Optimization Design of a Cost-Effective Surface-Mounted Permanent Magnet Generator Using Hybrid Ferrite and Rare-Earth Halbach Arrays

Surface-mounted permanent magnet (SPM) machines are highly capable for wind power generation due to their high output power, simple structural design, and effective thermal management. However, their heavy reliance on rare-earth magnets significantly increases the cost per unit power, limiting large-scale deployment. To address these challenges, this study proposes a cost-effective SPM wind generator featuring a hybrid NdFeB-ferrite Halbach PM array and flux barriers. The structural parameters are optimized using a genetic algorithm (GA) with sensitivity-based constraints. Finite element analysis (FEA) demonstrates that the proposed design reduces material cost by 18.2% and weight by 14% compared to conventional SPM generators, while delivering higher output power. Furthermore, cogging torque and torque ripple are reduced by 54% and 79%, respectively, enhancing its suitability for low-speed wind applications and ensuring smoother operation. Improved loss characteristics and efficiency further highlight the generator’s superior performance. These results position the proposed design as a cost-effective and practical solution for wind power generation.