Study on Air-Cooled Structure of Direct-Drive Outer-Rotor Permanent Magnet Synchronous Generator for Wind Power Generation

Direct-drive permanent magnet synchronous generators (DD-PMSGs) have been widely adopted in wind power generation systems owing to their distinctive advantages, including direct-drive operation, high power density, and superior energy conversion efficiency. However, the high power density of the generator inevitably leads to heat generation issues, which affect the reliability of the generator. To address the thermal issues in the 4.5 MW direct-drive permanent magnet synchronous generator (DD-PMSG), this paper proposes a novel forced air-cooling ventilation system. Through comprehensive computational fluid dynamics (CFD) simulations and fundamental thermodynamic analysis, the cooling performance is systematically evaluated to determine the optimal width of the stator ventilation ducts. Furthermore, based on the temperature distribution of the stator and rotor, three optimization schemes for non-uniform core segments are proposed. By comparing the ventilation cooling performance under three structural schemes, the optimal structural scheme is provided for the generator. Finally, the feasibility of the heat dissipation scheme and the accuracy of the simulation calculations are verified by fabricating a prototype and setting up an experimental platform. The above conclusions and research results can provide some reference for the design of the core ventilation ducts structure of subsequent wind turbines.