ПЕТТО СОВЕТУВАЊЕ

Охрид, 7–9 октомври 2007

Drago Ban
Damir Žarko
Faculty of Electrical Engineering and Computing, Zagreb, Croatia
Miroslav Mađerčić
Končar- KET d.d, Zagreb, Croatia
Zvonko Čulig
Marijan Petrinić
Institute for Electrical Engineering Inc., Zagreb, Croatia
Branko Tomičić
Josip Študir
Končar-GIM d.d, Zagreb, Croatia

GENERATOR TECHNOLOGY FOR WIND TURBINES, TRENDS IN APPLICATION

AND PRODUCTION IN CROATIA
Invited paper

ABSTRACT
In the paper an overview of achievements known in the world in the area of construction and
application of various electric generator systems for wind turbines is given. Using the available literature and
other technical data a comparison is made between the following commonly used types of generator:
induction, synchronous with classical excitation, synchronous permanent-magnet and doubly-fed induction
generator. A basic concept and some selected details from the design and construction of the first wind
generator developed and built in Croatia are given. The generator is three-phase, low speed, 60 poles,
designated for direct-drive, power rating 1000 kVA. At rotating speeds between 10 rpm and 30 rpm, the
generator voltage and frequency change in the range of 250-690 V and 5-14,5 Hz. Based on experience
acquired by carrying out the first project involving construction of the wind turbine and generator system, the
other types of generator are also considered and the optimal solutions are sought for future constructions.
Some theoretical and practical significance is given to the possibility and justification for construction of a
direct-drive permanent magnet generator, which is estimated to be the most promising technical solution.
Keywords: Wind power plant, synchronous generator, doubly-fed induction generator, permanent-magnet
generator, optimization.

ГЕНЕРАТОРИ ЗА ЕЛЕКТРАНИ НА ВЕТЕР, ТРЕНДОВИ ВО ПРИМЕНА И

ПРОИЗВОДСТВО ВО ХРВАТСКА
Поканет труд

КУСА СОДРЖИНА
Во рефератот е дадена кус преглед на познатите достигнувања во подрачјето на градба и
примена на електрични генератори за електрани на ветер. Врз база на литература и други технички
податоци е направена споредба на различни изведби на генератори: асинхрон, синхрон со класична
возбуда, синхрон со перманентни магнети и двострано напојуван асинхрон генератор. Накусо се
прикажува основната концепција и некои одбрани детали од проектот и изведбата на првиот

A1-01R 1/16
 MAKO CIGRE 2007 A1-01R 2/16

ветроагрегат развиен и произведен во Хрватска. Генераторот е синхрон трифазен спорооден, со број

на полови 60, за „direct-drive” погон и моќност од 1000 kVA. При брзини на вртење од 10 - 30 r/min,
напонот на генераторот се менува во граници од 250-690 V, а фреквенцијата од 5 - 14,5 Hz. Врз база
на искуствата стекнати при изведбата на првиот сопствен проект и реализацијата на системот на
ветроагрегатот се разгледуваат и други изведби и се бараат оптимални решенија за новите изведби.
При тоа од посебно теоретско и практично значење е разгледувањето на можноста и оправданоста на
изведба на генератор со перманентни магнети за погон без мултипликатор, што се проценува како
најперспективно техничко решение.
Клучни зборови: Ветроагрегат, синхрон генератор, двострано напојуван генератор, генератор со
перманентни магнети, оптимизација.

1 INTRODUCTION
The development, construction and exploitation of wind turbines on the global scale have achieved
an unexpected growth in the last decade. The total capacity for production of electric energy from wind
installed worldwide by the end of 2006 reached 74223 MW, while in 2006 alone the capacity was expanded
by 15197 MW. The expected increase in construction of new capacities is around 32 % annually [15].
Although in 2005 only 1 % of the total world production of electric energy was generated by wind turbines
[20], that sector becomes an important segment in the world energy market.
By the end of 2006 the total power rating of wind turbines installed in Europe was 48000 MW, and
the annual growth was around 19 % [16]. The number of active manufacturers of wind turbines in the world
already exceeds 30, and the leaders are European manufacturers. The leading manufacturers of wind turbines
are Germany, Spain, USA, India and Denmark. Those countries also have the highest number of
commercially exploited wind turbines. In 13 countries with the highest number of installed wind turbine
units the total power rating exceeds 1000 MW [20].
There is currently a large conjuncture on the market and a shortage of production capacities. A great
number of specialists around the world are conducting scientific research. The possibilities of more efficient
utilization of wind potential on acceptable locations with reduced environmental impact are being explored.
The larger and more efficient turbines and generators are being built. The new and improved systems for
guidance and control and for connecting the wind turbine with the power grid are also developed. The result
of progress made in development and construction of wind turbines is evident from the fact that in 1980 the
power rating of a single unit was 30 kW, while in 2006 it reached 5000 kW. The course of development
through increase of power rating and generated electrical energy per unit in the last 25 years is illustrated in
Fig. 1. In 25 years the energy production from wind turbines has increased around 500 times [1, 20].
According to trends in Europe and the obligations of European countries to produce a part of electric
energy from renewable sources, Croatia has also involved in utilization of its wind potential by purchasing
wind turbines on the world market and installing them on the following locations: island of Pag, 7 units,
850 kW each, and near Šibenik, 14 units, 800 kW each. According to a study made by Institute Hrvoje Požar
and ordered by Croatian utility company (HEP), the estimated wind capacity in Croatia is around 400 MW.
The development of the first Croatian prototype of a wind turbine is conducted by a group of Croatian
companies led by KONČAR Electrical Industry Inc. The aim of this paper is to give a brief overview of the
state-of-the-art and conditions on the world market and to present the basic features of the development of a
domestic prototype. As a reminder some basic equations and terminology from the area of wind power
engineering are given in the paper.
1.1 Basic equations related to wind power
The energy and power of wind can be illustrated using the familiar expression for kinetic energy of
moving air
1 1
E = m v 2 ⇒ P = ( ρ S v ) v2 (1)
2 2
 MAKO CIGRE 2007 A1-01R 3/16

