800W generator design | Online Design Tools for Locally Manufactured Small Wind Turbines

Submitted by karthikeyan on Tue, 04/12/2018 - 13:33

Duration:

00:06:34

Tabs

Results

Blade Rotor Outputs
Property	Value	Variable name
RPM at the cut-in wind speed (TSR)	208.997 RPM	n_cut_in
RPM at the nominal wind speed (TSR)	333.784 RPM	n_nom
Nominal tip speed ratio	4.19233	tsr_nom
RPM at the cut-in wind speed (Flux Linkage)	227 RPM	cutin_RPM
Cut-in Voltage (Flux Linkage)	48 V	cutin_Voltage
Wind speed at cut-in RPM (Flux Linkage)	3.25842 m/s	cutin_Vw
Mechanical power (Torque)	703.01 W	Pmech_Torque_x

Generator Rotor Outputs
Property	Value	Variable name
Rotor disk thickness	10 mm	hr
Magnet width-to-pole pitch ratio	0.45665	ai
Inner-to-outer magnet radius	0.614073	kd
Flux density in airgap	0.494466 T	Bmax
Flux density on magnet surface	0.641899 T	Bmg
First harmonic of flux density in airgap	0.411444 T	Bp
Flux per pole (Calculated)	0.000809433 Wb	Flux_pole
Magnets on a rotor disk	12	magnet_num
Distance between magnets	16.6566 mm	dist_magnet_Rin
Magnet mass	2700 g	MagnetMass
Magnet density	7.5 g/cm3	mag_density
Volume of a single magnet	15000 mm3	Vmag
Volume of all magnets	360000 mm3	VolumeMagnet
Remanent magnetic flux density	1.265 T	Br
Magnetic coercivity	982324 A/m	Hc
Maximum Energy Product	326 KJ/m³	BHmax
Outer diameter	260.32 mm	Dout
Average radius	104.558 mm	Ravg
Inner radius	79.5582 mm	Rin
Outer radius	130.16 mm	Rout
Effective outer radius	129.558 mm	Rout_eff
Mass of rotor disks	8.37738 kgr	BackIronMass
Volume of rotor disks	1064.47 cm3	BackIronVolume
Maximum flux density in the magnet rotor disk	0.995115 T	SaturMAX
Is the magnet rotor disk saturated?	No	Saturation

Generator Stator Outputs
Property	Value	Variable name
Stator thickness	17 mm	tw
Number of phases	3	nphase
Number of coils per phase	3	q
Total number of coils in stator	9	coil_num
Number of turns per coil	96	Nc
Copper wire diameter	1.4 mm	dc
Number of wires at hand	1	No_wires_at_hand
Winding fill factor	0.57	kf
Copper wire cross-sectional area	1.54 mm2	sc
Copper wire cross-sectional area (Calculated)	1.38207 mm²	sc_theor
Copper wire cross-sectional area of a sinlge wire	1.54 mm²	sc_multi_wires
Copper wire diameter (Calculated)	1.32688 mm	dc_theor
Coil leg width	15.257 mm	wc
Average length of coil turn	197.907 mm	lavg
Stator nominal temperature	82.6549 C°	tc_real
Stator surface area	543.503 cm²	stator_surface_area
Heat coefficient	0.297802	cq_real
Current density	5.38469 A	Jmax_real
Resistivity of copper at nominal temperature	2.11988E-8 Ohm.m	pt
Resistance of a single coil	0.261531 Ohm	Rc
Phase resistance	0.784594 Ohm	Rphase
Phase inductance	0.0017811 H	Ls
Nagaoka constant	0.27961	Kn
Winding coefficient	0.95	kw
Volume of a single coil	51330.8 mm3	coil_volume
Weight of a single coil	267.021 g	coil_weight_constr
Coil hole at Ravg	25 mm	coil_hole_Ravg
Coil hole at Rin	25 mm	coil_hole_Rin_constr
Coil hole at Rout	25 mm	coil_hole_Rout_constr
Coil mass for construction	2.67021 kgr	mcu_constr
RMS flux linkage of phase A	0.0468724 Wb	FluxRmsA
RMS flux linkage of phase B	0.0460448 Wb	FluxRmsB
RMS flux linkage of phase C	0.0467447 Wb	FluxRmsC
EMF at the cut-in wind speed (Calculated)	20.528 V	EMF_cut_in
EMF at the nominal wind speed (Calculated)	32.8252 V	EMF_nom
RMS of EMF of phase A (Flux Linkage)	28.9959 V	V_rmsA
RMS of EMF of phase B (Flux Linkage)	29.1318 V	V_rmsB
RMS of EMF of phase C (Flux Linkage)	29.0091 V	V_rmsC
Current at the nominal wind speed	8.29242 A	Iac_nom
Terminal voltage at the nominal wind speed	25.4034 V	V_term_line
Nominal frequency	33.3784 Hz	fnom
Generator power (Calculated)	631.967 W	Pnom
Generator power (Torque)	527.539 W	PelN_Torque_x
Electromagnetic power (Torque)	690.934 W	PHMN_Torque_x
Copper losses (Calculated)	161.856 W	Pcopper
Copper losses (Torque)	161.856 W	PcopperN_Torque_x
Eddy current losses (Torque)	1.53916 W	PeddyN_Torque_x
Generator efficiency (Torque)	0.7504	efftotalN_Torque_x
Generator efficiency (Calculated)	0.779639	efficiency_real
AC Power at the rectifier (Calculated)	568.771 W	Pnom_rect
AC Power at the rectifier (Torque)	474.785 W	PelN_Torque_x_rect
DC Power at the batteries (Calculated)	511.894 W	Pnom_dc
DC Power at the batteries (Torque)	427.306 W	PelN_Torque_x_dc

