Optimal Shape Design of Direct-Drive Permanent Magnet Generator for 1 kW-Class Wind Turbines

Direct-drive permanent magnet generators are becoming an attractive option for highly efficient small-scale wind turbines due to their high-power density and size reduction capabilities. In this study, the optimal shape design of a direct-drive permanent magnet generator for 1 kW-class wind turbines was conducted while considering power generation and weight. Half of the geometry of a single stage in the generator was considered for a electromagnetic analysis under given electrical parameters. In order to construct a response surface model, a sensitivity analysis was conducted on seven design parameters of the proposed generator. The desirability function was used to minimize the weight of the generator while meeting a requirement of the target specification. The results indicated that the optimized design parameters for the generator met the target specification while maintaining the generator's weight at the same level as the initial design model. From the comparisons with other research, the optimized generator exhibited a higher power generation/weight ratio than the generator with a rated capacity under 3 kW.