Year 1980. 1985. 1990. 1995. 2000. 2005.

Rated power [kW] 30 80 250 600 1.500 5.000
Rotor diameter [ m] 15 20 30 46 70 115
Hub height [m] 30 40 50 78 100 120
Annual production 35.000 95.000 400.000 1.250.000 3.500.000 17.000.000
[kWh]

Fig. 1 Growth of power and size of wind turbines in the period between 1980 and 2005
where E is the energy, P is the power, m (kg/m3) is the mass of moving air, ρ (kg/m3) is the density of air,
v (m/s) is the wind speed and S (m2) is the effective area circumscribed by the turbine blades. The wind
turbine can utilize only a part of the total wind energy which is taken into account by power coefficient Cp
which is a function of aerodynamic properties of the turbine and the orientation of the turbine with respect to
the wind direction. The theoretical maximum for Cp is 0,593 (Betz’s law). Taking into consideration (1) the
power captured by the wind turbine can be written as
1
P = C p ρ S v3 (2)
2
The wind power is proportional to its speed raised to the power of three according to which the
turbine should be controlled. In an ideally designed turbine, according to the theory by German scientist
Betz, only 59,3 % of the wind energy can be captured [5]. In real life the power coefficient is achieved in the
range 0,25 - 0,45. For the optimal Cp the speed of rotation of a turbine should be adjusted according to
constantly changing wind speed. In technical considerations Cp is calculated for a concrete turbine as a
function of coefficient λ, which is the ratio of tip speed [m/s] over wind speed [m/s], and the blade pitch
angle θ which depends on wind direction. The expression for the power of wind turbine can now be written
in the form
1 1
P = C p ( λ ,θ ) ρ S v 3 = C p ( λ , θ ) π r 2 v 3 (3)
2 2
For turbines whose speed is not controlled the coefficient λ is constant, and for uncontrolled it varies.
Practically all installed wind turbines are based on three basic types:
1. fixed-speed,
2. semi-variable speed,
3. regulated variable-speed.
The principle characteristic of a wind turbine showing the dependence of power on wind speed is
shown in Fig. 2. The generator and the power control system with varying wind speed are designed
according to that characteristic. The rated power of the turbine is achieved in the wind speed range from vrated
to vmax. For wind speeds from cut-in speed vc to rated speed vrated the power of the unit is optimized by
adjusting the aerodynamic profile of the blades in order to maximize the power output. From rated speed
vrated to cut-out speed vmax the turbine must be controlled to limit the mechanical and electrical power output
 MAKO CIGRE 2007 A1-01R 4/16

to their rated values. Various techniques of optimization and power limitation are applied (stall control,
active stall control, pitch control). The details are given in [5], [13].

Fig. 2 Typical static power characteristic of a wind turbine with active stall control

2 GENERATOR TYPES FOR WIND TURBINES

Since rotational speeds of wind turbines are naturally low, approximately in the range 5 to 30 rpm,
the selection of the type of generator, regardless of the applied type of control, depends on the type of
connection to the power grid and whether or not a gearbox is used. In modern constructions induction and
synchronous AC generators are used in several variants defined later in the paper. DC generators are used for
power levels of several kW.
For fixed-speed wind turbines squirrel cage or wound rotor induction generators are commonly used
which are directly connected to the power grid (without a power converter). A gearbox is necessary whose
gear ratio is high enough so that a 4-pole or a 6-pole induction generator can be used. The induction
generator with high number of poles (2p>20) is unacceptable for practical applications due to low power
factor cos ϕ (0,6 or less without compensation) and consequently poor power conversion capability. For
turbines with variable or semi-variable speed there is a variety of applied power conversion systems. The
development of these systems involves detailed technical and economic studies dealing with selection of the
gearbox, electric generator, power converter and connection to the power grid. Further in the paper
descriptions of various drive-trains, significant for practical implementation in newly built wind turbines, are
given.
2.1 Fixed-speed wind turbine with squirrel cage induction generator
Between the rotor of a turbine and the induction generator a gearbox is located (usually three-stage
with high gear ratio up to 1:100) which is selected so that a 4-pole or a 6-pole three-phase squirrel cage
induction generator can be used. Such a generator has a simple construction and can be picked from a
catalogue of standard induction machines. It is connected directly to the 50 Hz or 60 Hz power grid via soft-
start device which reduces the starting current. The load of the generator is limited by aerodynamic
construction of the turbine blades using the stall principle, and the speed of the series turbine+ gearbox+
generator varies very little around the rated speed of the generator. The slip of the generator is around 1-2 %
so that losses in the rotor are tolerable. The wind turbine cannot operate without connection to the power grid
from which it draws reactive power for magnetization. For low power and island operation capacitors can be
used for excitation of the generator. For compensation of reactive power the capacitors are used. Very often a
squirrel cage induction motor with selectable number of poles, usually for two different speeds as shown in
Fig. 3, is used. The company Mitsubishi uses such technology in their units rated 1000 kW [17].
The turbine is constructed for two fixed speeds which are optimized to obtain maximum power from
the wind and to reduce noise in changing conditions. There are constructions using wound-rotor induction
motor in which rotor resistance is changed electronically to regulate the speed and reduce mechanical stress
on the power generating unit.
 MAKO CIGRE 2007 A1-01R 5/16

