Optimisation of additively manufactured permanent magnets for wind turbine generators

Research output: Contribution to conferencePaper

Abstract

With the increased demand for higher efficiency electrical machines, renewable energy and in all-electric transport systems, there is a growing market for permanent magnet machines and hence usage of rare earth magnet materials. One application – direct drive wind turbines – has a particularly large requirement in terms of magnet kg/MW and an aspiration to reduce this usage. That in turn motivates the authors of this paper to examine the optimal shape, distribution and mixture of permanent magnet poles by that could be produced through an additive manufacturing (AM) route. AM is a relatively new technique of magnet manufacture which has the potential to replace conventional forming techniques that are wasteful and often struggle with complex geometries. A genetic algorithm coupled to a finite element code is used to optimise magnet size and material configuration, and compares the results with conventional manufacturing/shaping techniques. This proposal investigates if additive manufacturing can meet the same level of performance whilst reducing permanent magnet material cost. Results which use additive manufacturing show that a reduction in the total magnet cost can be achieved with virtually no penalties in overall machine performance. Although the evaluation focuses on the cost of the rare earth magnet material in use – and excludes manufacturing cost and time – the results highlight that by using additive manufacturing a cost reduction of up to 3% can be achieved highlighting that AM has significant potential to compete with, if not succeed, existing magnet forming techniques.

Conference

ConferenceInternational Electrical Machines and Drives Conference 2019
CountryUnited States
CitySan Diego
Period12/05/1915/05/19
Internet address

Fingerprint

3D printers
Turbogenerators
Wind turbines
Permanent magnets
Magnets
Rare earths
Costs
Cost reduction
Poles
Genetic algorithms
Geometry

Keywords

  • permanent magnet generator (PMG)
  • additive manufacturing
  • optimisation
  • direct drive wind turbine

Cite this

McGarry, C., McDonald, A., & Alotaibi, N. (2019). Optimisation of additively manufactured permanent magnets for wind turbine generators. Paper presented at International Electrical Machines and Drives Conference 2019, San Diego, United States.
McGarry, Connor ; McDonald, Alasdair ; Alotaibi, Nasser. / Optimisation of additively manufactured permanent magnets for wind turbine generators. Paper presented at International Electrical Machines and Drives Conference 2019, San Diego, United States.8 p.
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McGarry, C, McDonald, A & Alotaibi, N 2019, 'Optimisation of additively manufactured permanent magnets for wind turbine generators' Paper presented at International Electrical Machines and Drives Conference 2019, San Diego, United States, 12/05/19 - 15/05/19, .

Optimisation of additively manufactured permanent magnets for wind turbine generators. / McGarry, Connor; McDonald, Alasdair; Alotaibi, Nasser.

2019. Paper presented at International Electrical Machines and Drives Conference 2019, San Diego, United States.

Research output: Contribution to conferencePaper

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T1 - Optimisation of additively manufactured permanent magnets for wind turbine generators

AU - McGarry, Connor

AU - McDonald, Alasdair

AU - Alotaibi, Nasser

N1 - © 2019 IEEE. Personal use of this material is permitted. Permission from IEEE must be obtained for all other uses, in any current or future media, including reprinting/republishing this material for advertising or promotional purposes, creating new collective works, for resale or redistribution to servers or lists, or reuse of any copyrighted component of this work in other works.

PY - 2019/5/14

Y1 - 2019/5/14

N2 - With the increased demand for higher efficiency electrical machines, renewable energy and in all-electric transport systems, there is a growing market for permanent magnet machines and hence usage of rare earth magnet materials. One application – direct drive wind turbines – has a particularly large requirement in terms of magnet kg/MW and an aspiration to reduce this usage. That in turn motivates the authors of this paper to examine the optimal shape, distribution and mixture of permanent magnet poles by that could be produced through an additive manufacturing (AM) route. AM is a relatively new technique of magnet manufacture which has the potential to replace conventional forming techniques that are wasteful and often struggle with complex geometries. A genetic algorithm coupled to a finite element code is used to optimise magnet size and material configuration, and compares the results with conventional manufacturing/shaping techniques. This proposal investigates if additive manufacturing can meet the same level of performance whilst reducing permanent magnet material cost. Results which use additive manufacturing show that a reduction in the total magnet cost can be achieved with virtually no penalties in overall machine performance. Although the evaluation focuses on the cost of the rare earth magnet material in use – and excludes manufacturing cost and time – the results highlight that by using additive manufacturing a cost reduction of up to 3% can be achieved highlighting that AM has significant potential to compete with, if not succeed, existing magnet forming techniques.

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KW - optimisation

KW - direct drive wind turbine

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McGarry C, McDonald A, Alotaibi N. Optimisation of additively manufactured permanent magnets for wind turbine generators. 2019. Paper presented at International Electrical Machines and Drives Conference 2019, San Diego, United States.