Design & Analysis of Wound Rotor Synchronous
Machine
Ch. Muhammad Arbab Waheed Ahsan Fayyaz
Department of Electrical &Computer Department of Electrical &Computer
Engineering Engineering
Comsats University Islamabad Comsats University Islamabad
Islamabad, Pakistan. Islamabad, Pakistan.
ch.arbab98@gmail.com abbasiahsan6@gmail.com
Abstract—This paper presents different designs of brushless
wound rotor synchronous machine. The main idea of these
models is to generate and then utilize both sub harmonic and
fundamental components of stator MMF. Two novel winding
schemes are also presented in this paper which include both
single inverter and dual inverter designs. Additional stator
winding is added to increase the slot fill factor and different
winding patterns are implemented. A 2D finite element analysis
(FEA) is performed to analyze the proposed designs and to
verify the operating principle of the brushless WRSM.
Keywords—Wound Rotor Synchronous Machine, brushless,
additional winding, novel winding schemes
I. INTRODUCTION
Synchronous machines with permanent magnets have
been considered for applications in which reliable and strong
structure, high efficiency, easy control, and no external
excitation is needed. In PMSMs rotor flux is generated and
torque is produced by utilizing permanent magnets (rare earth
minerals). The rise in the price of rare earth minerals is a key
consideration while developing PMSMs. In such conditions
WRSMs are beneficial as compared to PMSMs. WRSMs have
an electromagnet as a rotor instead of a permanent magnet.
The stator of other AC machines and WRSM is similar in
construction. Its stator contains three-phase armature
windings and rotor has field windings to which DC current is
supplied through slip rings and brushes. A magnetic field is
produced through field current of the rotor. A three-phase
current which is produced by the application of a set of three-
phase voltages to stator armature windings produces a uniform
rotating magnetic field. The rotor magnetic field chases the
rotating magnetic field of stator [1].
In [2], performance of WRSM was analyzed for
application of electric vehicle. It was declared that a WRSM
could be a good alternate to PMSM for application of electric
vehicle. WRSM has following advantages over PMSM:
• Only field current and copper winding are used
for excitation which significantly decreases the
cost of rotor.
• There are three control variables i.e., id, iq, and if
which can be used for a wide speed range in
WRSM whereas there are only two control
variables in case of PMSM.
• The machine cost has no relation with the use of
permanent magnet.
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• There is a limited risk of over voltages for
highspeed applications because of possibility of
cancelling the field current.
Conventional (brushed) WRSM has brushes and slip rings
assembly to excite rotor field winding, therefore, the
mechanical contact between moving slip rings and static
brushes require maintenance. Also, electrical contact can
generate spark and thus these machines cannot be installed in
explosive environments. To overcome the issues of brushed
WRSM, brushless topology was proposed in which stator
windings were used to excite the field winding of rotor. The
conventional brushless method was not as much successful
because both windings were present on the same stator and a
large stator volume was required. After this another topology
was proposed in which the stator MMF higher harmonics were
utilized. These brushless machines were designed without any
exciter or additional winding of stator which were used as
alternative to conventional WRSM and PMSM.
In case of BL-WRSM the dual inverter fed WRSM has
ripples in current and torque due to undesirable harmonics. In
single inverter fed WRSM, the no. of turns of stator winding
are not fully utilized. There is a need of using the armature
windings with high slot fill factor. Previous models need
optimization as they contain high ripples in their outputs.
II. LITERATURE REVIEW
The conventional WRSM requires brushes and slip-rings
for the excitation of rotor field winding. However, the
establishment of mechanical contact between static brushes
and moving slip-rings wears them and involves their
maintenance. Dust generated by wearing of brushes can also
be harmful for motor insulation. Moreover, any fault on
electrical contact can generate sparks, restraining these
machine installations only at non-explosive environments.
For brushless excitation, conventionally, additional
(auxiliary) stator windings are used to excite the rotor field
winding which is based on generating an additional six-pole
magneto-motive force component without the use of an
inverter. For brushless excitation another scheme is such that
in an open-winding machine, three-phase stator currents can
be controlled such that the input armature currents may
contain the third-harmonic current component in addition to
the fundamental. Considering this attribute of open-winding
patterns, a harmonic current field excitation technique for a
wound rotor synchronous machine (WRSM) is used based on
the control of time-harmonic magneto-motive force [3] & [4].
Two inverters connected to both terminals of the stator
winding are controlled so that the input armature current
generates an additional third-harmonic current component.
This third-harmonic component generates a vibrating
magnetic field that induces a current in the specially designed
rotor harmonic winding. The current is supplied as DC current
to the rotor excitation winding to generate a rotor field by
using a full-bridge diode rectifier in order to achieve brushless
operation. Already proposed scheme for brushless excitation
comprises a single inverter with symmetrical stator winding (a)
distribution and the same fill factor for all stator slots. The
generated additional subharmonic magnetomotive force (SH-
MMF) component in the scheme is induced in the harmonic
winding wound on the machine rotor [5]. A rotating bridge
rectifier mounted on the rotor periphery connects the rotor
harmonic winding with the rotor field winding, and rectified
dc is supplied to the rotor field winding.
III. DESIGNS
Different models of brushless wound rotor synchronous
machine (BL-WRSM) and their optimization are discussed in
this research. As discussed earlier WRSMs have low costs and (b)
are also permanent magnet free which make them beneficial Fig. 2. BL-WRSM with AW. (a) Simple BL-WRSM with AW. (b) CPH-
over PMSMs. The field winding of WRSM is supplied a DC WRSM with AW.
current through which flux of the rotor is generated. Brushless
method of rotor excitation is chosen because it is more Figure 1 shows machine layouts of BL-WRSM. Stator is
effective as it does not have losses and it is maintenance free same i.e., 8-pole, 48-slot distributed winding with double
method. layers for both cases but rotor of CPH-WRSM has small
magnets on the edges of consequent poles.
The key idea is the generation of additional sub harmonic
and fundamental component of MMF of stator. Two different Figure 2 shows machine layouts for the case of additional
windings i.e., excitation and field windings are present on winding (AW). The stator winding in figure 1 is not fully
rotor. Sub harmonic component is responsible for induction of utilized has low slot fill factor for half of the stator. Stator
voltage in excitation winding and the field winding is fed a winding in case of AW is split into to portions and given same
DC current through a rotating rectifier present on rotor. The no. of turns (10 no. of turns) and main winding has 20 no. of
proposed topologies are implemented through an 8-pole, 48- turns. In this way stator winding is efficiently used in case of
slots WRSM. The ideas proposed are then verified by AW.
performing 2D FEA.