Fig. 3 Fixed-speed wind turbine with induction generator

2.2 Variable-speed turbine with synchronous or doubly-fed induction generator
Classical synchronous generators constructed for fixed speed set by a primary mover have a DC
current excitation on the rotor. In general, such units (generator + primary mover) are main producers of
electric energy in power plants, for 50 or 60 Hz systems. If it is required to regulate the speed of the turbine
and the generator to improve the overall efficiency or for some other reasons, and at the same time the
generator should be connected to the power system with fixed frequency, it can be done in two ways:
1. The power converter located between the armature winding of the generator and the power grid
of fixed frequency can be used, as illustrated in Fig. 4. The excitation current in the rotor winding
with voltage regulation system or permanent magnets are required.
2. The AC current in the rotor winding of a doubly-fed induction generator can be used which is
generated by a cycloconverter or a two-way static power converter connected to the same power
grid as the armature winding (see fig. 5). The stator winding of the generator is connected
directly to the 50 Hz power grid. The rotor winding is connected via frequency converter and the
accompanying power transformer. Due to great significance of this type of power generating unit
for wind turbines and hydroelectric power plants, it will be described in more detail further in the
paper.

Fig. 4 Variable-speed wind turbine with synchronous machine

For wind turbine applications there is always a gearbox between the turbine and the generator, which
increases the speed of the generator to 1000 rpm or 1500 rpm (6-pole or 4-pole machine at 50 Hz). In
hydroelectric power plants there are no gearboxes because natural speeds of hydro turbines are higher than
the speeds of wind turbines. From the aspect of construction, the doubly-fed induction machine is a well
known wound-rotor induction machine in which the stator and rotor windings are connected to the voltage
sources of different frequencies. The classical synchronous machine is also a doubly-fed machine, only in
this case the rotor current frequency is equal to zero (DC excitation). According to basic classification of
electric machines with rotating filed, the doubly-fed machine can be classified as a synchronous machine.
 MAKO CIGRE 2007 A1-01R 6/16

Fig. 5 Variable-speed wind turbine with doubly-fed induction generator

The construction shown in Fig. 5 is more favorable than the one in Fig. 4 due to smaller size and cost
of the power converter, lower harmonic content in the power grid generated by the converter, better
controllability, smaller required space, better stability of the power system and possibility to generate
reactive power. The further advantage is the possibility to increase the efficiency of primary movers in
variable operating conditions, e.g. pump-turbine in reversible hydroelectric power plants of power rating up
to several hundred MW [11] and wind turbines up to 5 MW.
The method which involves AC current in the rotor winding, i.e. the additional voltage of variable
frequency, is based on the knowledge that for electromechanical power conversion magnetic fields generated
by stator and rotor currents must be mutually static, i.e. they have to rotate with the same speed. The stator
and rotor windings are three-phase, rotor has slip rings and brushes and the rotor winding is constructed in
the same way as the winding of a classical three-phase wound rotor induction motor. Hence, this machine is
usually called doubly-fed induction machine. The brushes and slip rings are its main disadvantage because
they wear out and require constant maintenance.
In the following expressions the basic relations in the case of AC excitation of the rotor winding are
given. In the rotor winding which has 2p2 poles and is connected to the three-phase voltage of frequency f2 a
rotating magnetic field is created which rotates at speed of n2 = f2 /p2 with respect to the rotor. The turbine
rotates the rotor at speed of n. In these conditions the rotating field of the rotor winding will rotate with
respect to the stator winding with p1 pole pairs at the speed of
no 2 = n + f 2 p 2 (4)
The frequency of the voltage induced in the stator winding due to rotating field of the rotor will be
f1 = ( n + n2 ) p1 = np + f 2 (5)
because for power conversion we must always have p1 = p2= p. If direction of the rotor field changes, then
we will have
n = ( f1 ± f 2 ) p (6)
Since in such applications the stator frequency is always fixed, the rotor frequency and the turbine
speed are regulated. For example, if the rotor of a 4-pole three-phase generator rotates at n = 27,5 s-1 and the
frequency of the grid is 50 Hz, then rotor must be excited with current of frequency f2 = 5 Hz in order to
convert mechanical power into electrical. The relations between the rotor speed n, rotor frequency f2 and
stator frequency f1 are illustrated in Fig. 6.

