Direct-drive permanent magnet generators are becoming an attractive option for highly efficient small-scale wind turbines due to their high-power density and size reduction capabilities. In this study, the optimal shape design of a direct-drive permanent magnet generator for 1 kW-class wind turbines was conducted while considering power generation and weight. Half of the geometry of a single stage in the generator was considered for a electromagnetic analysis under given electrical parameters. In order to construct a response surface model, a sensitivity analysis was conducted on seven design parameters of the proposed generator. The desirability function was used to minimize the weight of the generator while meeting a requirement of the target specification. The results indicated that the optimized design parameters for the generator met the target specification while maintaining the generator’s weight at the same level as the initial design model. From the comparisons with other research, the optimized generator exhibited a higher power generation/weight ratio than the generator with a rated capacity under 3 kW.

Ball valves are widely used as flow control devices wherein a hollow, perforated ball pivots to control the liquid flowing through it. Due to a simple structure and only a quarter-turn of the stem required for either a fully open or fully closed state, ball valves are known for being durable with excellent shut-off properties, albeit without offering precise flow control. V-port ball valves are used as an alternative to allow for linear and even equal percentage flow characteristics, but a robust construction is required for higher velocity working fluids in the small end opening of the V-shape; otherwise, the valve could sustain damage. In the present study, a cylinder-in-ball valve is proposed through a structural conceptual design, wherein the opening begins at the center of the flow path. The flow characteristics and flow rates according to the opening rate were quantitatively evaluated via computational fluid dynamic analysis. The results showed that the flow coefficient, CV, with a range of 1.05~109.87, increased exponentially over the opening rates of 20~100%. A numerical analysis for the multi-phase flow was performed to calculate the vapor volume fraction to confirm the effects of cavitation. In addition, an experiment was conducted on the CV values to verify the validity of applying the proposed cylinder-in-ball valve as a flow control valve. Good agreement for the CV values was obtained between the experimental and numerical results.

Lithium tantalite (LiTaO3) is a representative multifunctional single-crystal material with electro-optical, acoustic, piezoelectric, pyroelectric, and nonlinear optical properties used as a substrate for surface acoustic wave (SAW) devices. To enhance SAW device performance, thinner LiTaO3 substrates with improved surface roughness are desired. Chemical mechanical polishing (CMP) is employed to achieve the desired surface roughness after grinding. However, the thinning process increases the risk of substrate fracture, especially at the edges, resulting in edge chipping. Edge chipping can lead to complete substrate failure during SAW device fabrication, requiring an effective wafer geometry to prevent it. The study utilizes scratch tests and finite element analysis (FEA) to identify the optimal edge shape (C-cut, trimmed, and thinned) for preventing edge chipping on LiTaO3 wafers. The C-cut edge refers to the rounding of the wafer’s edge, while the trimmed edge refers to the machining of the wafer’s edge to be perpendicular to the wafer surface. As a result of the scratch tests, we observed edge-chipping lengths of 115 and 227 μm on the C-cut and trimmed edges, respectively, while the thinned edge (half C-cut) resulted in complete wafer fracture. In the finite element analysis (FEA), edge-chipping lengths of 80, 120, and 150 μm were obtained on the C-cut, trimmed, and thinned edges (half C-cut), respectively. In conclusion, it has been confirmed that the C-cut, trimmed, and thinned edge shapes are effective in preventing edge chipping. However, considering that the C-cut edge shape becomes thinner through grinding, using the trimmed edge shape appears to be the most effective.