A Study of the Research Activity in the Nordic Countries on Large Permanent Magnet Synchronous Machines Ø. Krøvel, R. Nilssen, A. Nysveen Department of Electrical Power Engineering, NTNU 7491 Trondheim, Norway Phone: +47 73594241 Fax: +47 73594279 Email: oystein.krovel@elkraft.ntnu.no II. LARGE PERMANENT MACHINES Abstract- This paper presents an overview of the activity on large Permanent Magnet Synchronous Machines (PMSM) in the Nordic countries. It is found that the Nordic countries are in the leading end of the development of large PMSM. This is much due long traditions of ship building, an important application for large PMSM, and pioneer work in wind conversion. The focus has mainly been on the radial flux permanent magnet machines, but in the later years also attentions has been given to axial and transverse flux permanent magnet machines. The industry has started to use large PMSM; e.g. ABB has their compact azipod® with radial flux machine, Siemens has a radial flux submarine motors and Jeumont uses axial flux generator in wind turbines. The impression is that at the time, the large machine manufacturers in Europe have radial flux machines in their assortment and are developing the axial flux technology. While the smaller and more specialised companies have already developed axial flux machines for their applications. T Permanent magnets have been used for different small applications since 19th century. In the 20th century the PMtechnology has conquered a large part of the market for small machines; either it is DC-machines or AC machines. It is only in the last 20 years that the quality has become so high and price so low that the PM-technology can compete with the field wound machines for applications with higher power (>1MW) [4]. For small machines it is cheaper to use magnets than wound poles, and this will be true for machines up to a diameter of 150mm [2]. This is also true for larger machines as long as the poles are kept small. This together with other aspects as rotor losses, efficiency, cooling of rotor, space etc. favours the PMSM for many applications, especially for large multi pole machines e.g. direct driven wind generators. But also on other applications as paper mill motors and ship propulsion the PMSM replaces the induction and wound field machines. A way to determine whether a machine is large, medium or small (electrically) is to look at the power pr pole of the machine. An example is a typical wind turbine of 3MVA and 17rpm which gives a power pr pole of 14kVA, while a field wound machine for hydro power will have power pr pole of 8MVA (14 poles, 112MVA). Using this approach almost all PMSM can be considered small, electrically. Therefore large PMSM just means that the machine is among the largest in power and size of the PMSM. Mechanically the dimensions can be rather large. A typical wind turbine of 3MW and 17 rpm might have a diameter of 6m, a length of 2m and weight about 80 tons. Typical power range for large PMSM is 1MW and up to 20MW, with low speed and high torque applications. The upper limit for PMSM has not been reached. Some major limitations and challenges have partly been met the latest years. Examples of improvements which have made the permanent magnets more interesting for large machines are lower price, higher energy density and that the magnets have become more resistant to demagnetization. I. INTRODUCTION his paper present an overview of the research activity on large permanent magnet synchronous machines in the Nordic countries. It is the result of the initial stages of a PhDstudy on design of large PMSM, the work was initiated at NTNU by prof. Dr.ing Robert Nilssen to meet the growing need for knowledge on large PMSM in Norway. The focus is on the activities in the Nordic academic institutions. Some examples of industrial activities on large PMSM are also mentioned together with some academic institutions outside of the Nordic countries. Those examples are meant to put the Nordic effort on large PMSM in perspective to the world wide development of large PMSM’s. There are several areas where large PMSM can be used. Applications described in the literature are ship propulsion, wind turbines, paper mills and elevators, [1]-[3]. In addition large PMSM can also be used in drilling, actuators and other special adapted machines. Examples of smaller machines than 1 MW, is also presented in this paper. This is mostly due to the fact that it is more convenient to build small machines and test the theories concerning large machines on smaller ones (50-500kW). Therefore also most research is done on smaller models of large machines. The papers [1]-[3] present an overview of large PMSM seen from Siemens and ABB and some applications for large PMSM. They