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In this study, by using the electromagnetic field analysis, the design of brushless DC generator with a novel construction and controller, appropriate for variable speed applications, is proposed. In the proposed machine, unlike the conventional structure, an assisted DC field coil is employed instead of permanent magnet excitation to provide a regulated voltage. Results of the electromagnetic field analysis show that including the DC field coil increases the controllability of the flux in different machine parts which provide a regulated terminal voltage in a wide speed range appropriate for variable speed applications. Moreover, the maximum power point tracking is achieved by controlling the DC field current along with producing optimal turn‐on and turn‐off angles for stator winding using the electromagnetic analysis based on optimal finite element analysis. Also, an appropriate controller is designed to control the DC field coil current. To verify the actual performance of the proposed configuration, a 1.5 Kw machine is manufactured and tested followed by the discussion on results. The obtained experimental results are in good agreement with the results of the electromagnetic analysis which confirm the maximum power trackability and robust output voltage regulation of the proposed conversion system under different shaft speeds and load conditions. [ABSTRACT FROM AUTHOR]