooftop wind power generation system lsk
λ= (3)
has a power rating variation from 0.6 kW to 15 kW. The rated D
speed of 2.4 kW machine is 200 rpm (aprox). So, prototype From equations 2 and 3 the air gap diameter is given by
machine is designed for 2.4 kW, 50 Hz and 214 rpm. 
For the chosen wind turbine, speed variation is from 150 2Te
D= 3 (4)
rpm to 300 rpm. For this range suitable FRM configurations πft λ
are
• 12/16 pole configuration.
The PM flux per stator pole φP M is given by
• 6/14 pole configuration.
φP M = lsk .BP M i .τP M .npp .Kf ringe (5)
The details of both machine configurations are given in Table
I. It is observed that 6/14 pole configuration has flux pattern where, npp = number of magnet pairs per stator pole.
of 2 poles while, 12/16 configuration has flux pattern of 4 Kf ringe = ratio of flux linking the stator winding to airgap
poles. Stator flux linkage in 6/14 pole configuration is twice flux.
as that of 12/16 pole configuration for same magnet volume, τP M = permanent magnet pole arc length.
physical dimensions and number of turns. Therefore, 6/14 The ideal flux density in the airgap BP M i is given by
pole configuration has more power density than 12/16 pole hP M
configuration. Hence, 6/14 pole FRM configuration is selected. BP M i = Br (6)
hP M + g
The 6/14 pole FRM consists of 14 salient pole rotor and 6
salient pole stator with concentrated windings. Two pairs of where, Br = remainent flux density of PM
permanent magnet are fixed on stator pole. Outer rotor FRM hP M = permanent magnet thickness.
generator for rooftop wind energy conversion is shown in Fig. g = airgap thickness.
1. FEM analysis shows that stator flux linkage variation is almost
The frequency and speed relationship for FRM is given by sinusoidal with rotor position θr .
[3]
n × nr φP M (θr ) = φP M sin(Nr θr ) (7)
f= (1)
60

where, n = rotor speed (rpm). dφP M (θr )

= lsk .BP M i .τP M .npp .Kf ringe .Nr .cos(Nr θr )
nr = number of rotor teeth (poles). dθr
f = frequency (Hz). (8)
This machine generates 50 Hz at 214 rpm. The specifications There are N3s stator poles per phase and N3s coils in series
of 6/14 pole, 2.4 kW, 50 Hz outer rotor FRM are given in with nc turns per coil. The EMF amplitude per phase is
Table II. Ns
Em = .nc .2.π.n.lsk .BP M i .τP M .npp .Kf ringe .Nr (9)
3

2
 In constant torque region FRM is controlled by maintaining IV. G ENERATOR P ERFORMANCE
Id = 0. The rated phase current of the machine is given by
The three phase 6/14 pole outer rotor FRM is shown in Fig.
2πnTe 1. FEM analysis is carried out to evaluate the performance of
I= 3E
(10) the machine [8]. Flux distribution in the machine at no load
√m
2 is shown in Fig. 2, while flux due to armature current alone is
shown in Fig. 3. The normal component of flux density at the
Having determined the number of turns per coil and phase
middle of stator pole along the periphery of 6/14 pole FRM is
current, the slot area required for the winding is obtained by
shown in Fig. 4. A close look at the normal component of flux
considering the slot fill factor (Kf ill ) and winding current
density plot reveals that the machine has two pole flux pattern.
density (jcn ). The slot area is given by

2nc I
Aslot = (11)
jcn Kf ill

Stator pole width is decided based on magnet width τP M

and flux density in stator pole. Stator slot area will determines
the stator pole height. Stator core width is taken to be equal to
stator pole width. Stator pole arc to pole pitch ratio is taken as
0.8 for 6/14 pole FRM [2]. Two magnet pole pairs per stator
pole are used. The rotor pole span is taken as 120o electrical.
The airgap between stator and rotor is 0.5 mm and magnet
thickness is 2.5 mm.

B. Sizing of outer rotor FRM

The main dimensions of 6/14 pole, 2.4 kW (122.5 Nm) outer Fig. 2. Flux distribution in 6/14 pole outer rotor FRM at no load
rotor FRM are determined using the procedure given above.
Following data is assumed for the design of the machine.
• Specific force ft = 1.30 N/cm2
• λ ≈ 0.75
• Efficiency of the machine = 88 %
• PM remainent flux density Br = 1.2 Tesla
• Flux leakage factor Kf ringe = 0.44
• Slot fill factor Kf ill = 0.3
• Winding current density jcn = 3.5 A/mm2
Table III shows the dimensions of 6/14 pole, 122.5 Nm, 214
rpm outer rotor FRM.

