Design for Manufacturability of an Off-Shore Direct-Drive Wind Generator: An Insight into Additional Loss Prediction and Mitigation

Direct-drive generators to be used in off-shore wind farms are very large low-speed electric machines which pose remarkable design and manufacturing challenges. Demand forecasts for this kind of machines are urging manufacturers to work out design and technological solutions capable of facilitating series production at competitive costs. This paper presents the development of an interior-permanent magnet generator design and technology aimed at reducing series manufacturing costs while preserving good performance levels. The focus is placed on two of the most critical issues in the machine design and analysis, namely the prediction and reduction of eddy-current losses in stator conductors and in permanent magnets. The proposed design solutions are validated through the construction and testing of a 780 kVA generator prototype conceived for easy scalability to higher power ratings (up to around 2.5 MVA) by core length increase.