Supporting a rare earth free generator for large scale wind turbines
Xi Engineering Consultants developed advanced Multiphysics models for GreenSpur’s ferrite based axial flux generator, enabling the team to optimise layout, cost and performance without extensive physical prototyping.
The Challenge
Conventional large scale wind turbine generators depend on rare earth magnets, which are costly, supply constrained and associated with environmentally damaging extraction. GreenSpur set out to develop a generator using abundant ferrite magnets that could match or exceed existing performance while reducing cost and environmental impact. Their ferrite based axial flux direct drive design introduced complex interactions between electromagnetics, structural dynamics, thermal management and manufacturability. Trial and error physical prototyping of such a system would have been prohibitively expensive and slow. GreenSpur needed robust, scalable models to guide design decisions and demonstrate feasibility to investors and partners.
Our Approach
Xi built a suite of numerical models in COMSOL Multiphysics that captured the coupled behaviour of the generator. Electromagnetic models were used to explore different magnet layouts, coil materials and geometries, predicting output power and losses. These were linked with structural and rotating machinery models to assess mechanical integrity, dynamic response and vibration. The modelling framework allowed rapid comparison of design variants in terms of power output, mass per megawatt, material cost and manufacturability. Where required, the models were extended to include thermal and acoustic behaviour, supporting a more holistic optimisation. Results were used by GreenSpur to iterate towards a design that balanced efficiency, cost and environmental benefit.
The Results
We engaged Xi Engineering for their evident expertise in modelling, their clear understanding of the industry, the technology, the markets and their professional positive and enthusiastic mindset. We have been delighted with their work on our behalf. We are looking forward to developing our technology alongside Xi Engineering.”
Andrew Hine
Commercial director, greenspur wind ltd
Why it matters
The transition to low carbon energy depends on technologies that are not only efficient but also sustainable and affordable. This project highlights how Xi’s Multiphysics simulation capability can accelerate innovation in the renewables sector, enabling ambitious concepts to be de risked before large investments are made. The same approach can support novel generators, drive trains, power electronics and other critical components across energy projects.