B. Flow Chart
A. Machine Layouts

(a)

(b)
Fig. 1. BL-WRSM. (a) Simple BL-WRSM. (b) CPH-WRSM. Fig. 3. Flow chart.

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C. Machine Topologies
Fig. 4. Single inverter fed BL-WRSM [6].
Fig. 5. Dual inverter fed BL-WRSM [7].
Figure. 6. BL-WRSM with symmetrical stator winding [5].
Figure. 7. Single inverter fed BL-WRSM with novel winding scheme.
Figure. 8. Dual inverter fed BL-WRSM with novel winding scheme.
3
Figure 4 shows single inverter fed BL-WRSM in which
there are four different windings in each phase. No. of turns of
winding X is double than winding A. This arrangement is
responsible for generation of sub harmonic and fundamental
components of MMF of the stator.
Figure 5 shows dual inverter fed BL-WRSM in which no.
of turns of all windings are kept same (symmetrical stator
winding). Inverter 1 is supplying double current than inverter
2 and this arrangement is responsible for generation of sub
harmonic and fundamental components of MMF of the stator.
Figure 6 shows BL-WRSM with symmetrical stator
winding. There is same slot fill factor for every slot of the
stator and windings x1 and x are placed in parallel to generate
sub harmonic and fundamental components of MMF of the
stator.
Figure 7 shows single inverter fed BL-WRSM with novel
winding scheme in which half of the stator windings (which
were previously not fully utilized) are split into two halves and
no. of turns of windings A & a are half than winding X. Left
portion of figure 6 is performing motor action while right one
can be utilized as generator.
Figure 8 shows dual inverter fed BL-WRSM with novel
winding scheme in which no generator action is performed
and machine is fed with two inverters one having half current
than other. Left inverter is supplying 18A current and
windings on left side have 10 no. of turns. Right one is
supplying 9A current and no. of turns of all windings are 20.
This arrangement generates sub harmonic and fundamental
component of MMF.
IV. RESULTS AND TABLES
This section presents results and tables of all designed
models.
A. Tables
Table I. Structural Parameters
Parameter BL-WRSM
No of turns of winding XYZ 10
No of turns of winding ABC 20
No of turns of field winding 25
No of turns of excitation winding 12
Speed of rotation 900rpm
Frequency 60Hz
Core material 35JN210
Winding material Copper
 Table II. Stator Parameters Table V. CPH-WRSM
Parameter Unit Value Parameters Single Brushless Single Dual
Inverter WRSM with Inverter Inverter
Stator outer radius mm 115 Fed BL- Symmetrical Fed BL- Fed BL-
WRSM Stator WRSM WRSM
Stator inner radius mm 47.5 Winding with with
Novel Novel
Total no of slots -- 48 Winding Winding
Scheme Scheme
Total no of poles -- 8 CPH- Brushless CPH- CPH-
WRSM CPH-WRSM WRSM WRSM
with SSW with AW with AW
Length of stack mm 120
Back EMF 84.69 86.30 76.26 76.26
(V)
Air gap mm 0.5
Field 7.83 7.83 6.94 4.92
Current
(Arms)
Excitation 6.70 6.69 6.17 8.25
Table III. Rotor Parameters Current
(Arms)
Parameter Unit Value Torque 14.09 14.1 11.61 12.41
(Nm)
Rotor outer radius mm 47
Torque 31.9 31.9 30.8 49.7
Rotor inner radius mm 12.5 Ripple (%)
Total no of poles of excitation -- 4
winding
B. Results
Total no of poles of field -- 8
winding