also present some trends and visions for the development of large PMSM in the 21st century. III. TYPES OF PERMANENT MAGNET MACHINES There are generally three types of PM-machines [5]. The different types are: Radial, Axial and Transversal flux machines. Also some types of switched reluctance machines (SRM) use PM in their construction, but they will not be considered here. General theory about permanent magnet 1 but it is somewhat more common to use concentrated windings. It is also used ironless stators; this reduces iron losses, makes it possible to cool the winding more effectively and also eliminates the attractive forces between the magnets in the rotor and the iron in the stator, but increases the need for magnets, [6]. machines can be found in different textbooks, one example is Hanselmann [6]. A. Radial Flux Permanent Magnet Machine The radial flux machine (RFPM) is the classic type and most common. It is quit similar to other AC-machines and are also used in mostly the same areas. The rotor can have buried or surface mounted magnets, the poles can be skewed, have pole shoes etc. The stator is quite similar to other classical AC-machines (induction and synchronous) both for windings and tooth shape. It is common, but not always necessary, to use semi closed slots. Magnetic slot wedges is also an option. Two layer fractional windings are mostly used even though the simplicity of concentrated windings has begun to be appreciated. The active materials; copper, magnets, iron, sheet metal, converting the mechanical energy to electric or visa versa, are placed along the air gap. For RFPM with large diameter this means that the active material becomes a thin shell around the air gap thus most of the volume to the machine is air or supporting structures to transfer the torque to or fro the shaft to the rotor rim. Since the force is acting at a large radius a high torque is produced. C. Transversal Flux Permanent Magnet Machine Transversal flux machines (TFPM) is the most complex and least equal to classic machine design. It can be single sided [8] or double sided [9] respectively with one or two wound rings of copper with iron cores to lead the magnetic flux around the copper. The TFPM has a rotor with either buried or surface mounted permanent magnets. The TFPM have a very high force and power density and therefore the TFPM has been considered very promising in application with high torque and low speed. One major problem with TFPM is that to achieve this high force density the synchronous reactance can grow very high which in turn makes the converter expensive. Another factor is cost due to the many parts in a TFPM. For more detailed information, confer Hystad’s dissertation [10]. IV. THE ACADEMIC ACTIVITY ON LARGE PERMANENT MAGNET MACHINES Axial Radial La Lr Dg Active material As mentioned before, the area where PM-machines is better than field wound machines and induction machines is where the power pr pole is low, in low speed, high torque applications and in special application with special requirements to size, weight, inertia, design, etc. This study of research activity in the Nordic countries shows that the applications for PM-machines are mainly wind conversion and ship propulsion. This chapter seeks to explain what the different universities in the Nordic countries have done of research on large PMSM. In addition some publication from other universities has been mentioned. Do Di Center/Shaft Fig 1 Comparison of the diameter of active material in radial and axial machines B. Axial Flux Permanent Magnet Machine Axial flux machines (AFPM) is magnetized in the axial direction. The air gap is radial to the shaft. Therefore, compared to RFPM, the length of AFPM (La) is equal to the thickness of active materials in the RFPM and the thickness (Do-Di) of the AFPM is equal to the length of RFPM (Lr), see Fig 1. Given the same outer diameter and the same force pr area in the air gap, the AFPM have a lower torque pr volume of active material due to the fact that much of the force is working on a smaller radius and thus producing less torque. The great advantage of the AFPM contra the RFPM is the possibility to use the volume of the machine more effectively, the power density (W/m3) gets higher. The AFPM usually have a disc shaped design, with large diameter and short length, which are useful in different applications. Several discs can be connected in series and make a multi disc machine. As for RFPM the rotor in an AFPM can be made with surface mounted or buried magnets. The stator has also the same possibilities for different design of teeth and windings, A. Activity in the Nordic Countries At the universities in the Nordic countries it has been conducted research on the design of PM-machines