Design and Simulation Study of 40 MW PM Generator for the CRAFT

Design studies of two counter rotating permanent magnet (PM) synchronous generators have been performed. The two 40 MW generators have been designed and compared for the Counter Rotating Axis Floating Turbine (CRAFT) with different air-gap diameters. The generators are modelled with validated full physics finite element method (FEM) which also includes dynamic simulations. The simulations are performed by using an electromagnetic model. The model is described by combined field and circuit equations and is solved in a finite element environment. The stator winding of the generators consists of circular cables and the rotor consists of buried ferrite PM. The generator with smaller air-gap diameter will have lower material costs due to smaller frame but higher due to use of more active materials. A comparison of the counter rotating generators with a traditional direct drive has also been performed by maintaining the same voltage but reducing the rotational speed by half. This shows that a generator with a higher rotational speed will have lower material costs due to smaller dimensions and lower weight. Furthermore, a design variation, to reduce the cogging and harmonic content of the voltage by changing the pole shoe, was analyzed. In conclusions, a 40 MW generator design for the CRAFT has successfully been simulated with a multi-physics-FEM. The advantages of using a counter-rotating generator has been established.