Our Generator

Introducing the GreenSpur Solution

The GreenSpur Solution offers the wind and tidal industries a clear pathway to addressing critical materials supply chain risks by introducing an innovative generator based on a new modular axial-flux architecture. This design incorporates ferrite magnets, aluminium coils, and composite materials, eliminating the need for Rare Earth magnets and copper windings found in traditional generators. This breakthrough is supported by 53 international patent filings in 11 countries.

Dyer Engineering
Teesside University

Proven Performance and Patented Innovations

The GreenSpur generator has successfully undergone extensive testing at the Offshore Renewable Energy Catapult (OREC) in Blyth, UK, demonstrating superior performance and sustainability compared to state-of-the-art wind turbines and industry benchmarks. GreenSpur have 33 granted patents, which will soon increase to 35 once the European anti-cogging and anti-flexure cases are confirmed. Additionally, GreenSpur have 18 pending patent applications. Our mission is to deliver the most environmentally friendly generator ever built, with a unique modular design that supports solutions ranging from 10kW to over 20MW, guided by a clear technology roadmap for commercialisation within wind and tidal markets.

Modular and Scalable Design

The GreenSpur generator is modular, with each module comprising a rotor embedded with magnets and two stators housing coils. This modular approach facilitates scalability and customisation, allowing GreenSpur to offer solutions ranging from 10kW to 20MW and beyond, guided by a clear technology roadmap for commercialisation within wind and tidal markets. In collaboration with the Offshore Renewable Energy Catapult and Warwick Manufacturing Group, GreenSpur continues to scale its technology and showcase the benefits of its Rare Earth-free PMG through a comprehensive whole-system model.

GreenSpur Rare Earth Free Generator 75kw 3 stage stackable demo

Game-Changing Benefits

The game-changing benefits of this technology are significant. By utilising low-cost materials like ferrite magnets and aluminium coils, GreenSpur achieves reductions in the Levelised Cost of Energy (LCOE) compared to conventional generators. The axial-flux design maximises interaction between magnets and coils, supported by a simple air-forced cooling system that ensures operational efficiency. Unlike conventional radial-flux designs relying on Rare Earth magnets, GreenSpur’s Rare Earth-free magnets can operate at 140 degrees Celsius, simplifying thermal management.

Let’s take a look at the Benefits…

Lower Costs

LCOE reductions are achieved by using low-cost materials in place of more expensive ones. High-cost Rare Earth magnets and copper windings are replaced with low-cost ferrite alternatives and cheaper aluminium coils.

Innovation

GreenSpur’s axial-flux design incorporates many innovate design features. The rotor and stator are arranged as discs along the axis of the machine, which opens up a greater surface area for our magnets and coils to interact. A simple air-forced cooling system maintains the operational temperature. Our Rare Earth-free magnets can safely operate at 140 degrees Celsius, so the thermal management of our generator is less challenging than for existing Rare Earth radial-flux designs.

Supply Chain Strengths

By moving to abundant and low-risk materials the GreenSpur generator eliminates the price and supply risks associated with Rare Earth magnets and copper windings.

Sustainable

The mining and processing of Rare Earth magnets is environmentally challenging. Hazardous and sometimes radioactive biproducts are generated as part of the production process. The use of low-risk Rare Earth-free magnets and aluminium materials enables the development of a long-term, environmentally friendly and sustainable production processes.

Our Axial-Flux Design

GreenSpur’s generator design is based around an axial-flux architecture, as opposed to the radial-flux architecture used in most motors and generators and the direct drive generators used in offshore wind turbines.

In conventional, radial-flux generators, the rotor (rotating part of the generator) and stator (stationary part) are concentric cylinders, with magnetic flux flowing between them. The flux lines flow to and away from the axis of rotation of the generator, as shown in “radial lines” in the left-hand diagram.

In an axial-flux generator, the rotor and stator are arranged as discs along the axis of the machine, and the magnetic flux flows parallel to this axis as “axial lines”, as shown in the right-hand diagram.

The Greenspur Design

The GreenSpur design is modular, with each module containing a rotor, into which the magnets are embedded, sandwiched between two stators into which the coils are placed and in which the current is induced.