since the eighties. At NTNU, Ådnanes [5] submitted his thesis in 1991 on “High Efficiency, High Performance Permanent Magnet Synchronous Machines”. This was a general study of surface mounted PM-machines and the control of them. He has also gathered general information about the permanent magnet, how it works, how it is manufactured, history of PM, etc, and made a user manual for permanent magnets. Other than general theory about PM and design, the thesis mostly treats the control of a PMSM. At NTNU this thesis was followed by Hystad’s [6] “Transverse Flux Generators in Direct Driven Wind Energy Converters” from 2000. He examined the single and double sided TFPM and compared them with Grauers’ [11] RFPM for direct driven wind generator. Hystad’s work was a followup of Grauers’ work. Hystad included the converter design into the optimizing routine and found that even though the 2 Leijon has played an important role. ABB uses this technology in i.a. Windformer® and Powerformer®. Finland is the Nordic country which has most publications and research on large PM-machines. Both at the universities in Helsinki (HUT) and Lappeenranta they have had several doctoral studies on different subject concerning large PMmachines. At HUT, Lampola [17] presented his dissertation “Directly Driven, Low Speed Permanent Magnet Generators for Wind Power Applications” in 2000. He looked at several different types and variations of directly driven generators, and found that the best type of directly driven PM-machine is a radial machine with diamond winding and curved surface mounted permanent magnets. He comments in his conclusion that a solution with concentrated windings will be almost as good as with the conventional double layer diamond winding because of the simplicity of concentrated windings. TFPM has extremely high torque density, the cost of the converter due to the high reactance makes the double sided TFPM just slightly better than Grauers’ PM-machine at power ratings below 3 MW. The single sided TFPM was found not to be competitive on neither cost nor force densities. The research on large PM-machines has continued at NTNU with radial and axial flux machines. Though few publications, there has been done a lot of work on PMmachines for ship propulsion, thrusters and wind generators in cooperation with the industry. Later this year an integrated 100 kW PMSM in a thruster application will be presented at ICEM’04 in Cracow. In Sweden the research on large PM-machines has mostly been done at Chalmers and been connected to wind energy. As mentioned, Grauers [11] conducted a thorough study of radial magnetized direct driven permanent magnet machine with surface mounted magnets. He optimized a 500 kW generator and found that the outer diameter would only be slightly larger than the nacelle of the an already existing wind converter i.e. minimal changes in construction. The efficiency, including the frequency converter, is also higher than traditional drive trains for wind conversion. Grauers also looked at the design of PM-machines from 30kW to 3 MW and compared them with other generators proposed by other authors (induction generator with gear, TFPM, RFPM, AFPM and wound field synchronous generator). The proposed generator from Grauers has higher efficiency and lighter weight than the other. Only the TFPM from Weh [12] is better, but as Hystad later showed, when including the converter into the optimizing routine, it is only slightly better. At KTH, Stockholm, they have developed a high speed PM-generator for distributed generation of power together with ABB [13]. The high speed generator operates at 30000rpm to 70000rpm with an output frequency up to 2.4kHz. It has surface mounted magnets which are covered by a carbon-fiber bandage to retain them at the high speeds. The generator also works as a starter for the gas turbine. Calculations and measurements of the losses both as generator and converter fed motor have been conducted and the efficiency was found to be 97% for generator operation and 96% for motor operation [14]. This is clearly not a low speed high torque application, but it proves that the permanent magnet technology is spreading to other applications. In Uppsala several projects concerning large PMSM is in progress under supervision of prof. Mats Leijon. Segergren finished his licentiate thesis on “Simulation of Direct Drive Generator for Underwater Power Conversion” in 2003 [15]. He investigates the possibility to use cable wound generators with large diameter in underwater power conversion (UPC). The cable winding has several advantages in under water applications. He concludes that a cost effective underwater power converter is possible to realize. Other projects at the University of Uppsala