Fig. 6 Relations between frequency and speed of a doubly-fed induction machine

 MAKO CIGRE 2007 A1-01R 7/16

It follows from Fig. 6 that different relations between f1, n i f2 are possible. Since f1 is set by the
power grid, the frequency of the rotor current is adjusted according to the varying speed of the turbine. By
regulating the speed of a turbine or a pump the best energy efficiency can be achieved in concrete conditions
of wind speed or water level in the accumulation lake of a reversible hydroelectric power plant. The above
mentioned system of speed control can be used to generate both inductive and capacitive reactive power of
frequency equal to the frequency of the power system. The doubly-fed induction generator has a wide
application in wind turbines [5,11,13] because of the unpredictable and constantly changing wind speed
which is the reason why it is necessary to regulate the turbine speed. The power generating units are
constructed for rotor frequencies which are roughly 4-10 times lower than the stator frequency which allows
the rated power of the converter to be around 35% of the rated power of the generator.
Let us consider the power conversion relations in a wind turbine (for simplicity the losses in the
generator are neglected) according to notation in Fig. 5. The mechanical power of the turbine at the exit from
a gearbox Pmech is by means of rotating magnetic field converted into electric power Pg, which is delivered to
the power grid, and the slip power in the rotor Pr = - sPg. This can be shown using expression
Pg = Pmeh + sPg (7)
The rotor slip s is defined as the difference between the speed of the rotating stator field and the rotor
speed s = (ns – n)/ ns and in the generating mode it is always negative. In generating mode the sign of power
Pr will be positive (into the grid), and since the slip s is positive for motoring mode, the power Pr in the
motoring mode will be negative (from the grid). For the usual range of turbine speed regulation, from 70 %
to 110 % of the rated speed, and the synchronous speed of the generator of around 90 % of the rated speed of
the turbine, the slip is in the range ±23%, and the required power of the converter in the rotor is around 30 %
of the power which is electromechanically converted in the machine.
The variable-speed wind turbine technologies are becoming dominant, especially for high power (1-5
MW) wind turbines. In 2002, according to [3], 47 % of all wind power units were made with doubly-fed
induction machine. The power converters were rated around 35 % of the rated power of the generator.
In electrical engineering there are many known solutions for large controlled electric drives (power
up to 50 MW) with subsynchronous cascades where the only difference is that they are used in
subsynchronous motoring mode where the rotor slip is always positive. In large reversible power plants rated
up to several hundred MW doubly-fed induction machines are used for higher energy efficiency at transition
from pump (motoring) to turbine (generating) mode of the hydroelectric power unit [13]. The efficiency of
large hydraulic machines can differ by several percent in turbine and pump mode at different hydraulic
conditions. The speed variation of such units is in the range ±10-15 %.
2.3 Variable-speed turbine and synchronous generator
Besides induction generator a synchronous generator for small rotating speeds (5-30 rpm) can be
used. Synchronous generator with high number of poles (60 or more) with classical excitation or permanent
magnets can be connected directly to the turbine without a gearbox, and the connection to the power grid is
carried out via power converter. The power rating of the converter is equal to the power rating of the
generator. Due to large number of poles and low rotating speed the generator must develop large torque.
Consequently it has relatively large weight and dimensions, which inevitably affects the constructions and
dimensions of the nacelle. An example of a system with this type of generator is shown in Fig. 7. These are
completely new, not classical constructions of the generator for which separate research and development
were required. Several leading manufacturers have successfully implemented their own technical solutions
which are still not fully optimized and are continuously being developed.
 MAKO CIGRE 2007 A1-01R 8/16

Fig. 7 Synchronous machine with classical excitation for direct-drive wind turbine
Both permanent magnet technology and classical excitation on the rotor have been developed. Details
can be found in numerous scientific papers. This type of power conversion unit is closely related to the
construction of the power converter which must deliver full power of the generator. The development and
application of direct-drive generators are inseparable from the development, application and cost of the
power converter. The reduction of cost of permanent magnets and their availability on the market have
significantly influenced the development and application of permanent-magnet generators for direct-drive
systems and for systems with single or three-stage gearboxes. Compared to generators with excitation current
on the rotor, permanent-magnet generators for the same power rating have higher efficiency due to lower
rotor losses, smaller dimensions of the rotor, simpler cooling circuit because rotor does not require cooling,
simpler maintenance, and no separate excitation system. Whether or not permanent-magnet generators will
prevail will depend on price and availability of the magnets on the market, solution of technical problems
related to attachment of the magnets to the rotor, and cost and reliability of the power converter. In that area
there is a noticeable research and development [14,17] going on and an increasing number of companies is
manufacturing or developing prototypes of permanent-magnet generators (Siemens, ABB, WinWinD,
Mitsubishi, ČKD Blansko,...)
2.4 Single gearbox for multiple generators
Fig. 8 illustrates solutions by some manufacturers of wind turbines in which several induction or
synchronous generators are connected to a single gearbox. With this type of construction the currently
available wind energy can be utilized in the best manner, because the number of active generators is adjusted
according to immediate power of the turbine.

a) b)

Fig. 8 Wind turbine with multiple generators : a) induction generators, b) synchronous generators
 MAKO CIGRE 2007 A1-01R 9/16

2.5 Comparison of different constructions

Table 1 contains comparison of basic properties, relative advantages and disadvantages for six most
commonly used power generating units in wind turbines.
Table 1 Comparison of various generator technologies for wind turbines

