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10 kW, 15φ Axial flux pancake generator for 2-blade Wind
Turbine
Abstract
A 10kW permanent magnet electric generator has been built and tested for use with a high tsr 5m blade
diameter wind turbine. The system was configured for 15 phase, 15 coils and 16 poles. Each coil is
individually rectified to dc, reducing cogging and allowing better control over the output voltage. Total
cost of the generator was AU$873 and was constructed with typical Ðhome-workshopÑ tools.
Keywords: Wind power, Permanent Magnet Generator, 10kw wind turbine
LIST OF FIGURES
Figure
Page
1
Rear half of the generator rotor
2
2
Front half of generator rotor
2
3
Generator stator
3
4
Front half of generator rotor with magnets attached
3
5
Assembled generator
4
6
Testing the assembled generator
5
7
Measured RMS Voltage under no load, internal resistance is 2.5 Ohms
6
8
Measured voltage into matched load (2.5 Ohm)
6
9
Measured RMS power generated for all 15 coils into a matched load
7
¨ 2003 Warlock Engineering Pty. Ltd. All rights reserved.
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http://warlock.com.au
4 th November 2003
1. Construction of the Permanent Magnet Generator
Figure 1. Rear half of the generator rotor
The rear plate (rotor) is mounted on a trailer axial bearing, it holds the first set of 16
neodymium magnets.
Figure 2. Front half of generator rotor
The front plate holds the second set of 16 neodymium magnets, this plate is bolted to
the rear half of the generator rotor completing the magnetic circuit.
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http://warlock.com.au
4 th November 2003
Figure 3. Generator stator
15 independent coils have been fixed into the stator using 24 hour epoxy resin. The
coils have a thickness of 12 mm, they measure 2.5 Ohms each and are wound using
0.6mm diameter wire. This stator will be remade out of fibreglass, and the holes in the
centre of the coils will be reduced to increase the power output. Epoxy and aluminium
should be avoided in the generator due the fact that epoxy softens in as little as 60 o C
and aluminium has no fatigue limit, any infinitesimally small stresses will eventually
cause failure.
Figure 4. Front half of generator rotor with magnets attached
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http://warlock.com.au
4 th November 2003
The neodymium magnets grade N38, 2Ñ x 1Ñ x 0.5Ñ magnetised through thickness fit
into the slots of the front and rear plates.
32 holes have been drilled into both plates to help cooling of the coils.
N
S
S
N
Rotor Front Plate Stator Magnets Trailer axial bearing
Figure 5. Assembled generator
The generator was assembled with the stator coils sandwiched between the two sets of
magnets, 2mm of clearance was given between coils and magnets. Care was taken
assembling as the magnetic force acting on the 32 magnets can be up to 640Kg!
The generator spins feely until current flows, this is due to no iron being in the stator
and the absence of cogging greatly helps starting in very low wind.
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http://warlock.com.au
4 th November 2003
2. Total cost of the Permanent Magnet Generator
System cost (AUD)
Magnets $500
2000m 0.6mm magnet wire $88
2 trailer axles $60
Steel $50
Primer and enamel paint $70
Welding rods $20
Metal cutting discs $40
Connector strips $25
Bolts and nuts $20
Total cost $873
3. Testing the Permanent Magnet Generator
Page 5

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