universiti putra malaysia fk 2012 107 design of double stator arc ...

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


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


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


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



(Internal Examiner)

Chandima Gomes, PhD

Associate Professor



(Internal Examiner)

Nasrudin Abd. Rahim, PhD

Professor



(External Examiner)

________________________________

BUJANG KIM HUAT, Ph.D

Professor and Deputy Dean

School of Graduate Studies


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



(Member)

Mohd Amran Mohd Radzi, PhD

Senior Lecturer



(Member)

___________________________________

BUJANG BIN KIM HUAT, PhD

Professor and Dean

School of Graduate Studies


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


3.4.4 Efficiency Calculation Method for


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

universiti putra malaysia fk 2012 107 design of double stator arc ...

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