Generator Advantages Disadvantages

- requires reactive power

Squirrel-cage single-speed or
two-speed induction generator (2p=4 ili 6)
Doubly-fed induction generator
Synchronous generator with rotor excitation
winding
- simple construction
- simple maintenance
- attenuated pulsations of turbine torque
- low cost
- direct connection to the power grid
- significantly reduced power rating and
cost of the converter
- possible speed regulation for optimal
utilization of energy (typically ±20-25%)
- reactive power for magnetization of the
machine is provided by the power
converter
- subsynchronous and supersynchronous
operation is possible
- simple control of reactive power
- wide range of speeds
- simple control
- requires soft start device for
initial connection to the grid
- applicable only for fixed turbine
speed
- requires a gearbox
- cannot be used for large number
of poles (>20)
- slip rings and brushes, wear and
tear, maintenance
- complex control of the entire
unit
- direct connection to the grid is
somewhat difficult
- requires power converter of the
same power rating as the machine
- requires an excitation system
- slip rings and brushes, wear and
tear, maintenance

- no gearbox - large dimensions and weight,

DIRECT-DRIVE - higher efficiency problems with construction,
transportation and installation

WITH GEARBOX
- high cost, losses ( 2-3) %
- small dimensions and weight
- problematic maintenance of the
- standard construction can be used
gearbox

- high cost of permanent magnets

- simple rotor with no parts prone to wear
Synchronous permanent magnet generator - possibility of demagnetization
and tear
- insufficient experience in
- very low rotor losses
construction and installation

- no gearbox
- higher efficiency - large dimensions and weight,
DIRECT-DRIVE problems with construction,
- simple maintenance
transportation and installation

WITH GEARBOX
- high cost, losses ( 2-3) %
- small dimensions and weight
- problematic maintenance of the
- standard construction can be used
gearbox
 MAKO CIGRE 2007 A1-01R 10/16

2.6 Generator systems of leading manufacturers of wind turbines

In Table 2 a brief overview of generator systems of world’s leading manufacturers is given. Only
systems with rated power higher than 100 kW have been selected.
Table 2 World’s leading manufacturers of wind turbines and the types of systems they use
Concept/
Manufacturer Power range [kW] Generator
design*
100 – 500 squirrel-cage single-speed and two-speed induction generator
ABB (SE)** VS/PC 500 – 5000 synchronous, classical and permanent-magnet generator
600 – 4000 doubly-fed induction generator
Bonus/(DK) CS/CS 600 squirrel-cage induction generator
Siemens Wind Power CS/AS 1000 – 2300 squirrel-cage induction generator
ČKD Blansko (CZ) VS/PC 1000 – 3000 synchronous permanent magnet generator - single-stage gearbox
DeWind (GB/DE) VS/PC 600 – 2000 doubly-fed induction generator
CS/CS
Ecotechnia (ES) 750 – 3000 doubly-fed induction generator
VS/PC
Enercon (DE) VS/PC 300 – 4500 direct drive synchronous generator
600 squirrel-cage induction generator
GE Wind Energy CS/CS
1500 – 3600 doubly-fed induction generator
(US/DE) VS/PC
2500 (new) synchronous permanent magnet generator + gearbox
Jeumont (FR) VS/PC 750 – 1500 direct drive synchronous generator
CS/CS 660-1320 squirrel-cage induction generator, two-speed (2p=4 , 2p=6)
Made (ES) VS/PC 800 synchronous generator (2p = 4) + gearbox
VS/PC 2000 brushless synchronous generator (2p=4)
250 – 1000 two-speed squirrel-cage induction generator
Mitshubishi (JP) CS/CS
2000 direct drive synchronous permanent-magnet generator
CS/CS 600 – 1500 squirrel-cage induction generator
NEG micon/Vestas
CS/AS 1500 – 2000 squirrel-cage induction generator
(DK)
VS/PC 2750 - 4200 doubly-fed induction generator
Nordex (DK) VS/PC 1300 – 2500 doubly-fed induction generator
CS/CS 600 – 750 squirrel-cage induction generator
Repower Systems (DE) VS/AS+PC 1050 squirrel-cage induction generator
VS/PC 1500 – 5000 doubly-fed induction generator
doubly-fed induction generator
3600
VS/PC squirrel-cage induction generator (gearbox 1:119) 2p=4
Siemens (DE) 400 – 2300
VS/PC two-speed squirrel-cage induction generator (2p=4, 2p=6)
3000
direct drive synchronous permanent-magnet generator and gearbox
Turbowinds (BE) CS/AS 400 – 600 two-speed squirrel-cage induction generator (2p=4, 2p = 6)
RB/PC 660 – 2750 doubly-fed induction generator
Vestas (DK)
PRS/OS 850 – 3000 two-speed squirrel-cage induction generator (opti-slip)
Winwind (FI) RB/PC 1000 – 3000 synchronous permanent-magnet generator
Zephyros (NL) VS/PC 1500 - 2000 synchronous permanent-magnet generator
Končar (HR)
VS/PC 1000 direct drive classical synchronous generator (testing stage)
(Prototype)

* Concept / design of a turbine

CS/CS – constant speed/classic stall - fixed pitch angle CS/GP – constant speed/combination with pitch adjustment
of the blades
CS/AS – constant speed/active stall – negative pitch PRS/OS – partly regulated speed, pitch control + OptiSlip, regulation
angle of the blades (3-5°) ± 10 %
VS/PC – variable speed/pitch control combined with VS/AS+PC – constant speed + pitch adjustment
classic stall
**only electrical equipment for wind turbines
SOURCE: www.ArchiExpo.com - Wind Turbines All the Manufacturers
 MAKO CIGRE 2007 A1-01R 11/16

