Post on 01-Feb-2017
UNIVERSITI PUTRA MALAYSIA
SUHAIRI RIZUAN BIN CHE AHMAD
FK 2012 107
DESIGN OF DOUBLE STATOR ARC TYPE PERMANENT MAGNET GENERATOR FOR PALM OIL MECHANICAL
CUTTER APPLICATION
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DESIGN OF DOUBLE STATOR ARC TYPE PERMANENT
MAGNET GENERATOR FOR PALM OIL MECHANICAL
CUTTER APPLICATION
By
SUHAIRI RIZUAN BIN CHE AHMAD
Thesis Submitted to the School of Graduate Studies, Universiti Putra Malaysia
in Fulfillment of the Requirements for the Degree of Master of Science
MARCH 2012
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Dedication
TO FATMA MULYANI, MY BELOVED WIFE, FATMA NUR IMAN, MY
BELOVED DAUGHTER, CHE AHMAD SENIK AND ZAINAB SAID, MY
BELOVED PARENTS, MY SISTERS, MY BROTHERS, MY FAMILY AND
MY FRIENDS.
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Abstract of thesis presented to the Senate of Universiti Putra Malaysia in fulfillment
of the requirements for the degree of Master of Science
DESIGN OF DOUBLE STATOR ARC TYPE PERMANENT MAGNET
GENERATOR FOR PALM OIL MECHANICAL CUTTER APPLICATION
By
SUHAIRI RIZUAN BIN CHE AHMAD
MARCH 2012
Chairman : Assoc. Prof. Eng. Norhisam Misron, PhD
Faculty : Engineering
Over the past few years, the usage and demand of portable generators are very high.
In accordance with its lightweight, small size, easy to carry anywhere and can
provide high power; it becomes necessary for everyone to have it. There are various
types of portable generators in the market, but mostly for use in homes, commercial
and industrial. Only a few of them are design for agriculture application. Therefore, a
portable power supply with a small size and lightweight of Permanent Magnet
Generator (PMG) for the agricultural sector is proposed.
In this research, the Permanent Magnet Generator (PMG) will be applied as a part of
new palm oil mechanical cutter system. A lot of research regarding previous work
that has been done by others and the characteristic and performance of the PMG is
described in literature. However, none of them focus on PMGs intended to be used
for agricultural application whereas the typical requirement is of high-power
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capability, small and ease of use. Recently, there were some existing products
developed for palm oil mechanical cutter. Due to the drawbacks of the existing
mechanical cutter are extra weight and limited height. The improvement of this
mechanical cutter by using PMG to supply the mechanical motor that will convert
rotational to linear motion for harvesting works.
The new system of palm oil mechanical cutter employs the Permanent Magnet
Generator (PMG) which is can operates in a single-phase, slot type with a double
stator, and with arc type permanent magnet that embedded in the rotor. This PMG
aimed to produce 500W at a speed 3000 revolution per minute (rpm). This PMG will
attach with a single cylinder two stroke engine (Stihl KM 85) with 0.95kW capacity.
The engine will act as a prime mover to this PMG. At the same time, in order to
evaluate on the best possible PMG that can be used for this application, new design
and analysis on the developed PMG is required. This thesis addresses the above issue
and discusses the choice of PMG for used in palm oil mechanical cutter application.
A Permanent Magnet Generator is designed with a double stator, and the rotor
consists of arc type permanent magnet in order to maximize its usage of flux. This
new design of generators are fabricated and tested experimentally to see their output
power capability. The design optimization is done by varying the size of permanent
magnet, it is to ensure the magnetic flux density is considered to determine the
amount of hysteresis and eddy current losses and thus the effects of the total output
power that can be generated by the PMG. As a conclusion, the proposed design
produced the highest output power and efficiency that can be used for palm oil
mechanical cutter system.
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Abstrak thesis yang dikemukakan kepada Senat Universiti Putra Malaysia
sebagai memenuhi keperluan untuk ijazah Master Sains
REKA BENTUK TERHADAP PENJANA KUASA MAGNET KEKAL JENIS
LENGKUK DUA STATOR UNTUK APLIKASI PADA PEMOTONG
MEKANIKAL KELAPA SAWIT
Oleh
SUHAIRI RIZUAN BIN CHE AHMAD
MAC 2012
Pengerusi : Prof. Madya Eng. Norhisam Misron, PhD
Fakulti : Kejuruteraan
Sejak beberapa tahun kebelakangan ini, penggunaan dan permintaan untuk penjana
mudah alih adalah sangat tinggi. Selaras dengan saiz yang ringan, kecil, mudah untuk
dibawa ke mana-mana dan boleh memberi kuasa yang tinggi, ia menjadi keperluan
untuk semua orang memilikinya. Terdapat pelbagai jenis penjana mudah alih di
pasaran, tetapi kebanyakannya untuk kegunaan di rumah, komersil dan industri.
Tetapi, hanya sedikit yang telah digunakan dalam bidang pertanian. Oleh sebab itu,
bekalan kuasa mudah alih dengan saiz yang kecil dan ringan Penjana Magnet Kekal
(PMG) bagi kegunaan sektor pertanian adalah dicadangkan.