TABLE III
D IMENSIONS OF 6/14 POLE , 122.5 N M , 214 RPM OUTER ROTOR FRM Fig. 3. Flux distribution in 6/14 pole outer rotor FRM due to armature
current
Sr. No. Description Symbol Value
1 Number of stator poles Ns 6
2 Number of rotor poles Nr 14
3 Number of magnet pairs npp 2
per stator pole
4 Air gap (mm) g 0.5
5 Magnet thickness (mm) hpm 2.5
6 Rotor pole span angle (◦ mech) βr 8.57
7 Stator pole span angle (◦ mech) βs 48
8 Stator pole height (mm) hps 35
9 Rotor pole height (mm) hpr 15
10 Outer diameter of rotor (mm) Di 270
11 Outer diameter of stator (mm) Do 200
12 Number of turns /phase Nph 132
13 Stack length of machine (mm) lsk 150
14 Stator core width (mm) Wsc 20
15 Shaft diameter (mm) Dsh 50 Fig. 4. Normal component of flux density in 6/14 pole FRM

3
 Fig. 5. Phase flux linkages with rotor position Fig. 7. Variation of self inductance with rotor position

Fig. 8. Variation of mutual inductance with rotor position

Fig. 6. No load induced EMF with rotor position

In other words, the machine has two effective poles. FRM has
6 slots, hence electrical angle per slot is 60◦ . Concentrated
stator pole winding has a coil span of 60◦ elec. and therefore
fundamental pitch factor of the stator winding is 0.5.
Phase flux linkages of outer rotor FRM is shown in Fig. 5.
The phase flux linkages are sinusoidal and hence the induced
EMF. The no load phase voltages are shown in Fig. 6.
Self and mutual inductances are determined using FEM
analysis. Variation of self inductance of 6/14 pole outer rotor
FRM with rotor position is shown in Fig. 7. It is observed Fig. 9. Full load torque of 6/14 pole FRM
that the variation of self inductance with rotor position is very
small and it’s average value is 30.57 mH. The variation of
mutual inductance between the phases of outer rotor FRM is A. Voltage Regulation of the Machine
shown in Fig. 8. The mutual inductance between the phases
is very low and its average value is 1.638 mH. Voltage regulation of outer rotor FRM generator for resistive
FEM simulation is carried out to find the full load torque of load is obtained at 214 rpm with FEM simulation. The no load
the machine. Variation of torque with rotor position is shown voltage of machine is 102 V. Fig. 11 shows the variation of
in Fig. 9. The average value of full load torque is 122.5 Nm terminal voltage with load. The regulation of the machine is
and ripple in torque is due to cogging torque. The cogging poor due to armature reaction. Series capacitive compensation
torque of the machine without skewing is obtained using FEM is provided to improve the voltage regulation. The uncompen-
and is shown in Fig. 10. The cogging torque of the machine sated regulation characteristic is used to calculate the value
is reduced by skewing of the rotor pole by an angle 8.57◦ of synchronous inductance Ls , which is used to determine
(mech.). the size of capacitor for series capacitive compensation of the

4
 Fig. 10. Cogging torque of 6/14 pole FRM without skewing of rotor

Fig. 12. Cross section of 6/14 pole inner rotor FRM

TABLE IV
D IMENSIONS OF 6/14 POLE , 214 RPM INNER ROTOR FRM
Sr. No. Description Symbol Value
1 Number of stator poles Ns 6
2 Number of rotor poles Nr 14
3 Number of magnet pairs npp 2
per stator pole
4 Air gap (mm) g 0.5
5 Magnet thickness (mm) hpm 2.5
6 Rotor pole span angle (◦ mech) βr 8.57
7 Stator pole span angle (◦ mech) βs 48
Fig. 11. Voltage regulation characteristics 8 Stator pole height (mm) hps 32.5
9 Rotor pole height (mm) hpr 30
10 Outer diameter of rotor (mm) Di 160
11 Outer diameter of stator (mm) Do 270
12 Number of turns /phase Nph 132
machine. The value of series capacitance is given by [9] 13 Stack length of machine (mm) lsk 150
1 14 Stator core width (mm) Wsc 19.5
C= (12) 15 Shaft diameter (mm) Dsh 50
ω 2 × Ls
where, ω = frequency of induced EMF (rad/sec)
Ls = synchronous inductance of the machine/phase (H).
The regulation characteristics for compensated outer rotor
FRM is shown in Fig. 11. The value of compensating capacitor
is 300 μF .
V. C OMPARISION WITH I NNER ROTOR FRM
Outer rotor and inner rotor FRM are designed for same
outer diameter and stack length. The inner rotor FRM is
shown in Fig. 12. The dimensions of 6/14 pole inner rotor
FRM are given in Table IV.
In outer rotor FRM the height of the rotor pole can
be reduced in comparison with inner rotor, which is just
Fig. 13. Electromagnetic torque of both machines with rotor position
sufficient for varying the reluctance of the magnetic path.
Therefore effective air gap diameter increases for same outer
diameter of the machine. From FEM simulation it is found
that airgap diameter of outer rotor FRM is 200 mm and inner rotor FRM). The electromagnetic torque of both machines
rotor is 160 mm for same machine outer diameter of 270 while supplying full load at rated speed is shown in Fig. 13.
mm. The no load voltage of outer rotor FRM is 1.56 times to For same outer diameter, stack length and number of turns,
that of inner rotor FRM for same electrical loading. But self the outer rotor FRM generates 1.25 times more power than
inductance increases by 1.65 times which causes poor voltage inner rotor FRM.
regulation. Therefore, outer rotor FRM is designed for same Self-inductance of both machines are approximately equal.
number of turns (reduced electrical loading compared to inner Regulation characteristics of inner and outer rotor FRM with