3. WIND TURBINE MANUFACTURED IN CROATIA

After detailed analysis of worldwide known technical solutions in construction of wind turbines and
trends in their development it was decided in 2004 in Končar Inc. to begin with development and
construction of the first wind turbine in Croatia. The wind potential at locations in Croatia was tested. The
results of these tests and the ability of Croatian industry to manufacture as many components of the wind
turbine as possible were also considered. The wind turbine with pitch control, power rating 750 kW and
direct-drive synchronous generator was selected. During research and development of the project and after
analyzing the wind potential it was decided to increase the rated power of the turbine to 1000 kW and to
adjust the design of the accompanying electrical equipment to that power rating.
With the engagement of numerous Croatian companies and scientific institutions (Končar Inc., Đuro
Đaković Inc., Institute Hrvoje Požar, Croatian shipyards, civil engineering companies, transportation
companies etc.) the prototype was finished early in 2007. During writing of this paper the tests had been
conducted in the company Končar-GIM. The initial field test is planned for June and July 2007 at location
Pometeno Brdo near Split. The basic technical data of the turbine is given in Table 3.
Table 3 Technical data of the wind turbine prototype KO VA 57/1
Type KO VA 57/1
Diameter of the blades 57,4 m
Power regulation pitch control
Rated power 1000 kW
Speed 10 – 30 rpm
Hub height 60 m
Tower height 59 m
Nacelle weight 62 t
Tower weight 82 t
Total weight 144 t

A three-phase synchronous generator entirely developed and manufactured by Končar - GIM is

installed in the wind turbine. It is a completely new construction of the generator since this is the first time a
generator was built for such a specific purpose. It is rated 1000 kVA, 60 poles, frequency 5 – 14,5 Hz,
connection to the grid via power converter. The detailed technical data of the generator is given in Table 4,
and two photos from the final stage of construction are shown in Figs. 9 and 10.
The outer diameter of the generator is 4200 mm. This dimension is crucial for the selection of the
wind turbine drive and the type of generator that would be used. Due to transportation problem in certain
countries it is required that this diameter should be limited to 4 m. Since this is a prototype of a generator
manufactured in Croatia, it is expected that during testing the valuable data will be collected to be used for
the construction of similar machines in the future.
Since there is a growing trend in the world of construction of high power (over 1000 kW) generators
for wind turbines, we will consider briefly advantages and disadvantages of two main constructions of such
generators, the permanent-magnet generator and the generator with classical excitation on the rotor.
Due to high cost of permanent magnets and the lack of experience in their application, until a decade
ago no permanent-magnet generators for wind turbines were constructed, except in rare cases. Wind turbines
were built with several versions of induction generators and synchronous generators with classical excitation.
Končar has obviously chosen a direct-drive synchronous generator with DC current excitation in the rotor
winding. In the case of permanent-magnet generators an experience in design and construction is required,
especially for problems related to installment and magnetization of the magnets on the rotor.
For the purpose of research we designed a permanent-magnet version of Končar’s generator and
compared these two designs from the aspects of weight and key parameters.
 MAKO CIGRE 2007 A1-01R 12/16

Fig. 9 Rotor of the generator SV 4205 – 60 Fig. 10 Hub mounted on the rotor of the
generator SV 4205–60

Table 4 Technical data of the three-phase synchronous generator

Type SV 4205 – 60
Rated power 1000 kVA
Rated voltage and frequency 690 V , 14,5 Hz
Rated current 836,7 A
Rated speed 29 rpm
Range of speed regulation 10 to 30 rpm
Range of frequency variation 5 do 14,5 Hz
Voltage regulation 150 – 760 V
Rated power factor , cos φ 0,95
Critical speed 36 rpm
Number of poles 60
Number of phases 3
Insulation class of stator and rotor H
Cooling air
Excitation system separate/self-excitation
Rated excitation voltage 170 V
Rated excitation current 119 A
0,25 0,5 0,75 1 load P/Prated
Efficiency
93,9 94,9 95,3 95,3 efficiency %
Total weight 27 t

4. PERMANENT-MAGNET GENERATOR
In the case of wind turbines it is very important to have a simple construction and maintenance of the
generator. This is why permanent-magnet generator appears to be a very good solution because it hardly
contains any parts that require maintenance. For these reasons many manufacturers are constructing such
generators (Siemens, ABB, Mitsubishi, ...). The connection of this type of generator to the power grid is
illustrated in Fig. 11.
 MAKO CIGRE 2007 A1-01R 13/16