Dalam kajian ini, Penjana Magnet Kekal (PMG) akan digunakan sebagai sebahagian
daripada sistem pemotong mekanikal kelapa sawit. Beberapa penyelidikan yang
dijalankan sebelum ini untuk menganalisis ciri-ciri dan prestasi PMG telah
diterangkan dalam kajian literatur. Walau bagaimanapun, tiada satu pun di antara
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mereka memfokuskan PMG dalam bidang pertanian yang memerlukan keupayaan
kuasa tinggi, bersaiz kecil dan senang digunakan. Sebelum ini, terdapat beberapa
produk pemotong mekanikal kelapa sawit yang telah dibangunkan dan dihasilkan.
Walau bagaimanapun, kuasa keluaran yang dihasilkan tidak cukup untuk
melaksanakan tugas yang diberi. Antara kelemahan pemotong mekanikal yang sedia
ada adalah berat yang berlebihan dan capaian yang terhad. Peningkatan prestasi
pemotong mekanikal dengan menggunakan bekalan kuasa daripada PMG untuk
dibekalkan motor elektrik yang akan menukar gerakan putaran kepada gerakan linear
untuk kerja-kerja penuaian
.
Sistem baru pemotong mekanikal kelapa sawit yang dibangunkan menggunakan
Penjana Magnet Kekal (PMG) yang boleh beroperasi dalam fasa tunggal, jenis slot
dengan pemegun berganda, dan dengan menggunakan magnet kekal jenis lengkuk
yang terdapat dalam pemutar. PMG ini bertujuan untuk menghasilkan 500W pada
kelajuan 3000 pusingan per minit (rpm). PMG ini akan disertakan dengan enjin satu
silinder dua lejang (Stihl KM 85) dengan kapasiti 0.95kW. Enjin ini akan bertindak
sebagai penggerak utama kepada PMG ini. Pada masa yang sama, dalam usaha untuk
menilai PMG terbaik yang boleh digunakan untuk aplikasi ini, reka bentuk yang baru
dan analisis pada PMG telah dijalankan. Tesis ini menangani isu di atas dan
membincangkan pilihan PMG untuk digunakan dalam aplikasi pemotong mekanikal
kelapa sawit.
Penjana Magnet Kekal direka dengan pemegun dua, dan pemutar terdiri daripada
jenis arka magnet kekal bagi memaksimumkan penggunaan fluks. Reka bentuk
penjana baru ini yang direka dan diuji secara eksperimen untuk melihat keupayaan
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kuasa keluarannya. Pengoptimuman reka bentuk dilakukan dengan mengubah saiz
magnet kekal, ianya bertujuan untuk memastikan fluks magnet yang terhasil dan
menentukan jumlah kehilangan histerisis dan arus pusar yang memberi kesan kepada
jumlah kuasa keluaran yang boleh dijana oleh PMG. Sebagai kesimpulannya,
cadangan reka bentuk baru PMG menghasilkan output kuasa dan kecekapan yang
tinggi berbanding diamana ianya dapat digunakan pada pemotong mekanikal kelapa
sawit.
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ACKNOWLEDGEMENTS
All praise to supreme Almighty Allah s.w.t. the only creator, cherisher, sustainer and
efficient assembler of the world and galaxies whose blessings and kindness have
enabled the author to accomplish this project successfully.
The author also would like to take this opportunity to gratefully acknowledge the
guidance, advice, support and encouragement he received from his supervisor,
Assoc. Prof. Dr. Norhisam Misron who keeps advising and commenting throughout
this project until it turns to real success. Great appreciations are expressed to Prof.
Dr. Ishak Aris and Dr. Amran Mohd Radzi for their valuable remarks, help, advice
and encouragement.
Furthermore, the author would like to give special thanks to En. Abdul Razak Jelani
of Malaysian Palm Oil Berhad for his support in sponsoring the project. The author
also would like to say deepest thanks to Raja Nor Firdaus, Siti Khodijah, Norafiza for
their kind assistance and guidance. Appreciation also to the Faculty of Engineering
for providing the facilities and the components required for undertaking this project.
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I certify that an examination committee met on (month, date year) to conduct the
final examination of Suhairi Rizuan Bin Che Ahmad on his thesis entitled “Design of
Double Stator Arc Type Permanent Magnet Generator for Palm Oil Mechanical
Cutter Application” in accordance with the Universities and University Colleges Act
1971 and the Constitution of the Universiti Putra Malaysia [P.U.(A) 106] 15 march
1998. The committee recommends that the student be awarded the degree of Master
of Science.
