Alternative Surface-Mounted Permanent Magnet Topology for Reducing Voltage and Torque Harmonics in Shaft Generators

Typically, a diesel generator on the merchant ship, composed of a wound rotor synchronous generator and a four-stroke diesel engine, supplies electrical power to various loads. Recently, shaft generators for merchant vessels are increasingly replacing diesel generators to reduce CO2 emissions through fuel efficiency improvement. In particular, permanent magnet generators replace induction generators due to their high-efficiency characteristics at light loads. The surface-mounted permanent magnet can be a suitable rotor topology due to the relatively short constant power range. This generator can also operate as a motor according to the propulsion mode, so minimizing the harmonics of the induced voltage and the torque ripple is necessary. This paper proposes an alternative NdFeB magnet pole topology combined with the modular step-skewed rotor. The step-skewed rotor affects to reduce higher-order harmonics, and the modular pole reduces the permanent magnet assembly process and harmonics in voltage and torque. A 2-D finite element method is used to evaluate the harmonics of induced voltage and torque pulsation for the proposed topology. The topology shows harmonic minimization effect by comparing the characteristics of three flatted-bottom magnets. Compared to the tapered bread-loaf magnet, voltage harmonics to the 100th component are almost the same, and the torque ripple is reduced by more than 12% at the same residual flux density. The analysis method is verified by comparing test and analysis results for prototype machines with similar specifications.