Fig. 11 Direct-drive permanent-magnet synchronous generator and its connection to the power grid
Until recently AC permanent-magnet generators were used only for specific applications and for low
power. The appearance of modern ferrite and neodymium permanent-magnet materials with magnetic
properties far better than the properties of previously used permanent-magnet materials, it became possible to
build electrical machines of power ratings similar to the machines with classical excitation. One of most
frequently used materials of the rare earth type is neodymium-iron-boron (NdFeB). The cost of such
materials has become acceptable and is continuously dropping (10 EUR/kg according to [14]).
Hence it considered that in Croatian industry the development and construction of such generators
should be initiated as well. There are various problems to be solved and the lack of experience in
construction of high power permanent-magnet synchronous machines with high number of poles (up to 100).
These problems include magnetization and fixation of the magnets on the rotor, demagnetization of the
magnets at high temperatures or in some undesirable regimes like short-circuits. Since there is almost no
experience in domestic industry, the only data from which one can start the design process are similarities
with already manufactured machine with classical excitation and limitations with respect to dimensions
inside the nacelle. The known data are power rating, voltage, frequency, characteristics of the turbine and
similar dimensions.
4.1 An example of optimal design of a permanent-magnet generator
The analyses of various types of permanent-magnet generators described in [14] have shown that
magnets with arc shape mounted on the rotor surface are optimal from the aspect of machine cost for a
certain power level. Generator design is a complex procedure of determining its geometric dimensions and
parameters. Due to high number of variables which must be varied during design and imposed limitations,
the optimization is used as a systematic, mathematically based system of decision making in the selection of
the machine dimensions. The general definition of the generator design optimization problem is: find a
G G
vector of variables x = [ x1 , x2 ,..., xD ] , x ∈ R D where xi(G ) ≤ xi ≤ xi( D ) , i = 1,..., D which must satisfy m
G G
inequality constraints g j ( x ) ≤ 0, j = 1,..., m and minimize the goal function f ( x ) . The optimization method
is Differential Evolution (DE) [24]. The DE performs calculations on a population of vectors which mutate
in every iteration and converge towards solution space where inequality constraints are satisfied and where
the goal function is minimized. Table 5 contains the definition of the optimization problem for the design of
a permanent-magnet generator.
The rated data 1 MVA, 690 V, 29 rpm is the same as for the generator described in chapter 3. The
model of the generator is analytical based on field calculations inside the air-gap by means of conformal
mapping [25]. The generator is connected to the active rectifier by which the armature current is kept in
phase with the induced voltage to achieve required power with minimum current. The design data of the
optimized generator are given in Table 6, and the partial cross-section of the generator is shown in Fig. 12.
 MAKO CIGRE 2007 A1-01R 14/16

Table 5 Definition of optimization problem of a permanent-magnet generator

1. Do/Do0 : Ratio of stator outer diameter and maximum allowed outer diameter (Dv0 = 4 m)
2. D/Do : ratio of stator inner and outer diameter
3. la/la0 : ratio of core length and maximum allowed core length (la0 = 0.6 m)
4. hs/[(Do-D)/2]: ratio of slot height and the difference between stator outer and inner radius
Generator
5. Br : permanent-magnet data
variables
6. Qs : Number of slots
(x)
7. p : number of pole pairs
8. bt/τs : ratio of tooth width and the slot pitch on the stator inner diameter
9. lm/δ : ratio of magnet thickness and the air-gap length
10. αp : part of the pole pitch covered by magnet
1. Bt ≤ 1,7 T : maximum flux density in the stator tooth
2. By ≤ 1,2 T : maximum flux density in the stator yoke
3. P ≥ 1 MW : minimum electrical output power
Inequality 4. K ≤ 60000 A/m : maximum linear current density
constraints 5. J ≤ 4 A/mm2 : maximum current density
g(x) 7. Θ1 ≤ 0,7Θ1max : limitation of the fundamental component of the armature winding MMF for protection of
the magnet from demagnetization (Θ1max - armature winding MMF on the knee of the magnetization curve)
8. η ≥ 0.95 : minimum efficiency
9. ΔT/T≤0.025 : maximum pulsating torque (2.5% of the average torque)
Goal function
V/V0 : ratio of active volume and maximum allowed active volume (V0=D2o0π/4⋅lao)
f(x)

Table 6 Results of the optimized design of a permanent-magnet generator

VACODYM 669AP
Rated power 1 MVA Magnet data at 120 0C
Br=1.05 T, Hc=801 kA/m
Rated voltage 690 V Number of turns per coil 1
Rated frequency 15,95 Hz Number of parallel paths 1
Rated current 908 A Coil pitch 5
-1
Rated speed 29 min Slot fill factor 0,4
Rated power factor 0,92 Current density 3,89 A/mm2
Number of poles 66 Linear current density 60000 A/m
Number of phases 3 Flux density in stator tooth 1,70 T
number of slots 333 Flux density in stator yoke 1,20 T
Stator outer diameter 3463 mm Flux density in rotor yoke 1,22 T
Stator inner diameter 3210 mm Torque pulsations 1.2%
Rotor outer diameter 3203 mm Efficiency 95,0 %
Rotor inner diameter 3026 mm Magnet mass 1162 kg
Core length 459 mm Copper mass 639 kg
Air gap length 3,5 mm Iron mass 7947 kg
Magnet thickness 40,5 mm Total mass (active parts) 9748 kg
 MAKO CIGRE 2007 A1-01R 15/16