Generator Bearing Hub Outputs
Property	Value	Variable name
Number of bolts on hub	4	No_bolts_hub
Mass of bearing hub	3708.65 g	BearingHubMass
Rotational losses (Calculated)	12.0758 W	Prot
Rotational losses (Torque)	12.0758 W	ProtN_Torque_x

Costs, Mass and Volume
Property	Value	Variable name
Total generator cost	378.524 EUR	Totalcost
Total generator mass	15.9062 kgr	TotalMass
Total generator volume	3.56598 dm3	TotalVolume
Blade rotor mass	3.30317 kgr	blade_rotor_mass
Softwood density	500 kgr/m³	softwood_density
Cost of magnets	249.559 EUR	Magcost
Magnet shipping cost	21.7391 EUR	shippingcost
Copper mass	2.35414 kgr	mcu
Cost of copper	34.7472 EUR	coppercost
Resin mass	2.47469 kgr	resinmass
Cost of resin	34.1827 EUR	resincost
Resin volume	1819.63 cm3	ResinVolume
Total mass of one generator rotor	5.53869 kgr	TotalMassRotor
Cost of iron	10.3042 EUR	ironcost
Surface area of moulds	0.313958 m2	woodS
Total cost of moulds	49.731 EUR	woodcost

Revolutions per minute (RPM)
0
333.784321

I_RMS (A)
0
8.29242

Output files

Octave/Matlab variable file:

simulation-5852.mat

Input parameters

Blade Rotor Inputs

Turbine radius:

1.20m

Aerodynamic coefficient:

0.30

Cut-in wind speed:

3.00m/s

Nominal wind speed:

10.00m/s

Cut-in TSR:

8.75

Design TSR:

7.00

Air density:

1.204kg/m³

Generator Rotor Inputs

AFPM rotor topology:

Double Rotor

Magnetic material:

NdFeB N40

Number of generator poles:

Magnet length:

50mm

Magnet width:

25mm

Magnet thickness:

12mm

Rotor disk thickness:

Calculated

Mechanical clearance:

3.00mm

Generator Stator Inputs

Select coil type:

Rectangular

Winding fill factor:

Calculated

Stator thickness:

Calculated

Current density:

6.00A/mm2

System Inputs

System voltage:

48.00V

Nominal voltage:

54.00V

Transmission cable losses:

10.00%

Rectifier losses:

10.00%

Financial

Copper price:

12.00€/kg

Iron price:

1.00€/kg

Resin price:

11.23€/kg

Plywood price:

17.60 €/m²

Simulation Inputs

Also run UserAFPM:

true

Simulation step:

Current step:

RPM Step:

Mesh size:

Automesh

Constants

Copper resistivity:

1.678E-8 Ω·m

Copper density:

8.94g/cm³

Iron density:

7.87g/cm³

Resin density:

1.36g/cm³