Table IV. Simple BL-WRSM

Parameters Single Dual Brushless Single Dual
Inverter Inverter WRSM with Inverter Inverter
Fed BL- Fed Symmetrical Fed BL- Fed BL-
WRSM Brushless Stator WRSM WRSM
WRSM Winding with with
Novel Novel Fig. 9. BL-WRSM field currents.
Winding Winding
Scheme Scheme
Simple Simple BL-WRSM BL- BL-
BL- WRSM with SSW WRSM WRSM
WRSM with AW with AW
Back 61.73 83.9 62.94 58.65 61.33
EMF (V)
Field 9.22 12.48 8.88 9.25 7.00
Current
(Arms)
Excitation 6.65 9.79 6.595 6.65 4.56
Current
(Arms)
Torque 9.79 11.59 9.535 7.64 8.04 Fig. 10. BL-WRSM excitation currents.
(Nm)
Torque 12.6 37.9 16.1 21.5 38.5
Ripple
(%)

Fig. 11. BL-WRSM torques.

Figures 9 and 10 show field and excitation currents of each

simple BL-WRSM model respectively. It is observed that dual
inverter fed BL-WRSM has highest values of currents.
Figure 11 shows torques of all designed simple BL-
WRSM without magnets. It can be observed that starting
torques of these machines are low and highest value of

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starting torque is 1.58Nm in case of dual inverter fed BL-
WRSM with novel winding scheme which also has highest
average torque of 11.59Nm.
Fig. 12. CPH-WRSM field currents.
Fig. 13. CPH-WRSM excitation currents.
Fig. 14. CPH-WRSM torques.
Figures 12 and 13 show field and excitation currents of
each CPH-WRSM model respectively. It can be observed that
field and excitation currents of single inverter fed CPH-
WRSM and CPH-WRSM with symmetrical stator winding
are overlapping each and have highest rms values.
Figure 14 shows torques of all designed CPH-WRSM
models. It can be observed that starting torque significantly
increased by using small magnets because permanent magnet
field combine with rotating magnetic field to strengthen
magnetic flux. Torques of both single inverters fed CPH-
WRSM and CPH-WRSM with SSW are overlapping each
other and almost have same average value which is highest of
all other cases.
V. CONCLUSION
The main objective of this research is to optimize the
results of already designed machines. For this purpose,
different parameters are applied to the basic BL-WRSM. An
8-pole and 48-slot simple brushless WRSM is selected to
compare the performance of different dual and single inverter
topologies. Different techniques are used to generate the sub
harmonic component. The feasibility of each design is
validated through 2D FEA. The low starting torque (0.8Nm)
of basic model required improvement because there was no
constant excitation source present. The starting torque and
torque density were improved by proposing CPH-WRSM.
The technique of SSW has been applied to both BL-WRSM
and CPH-WRSM and results are compared to previous
models. The average torque of CPH-WRSM with SSW was
increased to 14.1Nm with same starting torque and torque
ripple as of single inverter fed CPH-WRSM. A dual inverter
fed BL-WRSM has also been proposed by applying the same
parameters as of base machine.
A novel stator winding scheme was proposed and applied
to both single inverters fed (generator mode) BL-WRSM and
CPH-WRSM to increase the slot fill factor without addition
of second inverter to the design. Another novel stator winding
scheme has been proposed in which stator windings are
supplied with two inverters. The starting torque of dual
inverter fed BL-WRSM reached 1.58Nm which is highest of
previous BL-WRSM designs but torque ripple is also
increased to 38.5% with average torque of 8.04Nm. The
ripples in case of dual inverter fed CPH-WRSM are also
increased to 49.7% with average value 12.41Nm.
ACKNOWLEDGMENT
Above all else, acclaims and gratitude to the Allah, the
Almighty, for His showers of favors all through our research
work to finish the project effectively. He has provided us
everything needed to complete this project and strengthened
us even in the most difficult times.
We would like to express our deep gratitude to our project
supervisor, Dr. Junaid Ikram, Assistant Professor,
Department of Electrical & Computer Engineering, Comsats
University, Islamabad who gave us the opportunity to do this
project and his invaluable guidance throughout this project.
He has taught us the methodology to carry out the research
and to present the research works as clearly as possible. We
would like to thank you for all that you have done for us. We
have enjoyed our time working under your leadership. Thank
you so much!
I deem it a great honor to express my deepest sense of
gratitude to my honorable supervisor for the continuous
support during research, for the patience, motivation,
enthusiasm, and immense knowledge. His guidance helped
me in all the time of project and writing of thesis. I could not
have imagined having a better Supervisor and mentor for my
final year project.
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