Fig. 12 Partial cross-section of the optimized permanent-magnet generator

5. CONCLUSION
A research of current situation and trends in further development and application of wind turbines
has been conducted. The real boom in construction of wind turbines all over the world is continued. Many
scientific and expert papers have been published and the research is continuing.
In wind turbine systems induction and synchronous generators are used, depending on the turbine
size, the type of control and the connection to the power grid. Both direct-drive systems and systems with a
gearbox are used.
Induction squirrel-cage generators for power levels up to 1000 kW have advantage at fixed turbine
speeds, while doubly-fed induction generators have advantage at higher power levels and in the case of
limited regulation of turbine speed, ± 20-25% around rated speed. Induction generators always require a
gearbox.
Synchronous generators are used for turbines with regulated speed and for both direct-drive systems
and systems with a gearbox. Permanent-magnet generators are becoming more significant and it is realistic
that in new applications they will push out generators with classical excitation and the need for a gearbox.
Significant research and development is conducted in that area. Various patents have been applied for.
The wind power plant manufactured in Croatia is an important achievement. Although this is a
prototype, its parameters are comparable with those on the world market. For wind potentials found in
Croatia the selected power level and the dimensions of the generator are appropriate.
Using optimization for the design of a permanent-magnet generator it has been shown that it is
possible to design a generator whose dimensions and parameters make it a serious competitor to the
generator with classical excitation. The development and construction of a permanent-magnet generator
would bring Croatian trends of development closer to the trends in the rest of the world.

6. REFERENCES
[1] G. A. M. van Kuik. “Are wind turbines growing too fast?.” Proc. European Wind Energy
Conference and Exhibition. pp. 69-27. Copenhagen 2001.
[2] L. Mihet Popa, F. Blaabjerg, I. Boldea. “Simulation of wind generator systems for the power grid.”
Record of OPTIM – 2002. Vol 2, Nr. 423 – 428.
[3] F. Blaabjerg, F. Iov, R. Teodorescu, Z. Chen. “Power Electronics in Renewable Energy Systems.”
Record of EPE-PEMC 2006. Portorož, Slovenia, 2006.
 MAKO CIGRE 2007 A1-01R 16/16

[4] A. Bocquel, J. Janning. “4×300 MW Variable Speed Drive for Pump-Storage Plant Application.”
EPE 2003. Toulouse
[5] H.Poliender,S.W.H. de Han, Maxime R.Dubois, J. G.(Han) Slootweg. “Basic Operation Principles
and Electrical Conversion Systems of Wind Turbines.” EPE Journal. Vol. 15, No.4, December
2005.
[6] H.Poliender, Frank F.A.vander Pijl,G.J. de Vilder, P.Tavner. “Comparison of Direct-Drive and
Geared Generator Concept for Wind Turbines.” IEEE Trans. Energy Conv. Vol. 21, No 3, pp. 725-
733, Sept. 2006.
[7] Bogalecka, Z. Krzenmiski. “Sensorless control of doubly fed machine for wind power generators.”
Record of EPE – PEMC 2002, Dubrovnik – Cavtat, 2002.
[8] L. Morel, H. Godfroid, A. Mirzoian, J.M. Kauffmann. “Doubly – fed induction machine: converter
optimization and field orientation control without position sensor.” Proc. IEE. Vol. EPA – 145, No.
4, pp. 360 – 368, 1998.
[9] I. Serban, F. Blaabjerg, I. Boldea, Z. Chen. “A study of doubly-fed wind power generator under
power systems faults.” Record of EPE – 2003, Toulouse, France.
[10] P. Pena, J.C. Clare, G.M. Asher. “A doubly fed induction generator using back to back PWM
converter supplying an isolated load from a variable speed turbine.” Proc. IEE. Vol. EPA – 143, No.
5, pp. 380 – 387, 1996.
[11] T. Kuwabara, A. Shibuja, H. Furata. “Design and dynamic response characteristics of 400 MW
adjustable speed pump storage unit at Ohkawachi power station.” IEEE Transactions. Vol. EC – 11,
No. 2, pp. 376 – 384, 1996.
[12] T. Thiringer. “Grid-Friendly Connecting of Constant-Speed Wind Turbines using External
Resistors.” IEEE Trans. Energy Conv.. vol. 17, December, 2002.
[13] J.G. Slootweg, E. de Vries. “Inside wind turbines-Fixed vs. variable speed.” Renewable Energy
World, ,pp 30-40, 2003.
[14] A. Binder, T. Schneider. “Permanent magnet synchronous generators for regenerative energy
conversion.” Darmstadt university of technology, link: www.ew.e-technik.tu-darmstadt.de/ew.html
[15] European Wind Energy Association (EWEA) statistics. www.ewea.org.
[16] Wind turbine generator systems: Part 1- Part 21. IEC standards, IEC 61400-1& IEC 61400- 21,
1998.
[17] Y. Ueda, H. Iataka, K. Inoue. “Mitsubishi new wind turbines MWT-1000A & MWT-S2000.”
Mitsubishi Technical Review, vol. 40. No. 4, Aug. 2003.
[18] Web site: http://www.windpower.org/en/tour/wtrb/tower.htm
[19] Web site: http://www.abb.com
[20] Web site: www.northernpower.com
[21] Web site: Siemens, Turbowinds, WinWinD, ČKD Blansko
[22] Wind turbines manufactureres - google search
[23] Wind power - Wikipedia, 30/4/2007.
[24] J. Lampinen. “Multi-Constrained Nonlinear Optimization by the Differential Evolution Algorithm.”
6th On-line World Conference on Soft Computing in Industrial Applications (WSC6), Sept. 2001.
[25] D.Žarko, D.Ban, T.A. Lipo. “Analytical Calculation of Magnetic Field Distribution in the Slotted
Air Gap of a Surface Permanent-Magnet Motor Using Complex Relative Air-Gap Permeance.” IEEE
Trans. Magn. vol. 42, No 7, pp. 1828-1837, July 2006.