Improved Synchronous Machine Rotor Design for the Easy Assembly of Excitation Coils Based on Surrogate Optimization

Tiejiang Yuan,Zheng Tan,Wenping Cao,Wei Zhang,Guofeng Li,Ning Xing,Nan Yang

doi:10.3390/en11051311

Abstract

This paper introduces a new rotor design for the easy insertion and removal of rotor windings. The shape of the rotor is optimized based on a surrogate method in order to achieve low power loss under the maximum power output. The synchronous machine with the new rotor is evaluated in 2-D finite element software and validated by experiments. This rotor shows great potential for reducing the maintenance and repair costs of synchronous machines, making it particularly suited for low-cost mass production markets including gen-sets, steam turbines, wind power generators, and hybrid electric vehicles.

Highlights

Synchronous machines are a common machine type with numerous industrial applications, especially in power generation. It is still considered the universal machine for electric power generation including diesel/gas/steam turbines in heat power plants [1], large hydro-machines in hydro plants [2], and wind turbines in wind farms [3]
This paper has presented a new asymmetrical rotor topology which can shift the magnetic path and, alter the cross-sectional area of saliency
The new rotor optimization focuses on presenting the critical curvature of the rotor geometry by varying parameters, investigating the influence of the rotor shaping methods by surrogate models, and optimizing the rotor pole shape for high-efficiency outputs

Summary

Introduction

Synchronous machines are a common machine type with numerous industrial applications, especially in power generation. It is still considered the universal machine for electric power generation including diesel/gas/steam turbines in heat power plants [1], large hydro-machines in hydro plants [2], and wind turbines in wind farms [3]. One major issue with the manufacture of wound rotor synchronous machines is their rotor winding process, which is considered to be quite laborious as the windings are not pre-designed and need to be wrapped around the rotor pole. A pre-manufactured rotor winding that is installed directly on the rotor tips separating it from the rotor pole. The rotor will be placed on a winding machine and automatically wound with the rotation of the winding machine, but the economic cost of the winding machine would increase with the size of the rotor

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Conclusion