5
 VI. C ONCLUSION
The three phase outer rotor FRM has robust structure and
is well suited for low power direct driven rooftop wind power
generation. Its simple structure makes it cost effective and
suitable for mass production. Design details for 2.4 kW, 214
rpm 50 Hz outer rotor FRM are presented. The performance of
outer and inner rotor FRM is evaluated through FEM analysis.
Voltage regulation of both machines is improved with series
capacitive compensation. Outer rotor FRM has 1.25 times
higher power density than inner rotor FRM for same machine
outer dimensions and number of turns.
Fig. 14. Voltage regulation of 6/14 pole inner and outer rotor FRM
R EFERENCES
[1] R. P. Deodhar, Savante Anderson, Ion Boldea and T. J. E. Miller,
“The flux reversal machine : A new doubly salient permanent magnet
machine,” IEEE Trans. Industry Applications., vol.33, No. 4, pp. 925-
934, July/August 1997.
[2] C. Wang, S. A. Nasar, I. Boldea “Three phase flux reversal machine
(FRM),” IEE Trans. Electrical power application ., vol.146, No.2,
pp.139-146, March 1999.
[3] Ion Boldea, Jichum Zhang, S. A. Nasar, ”Theoretical characterization
of flux reversal machine in low speed servo drives-The pole PM
configuration.” IEEE Trans. Industry Applications., vol. 38, No. 6, pp.
1549-1557, November/December 2002.
[4] Tae Heoung Kim, Sung Hong Won, Ki Bong and Ju Lee, “Reduction
in cogging torque in flux reversal machine by rotor teeth pairing” IEEE
Trans. on Magnetics. vol. 41, No. 10, pp 3964-3966, October 2005.
[5] Tae Heoung Kim and Ju Lee “A study of the design for the flux reversal
machine,” IEEE Trans. on Magnetics., vol. 40, No. 4, pp. 2053-2055,
July 2004
[6] Jianzhong zhang, Ming Cheng, Wei Hua and Xiaoyong Zhu, “New
Fig. 15. Efficiency of 6/14 pole inner and outer rotor FRM approach to power equation for comparison of doubly salient electrical
machines,” in in Proc.IEEE Industry Applications Annu. meeting ., pp.
1178-1185, 2006.
TABLE V
[7] D. S. More and B. G. Fernandes.“Novel three phase flux reversal
C OMPARISON OF INNER AND OUTER ROTOR FRM machine with full pitch winding,” Proc. of International conference on
Sr.No. Parameter Outer rotor Inner rotor power electronics (ICPE 2007 ) Daegu, South Korea. pp. 1007-1012,
1 No load ph. voltage (V) 102.5 82 2007.
2 Self inductance (mH) 30 27 [8] CEDRAT, France “Flux 2-D FEM Software, ”.
3 Mutual inductance (mH) 1.64 0.8 [9] C. Wang, I. Boldea, S. A. Nasar “Characterization of three-phase flux
reversal machine as an automotive generator. ,” IEEE Trans. on Energy
4 Full load torque (Nm) 122.5 100
Conversion., vol. 16, No.1, pp. 74-80, March, 2001.
5 Full load efficiency % 88 83
[10] Miller T. J. E. ”Brushless Permanent Magnet and Reluctance Motor
Drives. Clarendon Press. Oxford-1989 .
[11] Gieras J. F. and M. Wing ” Permanent Magnet Motor Technology.
Design and Applications. Marcel Dekker Inc. 2002 .
series capacitive compensation for restive load is shown in
Fig. 14. Due to equal self-inductance, the drop in voltage
is same for both the machine. Electrical efficiency of both
machines with output power is shown in Fig. 15. Comparison
of both machines is given in Table V.