concerning large PMSM, is Wave and Wind energy conversion [16]. Much of the research on PMSM at the University is based on cable wound machines, which is a technology where M. Fig 2 The different rotor topologies evaluated by Rosu [18]. a) Surface mounted magnets without pole shoes, b) is with pole shoes, c) radially inserted magnets d) tangentially inserted magnets Rosu [18] finished his licentiate thesis, “Large OutputPower, Low-Speed Permanent Magnet Synchronous Motor Designs for Ship Propulsion Drives” in 2001. It consists of five publications, which deals with different aspects of PMmachines, ranging from general design, demagnetization of magnets and magnetic field distribution in the air gap. Rosu is focusing on the electromagnetic construction of the rotor. He proposes several different solutions; surface mounted PM with or without pole shoes and buried PM both tangentially or radially inserted (Fig 2). Both the surface mounted solutions are better than the buried magnets concerning torque pr volume. The buried PM solutions suffer from high portions of leakage flux. The solution without pole shoes uses the least magnet volume, but the pole shoe solution is more favourable when demagnetization, harmonics and resistive losses in 3 AFPM with different dimensions and pole numbers. The results of his calculation tool agree well with measurements done on an actual machine. Several different arrangements of the PM were calculated and tested to find the different torque patterns and minimize the torque ripple. He found that combination of magnet shape and asymmetric distribution of the magnets or in the teeth would minimize the ripple in the torque most. He would not conclude that a specific magnet shape is superior Aalborg University has in cooperation with Risø National Laboratory made a survey of generator and power electronics for wind turbines [22]. The survey presents the different machines, with or without gear, used as generators in wind turbines to day, and lists pros and contras and the challenges for the different types. For all the PM machines they find that the curie temperature (maximum temperature before demagnetization) might be to low at fault situations (250°C), and the voltage at runaway speed can cause problems. For AFPM the axial force in the air gap is mentioned as a challenge in the construction. The TFPM consists of many different parts which will cause increased fabrication cost. It also has a relative high reactance, which increases the cost of the converter and may cause an insufficient short circuit current to trigger the protection. The authors conclude that a wind turbine or a park of wind turbines has to be looked as an integrated system, where stability, efficiency, cost etc. has to be taken into account. magnets are concerned. Negrea has together with Rosu, looked at the temperature rise in a PMSM due to losses in the machine [19]. They have looked at the sensitivity of the temperature distribution due to losses in different part of the machine. They studied two different rotor topologies with surface mounted magnets, one with pole shoes and one without, and found that the one with pole shoes gave the lowest losses in the magnets and therefore also the lowest temperature in the magnets. But both topologies had temperatures in the magnets below the critical value for the chosen magnets. As expected they found that the temperature rise in all part of the machine was most sensitive to changes in the copper losses. B. Research on large PMSM in other countries It is obvious that is not only in the Nordic countries it has been conducted research on large PMSM. As chapter V shows institutions in France, Germany and England have all developed large PMSM. Also in Asia and the USA there has been development of the technology. Here follows some examples of activity in the academic circles on large PMSM outside the Nordic countries. Spooner has proposed a highly modular design for a PMSM as wind generator [23]. He uses ferrite magnets blocks in the rotor. In the stator he uses E-cores with a single rectangular coil. These elements are fastened to the framework by bolts. This gives a modularity which enables the machine manufacturer to produce machines with very different pole numbers with a minimum of different parts in stock. Repairs can also be done on site by replacing the damaged unit only. But the many modules also lead to higher assembly cost (as for TFPM). Spooner claims the machine has low reactance and high efficiency. In Delft, Nederland, Dubois, Polinder and Ferreira has made a comparison of different generator topologies for direct driven wind turbines [24]. They look at the torque density and the cost/torque. They conclude that the TFPM and the AFPM are