Design of high speed permanent magnet generator for solar co-generation system using motor-CAD

High speed brushless permanent-magnet generators (HSBPMGs) may be the most suitable choice for small solar co-generation systems due to a variety of merits. For instance, they offer substantial reduction in size, and thermally excellent high-power density, which reduces the running costs with good performance and reliability. Moreover, high efficiencies i.e. over 90%, light-weight, low operating temperature, high insulation, no brushes/slip rings and almost negligible cogging torque make HSBPMGs ideal for co-generation systems. However, because of the very high rotor speed and high stator frequency, the design of HSBPMG is quite different from designing a conventional generator with low speed and low frequency. As the speed increases, the losses and temperature go up, and thus careful attention is needed while selecting the design parameters and material for the machine. This paper is aimed to use the basic design process for HSBPMGs running at 60,000rpm, with 6.6kW capacity keeping the losses minimum by using an appropriate material and cooling method. Finite element analysis of the machine is carried by using Motor-CAD simulation software, and modeling of a prototype machine is presented.