This paper introduces a new asymmetrical rotor design for easy assembly and repair of field windings in synchronous machines. A new rotor geometry is adopted in order to simplify the manufacture and maintenance process of installing the rotor windings. The asymmetrical rotor design is simulated by the 2-D finite element analysis (FEA), and verified by experimental tests on a 27.5 kVA prototype machine. The proposed topology can drive down the maintenance and repair costs of the machine without impacting on the machine’s electro-magnetic performance. This design will have significant economic implications for machine design and repair industry, especially for mass production markets such as wind turbines and engine-generators.
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