the topologies which would be most interesting to look at for wind turbine generators. Dubois et al presented a prototype TFPM with toothed rotor at ICEM 2002 [25]. They developed a lumped magnetic circuit for the machine to optimize the cost/torque of the machine. Based on the Fig 3 Different topologies for paper mills, a) induction motor with gear, b) PMSM [20], [2]. At the Lappeenranta University of Technology Heikkilä [20] presented a dissertation with the topic “Permanent magnet synchronous motor for industrial inverter application” in 2000. It contains a good literature study and a brief history of permanent magnet machines. The dissertation is based on the calculation and testing of a 45kW 600 rpm PMSM with buried V-magnets. The results are used to calculate machines with higher power (>1MW) and lower speed. The conclusion of the thesis is that a medium speed (600 rpm) PMSM may replace inverter fed induction machines with gear in industrial applications (Fig 3). There has also been a study on torque vibration in axial machines at Lappeenranta University of Technology. Kurronen [21] presented his dissertation on “Torque Vibration Model of Axial Flux Surface Mounted Permanent Magnet Synchronous Machine”. He has developed analytic methods for calculating the torque of a machine based on electrical and magnetic loading. Instead of using time-consuming 3D-FEM tools he instead used analytic models which can be used on 4 module is kept low and gives better hydrodynamics for the azipod unit. optimization a machine with 68 kg/phase active material, a nominal torque of 1000Nm/phase and a speed of 100rpm were built. The tests revealed that the model agreed with the built machine. V. INDUSTRIAL APPLICATIONS Several manufacturers of electrical machines have in resent years developed large PMSM. The use of the large PMSM has focused on ship propulsion, wind turbines, medium speed drives, e.g. paper machines, and special applications such as elevators. A. Wind turbines For wind turbines and generators there are several manufacturers of PMSM generators. ABB has their Windformer® system with the cable wound high voltage generator [3]. Siemens has delivered a 3.3MVA RFPM to Scandwinds prototype test site at Hundhamarfjellet, Norway. Jeumont, Leitner Lifts, Mitsubishi, MTorres, Permapower, Zephyros and WinWinD are all companies which delivers wind turbines with PMSM [2], [26]-[32]. Jeumont has an AFPM generator of 750kW and are planning to deliver up to 2MW wind turbines. Permapower has a 1.2MW generator with external rotor. Zephyros uses a high voltage (4kV), 2MW generator from ABB. WinWinD uses a planetary one stage gear and a PM generator from ABB. They offer wind turbines from 1 to 3MW. Fig 5 A Compact azipod® propulsion unit from ABB [34] Siemens/Shottel has developed the SSP which also is a podded propulsion, but with twin propellers and a power range of 5MW to 20MW [35]. They also make PMSM for submarines [36]. Rolls Royce is developing a 180rpm, 20MW TFPM for propulsion of small warships. A 2MW demonstrator to demonstrate the technology ahead of the full scale TFPM has been built [37]. Kaman [38] has together with the US Navy developed a 3000 Hp (2.25MW) motor for ship propulsion. They have also developed a podded propulsion of 1000Hp (750kW) and 850rpm. They also have developed a motors and generators for other applications such as drilling. Kaman uses AFPM. C. Paper machines ABB has developed a medium speed PMSM for direct drive for paper mills. It replaces inverter fed induction motors with gear. (Fig 3) This reduces maintenance and increases the efficiency of the system. The first drives were installed in a paper machine in Finland in 1999. It is clear that other industries which use medium speed drives can benefit from the technology [34]. D. Elevators Jokinen [2] mentions Kone [33] and their AFPM machine for elevators as a interesting case of new PMSM. By developing a direct driven, low speed AFPM which can be placed inside the elevator shaft, Kone has eliminated the need for a machine room. Further Kone uses some sort of rope system and pulleys that have also eliminated the need for counterweights. Fig 4 The tower head of a Zephyros wind turbine B. Ship propulsion Several companies have developed PMSM for ship propulsion [2]. ABB has already delivered several azipods to different types of ships. They use PMSM in the power range from 400kW to 5MW and its typical used in e.g. offshore support vessels, floating oilrigs, cable layers and ferries. The PMSM is placed inside the submerged unit (Fig 5) and directly coupled to the propeller, and it is only the power cables which goes true the hull. By fitting the stator to the outer shell of the azipod, effective cooling of the stator is achieved. By