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An Assessment of Additively Manufactured Bonded Permanent Magnets for a Distributed Wind Generator

Conference ·
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In this paper, we examine and compare the performance of a generator design optimized using additively manufactured NdFeB-SmFeN in nylon-polymer-bonded permanent magnets (PMs) against a generator design with conventional NdFeB sintered PMs. To realize this, a commercially available 15-kW wind generator's rotor is re-optimized using both additively manufactured and sintered NdFeB magnets using simple geometric parameterization that allowed for two specific magnet shapes, namely, arc-shaped and crown-shaped designs. Results showed that for a similar generator performance, the designs with additively manufactured bonded PMs are more cost-competitive in terms of the estimated PM material cost and also have negligible eddy current magnet losses.

Research Organization:
National Renewable Energy Laboratory (NREL), Golden, CO (United States)
Sponsoring Organization:
USDOE Office of Energy Efficiency and Renewable Energy (EERE), Renewable Power Office. Wind Energy Technologies Office
DOE Contract Number:
AC36-08GO28308
OSTI ID:
2203914
Report Number(s):
NREL/CP-5000-87854; MainId:88629; UUID:ed77c758-bd29-4865-b30b-5ab6bc4e3e38; MainAdminID:70950
Resource Relation:
Conference: Presented at the 2023 IEEE International Electric Machines & Drives Conference (IEMDC), 15-18 May 2023, San Francisco, California; Related Information: 85626
Country of Publication:
United States
Language:
English

References (9)

Compression molding of anisotropic NdFeB bonded magnets in a polycarbonate matrix journal September 2021
Modern Electrical Machine Design Optimization: Techniques, Trends, and Best Practices journal October 2018
Current status and grand challenges for small wind turbine technology journal October 2022
State of the art of additively manufactured electromagnetic materials for topology optimized electrical machines journal July 2022
Combined Magnet Shaping and Asymmetries in Surface-Mounted Permanent Magnet Machines for Improved Torque Performance conference September 2022
Review of additive manufacturing of permanent magnets for electrical machines: A prospective on wind turbine journal May 2022
Manufacturing Processes for Permanent Magnets: Part I—Sintering and Casting journal February 2022
Modeling and Analyzing of Surface-Mounted Permanent-Magnet Synchronous Machines With Optimized Magnetic Pole Shape journal November 2014
MADE3D: Enabling the next generation of high-torque density wind generators by additive design and 3D printing journal March 2021

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Related Subjects

WIND ENERGY
additive manufacturing
permanent magnet
wind energy
wind generator