Members of the examination committee are as follows:
Suhaidi Shafie, PhD
Senior Lecturer
Faculty of Graduate Studies
Universiti Putra Malaysia
(Chairman)
Hashim Hizam, PhD
Associate Professor
Faculty of Graduate Studies
Universiti Putra Malaysia
(Internal Examiner)
Chandima Gomes, PhD
Associate Professor
Faculty of Graduate Studies
Universiti Putra Malaysia
(Internal Examiner)
Nasrudin Abd. Rahim, PhD
Professor
Faculty of Graduate Studies
Universiti Putra Malaysia
(External Examiner)
________________________________
BUJANG KIM HUAT, Ph.D
Professor and Deputy Dean
School of Graduate Studies
Universiti Putra Malaysia
Date:
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This thesis was submitted to the Senate of University Putra Malaysia and has been
accepted as fulfilment of the requirement for the degree of Master of Science. The
members of the Supervisory Committee were as follows:
Norhisam Misron, PhD Eng.
Associate Professor
Faculty of Engineering
University Putra Malaysia
(Chairman)
Ishak Aris, PhD
Professor
Faculty of Engineering
University Putra Malaysia
(Member)
Mohd Amran Mohd Radzi, PhD
Senior Lecturer
Faculty of Engineering
University Putra Malaysia
(Member)
___________________________________
BUJANG BIN KIM HUAT, PhD
Professor and Dean
School of Graduate Studies
Universiti Putra Malaysia
Date:
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DECLARATION
I declare that the thesis is my original work except for quotations and citations which
have been duly acknowledged. I also declare that it has not been previously and is
not concurrently submitted for any other degree at Universiti Putra Malaysia or other
institutions.
__________________________________
SUHAIRI RIZUAN CHE AHMAD
Date: 9 March 2012
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TABLE OF CONTENTS
Page
DEDICATION ii
ABSTRACT iii
ABSTRAK v
ACKNOWLEDGEMENTS viii
APPROVAL ix
DECLARATION xi
LIST OF TABLES xv
LIST OF FIGURES xvi
LIST OF ABBREVIATIONS xix
CHAPTER
I INTRODUCTION 1
1.1 Problem Statement 3
1.2 Aim & Objectives 5
1.3 Scope of Work 5
1.4 Thesis Outline 6
II LITERATURE REVIEW 8
2.1 Overview of Other Related Research on
Palm Oil Mechanical Cutter Application
2.2 Overview of Other Related Research on PMG 10
2.3 Introduction to Finite Element Method (FEM)
Analysis 19
2.4 Basic Principle of Permanent Magnet
Generator (PMG) 21
2.4.1 Induced Voltage and Power
Generation of PMG 21
2.5 Introduction of PMG with Different
Topologies 23
2.5.1 Single Stator Slot Type Rectangular
PM (SSRPM) 24
2.5.2 Single Stator Slot-Less Type
Symmetrically PM (SSLSPM) 26
2.5.3 Double Stator Slot Type Rectangular
PM (DSRPM) 29
2.5.4 Double Stator Slot-Less Type Single
Pole PM (SPPM) 31
2.5.5 Double Stator Slot-Less Type
Multiple Pole PM (MPPM) 33
2.6 Introduction on Overall system of Palm Oil
Mechanical Cutter Application 35
2.7 Summary 38
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III
METHODOLOGY 39
3.1 FEM Analysis of Single-phase Double Stator
DSAPM Generator
40
3.1.1 Modelling Structure for Simulation 42
3.1.2 Magnetic Analysis 43
3.1.3 Output Voltage and Power Calculation
for Permanent Magnet Generator (PMG) 45
3.2 Prototypes of Single-phase DSAPM
Generator 48
3.2.1 Basic Structure of Fabrications Single-
phase DSAPM Generator
49
3.2.2 Measurement Setup for Open and Short
Circuit Test of Single-phase DSAPM
Generator 51
3.2.3 Measurement Setup for Single-phase
DSAPM Generator (V-I Characteristics) 52
3.3 Measurement Setup for Comparison of
Single-phase DSAPM and DSRPM Generator 53
3.4 Analysis and Comparison of various PMG 55
3.4.1 Torque Calculation Method for
Permanent Magnet Generator (PMG) 57
3.4.2 Mechanical Power Calculation Method
for Permanent Magnet Generator (PMG) 58
3.4.3 Output Power Calculation Method for
Permanent Magnet Generator (PMG) 58
3.4.4 Efficiency Calculation Method for
Permanent Magnet Generator (PMG) 58
3.5 Summary 59
IV RESULTS AND DISCUSSION 60
4.1 Output Voltage and Power of Single-phase
DSAPM Generator from FEM Simulation
Results 60
4.2 Prototype of Single-phase DSAPM Generator 64
4.2.1 Fabrications of Single-phase DSAPM
Generator 65
4.2.2 Results of Open Circuit Test and
Short Circuit Test 68
4.2.3 Voltage and Current (V-I)
Characteristic of Single-phase
DSAPM Generator 72
4.3
Comparison of Results Single-phase DSAPM
and DSRPM
74
4.3.1 Performance Characteristics of
Single-phase DSAPM and DSRPM
generator 76
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4.4 Results and Analysis of Comparison Various
Types of PMG
80
4.5 Summary 86
V CONCLUSION AND RECOMMENDATION 87
5.1 Conclusion 87
5.2 Future Work 88
REFERENCES 90
APPENDICES 94
PUBLICATION 101
BIODATA OF THE STUDENT 102