using the PMSM, the diameter of the motor VI. SUMMARY This paper has focused on the Nordic activity on large PMSM. It is found that in the last 15 years universities in the Nordic countries has researched on all the three types of large PMSM and that the Nordic countries are in the leading end of 5 the development. Most of the research has been focused on applications for wind conversion and ship propulsion. The focus has been on RFPM, but also AFPM and TFPM has been investigated. It seems that the RFPM is the safe and cheap way to make a PMSM. AFPM can compete, but has a slightly higher cost and therefore is of interest for special applications which can allow large diameters, but must have short machines. The TFPM has supreme capabilities on torque pr volume, but the cost of the converter is high. Therefore it is most relevant for special applications where cost is secondary. Also the industry reflects the same attitude to the different PMSM. RFPM is the safe and cheapest way and therefore used by the established industry in the large production lines. The relative new technology of AFPM is embraced by the smaller companies and those with special needs. But both ABB and GE have started to develop AFPM for wind turbines. Rolls Royce has focused on the potential of the TFPM and is developing TFPM for ship propulsion. [12] Weh, H., Hoffmann, H., Landrath, J., Mosebach, H., Poscadel, J,. 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Large output-power, low-speed permanent magnet synchronous motor designs for ship propulsion drive. Licentiate Thesis, Helsinki University of Technology, Laboratory of Electromechanics, Report 64, Espoo 2001, 77 p. ISBN 951-22-5430-1, ISSN 1456-6001. [19] Negrea, M., Rosu, M., Thermal Analysis of a large Permanent Synchronous Motor for Different Permanent Magnet Rotor Configurations. Proceedings of the International Electric Machines and Drives Conference, Cambridge, Massachusetts, USA, 17–20 June 2001, pp. 777–781. [20] Heikkilä, T., Permanent Magnet Synchronous Motor for Industrial Inverter Applications – Analysis and Design, Dr.thesis, Lappeenranta University of Technology, 2002, ISBN 951-764-699-2, ISSN 1456-4491 [21] Kurronen, P., Torque Vibration Model of Axial-Flux Surface-Mounted Permanent Magnet Synchronous Machine, Dr.thesis, Lappeenranta University of Technology, 2003, ISBN 951-764-773-5, ISSN 1456-4991 [22] Hansen, L. H., Helle, L., Blaabjerg, F., Ritchie, E., Munk-Nielsen, S., Bindner, H., Sørensen, P., Bak-Jensen, B., Conceptual Survey of Generator and Power Electronics for Wind Turbines, Risø National Laboratory, Roskilde, Denmark, 2001. ISBN 87-550-2743-1, ISBN 87550-2745-8 (Internet), ISSN 0106-2840 [23] Spooner, E., Williamson, A.C., Catto, G., Modular design of permanent-magnet generators for wind turbines, Electric Power Applications, IEE Proceedings- , Volume: 143 , Issue: 5 , Sept. 1996 Pages:388 – 395 [24] Dubois M, Polinder, H., Ferreira, J. A., Comparison of generator topologies for direct-drive wind turbines. NorPIE/2000 workshop proceedings. 2000 IEEE Nordic Workshop on Power and Industrial Electronics (Aalborg, June 13-16, 2000), Aalborg University, Aalborg, 2000, p. 22-26. ISBN: 87-89179-29-3, cat. c, Projectcode: ET00-13 [25] Dubois M, Polinder, H., Ferreira, J. 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ACKNOWLEDGMENT This PhD-study is financed by strategic resources from NTNU, Norway and is a part of the project Energy Efficient All Electric Ship (AE3S). AE3S is a project with participants from NTNU (dept. of electric power engineering and dept. of marine technology), ABB, AkerKvaerner, Brunvoll, MARINTEK and NorPropeller. They are hereby acknowledged. VIII. REFERENCES Dorr, G., Trends and Development of Electrical Machines in the 21st Century, International Conference on electrical Machines, ICEM, Bruges, Belgium, 25-28 august 2002 [2] Jokinen, T., Large Permanent Magnet Machines, International Agean Conference on electrical Machines and Power Electronics, Istanbul, Turkey, 26-28 may 2004 [3] Waltzer, I., Technological Trends in Large Permanent Magnet Motor Applications, International Conference on electrical Machines, ICEM, Bruges, Belgium, 25-28 august 2002 [4] Overshott, K.J. Magnetism: it is permanent. IEE Proceedings A, Volume 138, No. 1, January 1991, p. 22-30. 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Transverse Flux Generators in Direct-driven Wind Energy Converters, Dr thesis, NTNU Trondheim, Faculty of Electrical Engineering and Telecommunication, Department of Electrical Power Engineering, 2000. ISBN82-7984-116-4, ISSN 0809-103X [11] Grauers, A., Design of Direct-Driven Permanent Magnet Generator for Wind Turbines, Dr. thesis, Chalmers University of Technology, 1996, ISBN 91-7197-373-7. [1] 6