Electrical machines for renewable energy converters keynote
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Transcript of Electrical machines for renewable energy converters keynote
Electrical Machines For Renewable Energy
Converters
Dr. Markus MuellerSchool of Engineering
University of Edinburgh
Presentation
Renewable Energy Systems Electrical Drivetrain Technology Challenges – engineering & economic Integrated Design Tools Electrical Machine Topologies Future Developments
Wind Energy
E uropean Wind E nergy Association
Wind Drivetrain
Direct Drive Wind
Enercon E112 4.5MW 220 tons Iron cored field wound
synchronous machine Large magnetic
attraction forces between stator and rotor.
Structural support >60% of total mass.
Wave Energy
Global Wave Energy Resource
EU Wave Energy Resource
Source : Future Energy Solutions
UK ResourceUK Resource
•Offshore: 50TWh/year Offshore: 50TWh/year (1/7(1/7th th UK Electricity UK Electricity Production) Production)
•Near-shore: 7.8TWh/yearNear-shore: 7.8TWh/year
•Shoreline: 0.2TWh/yearShoreline: 0.2TWh/year
Oscillating Water Column
Wave energy conversion device LIMPET on Islay since 2000 Turbines delivered to Mutriku, Spain 4MW scheme on Lewis consented
Oscillating Water Column (OWC)Shoreline and near shore
© Wavegen
Pelamis Full Scale – 750kW
Image © Aquatera.co.uk
Pelamis Wave Power
© Pelamis Wave Power
• Pelamis – sea snake• Designed for survivability• Uses off the shelf
components• A 750 kW device will be
150m long and 3.5m in diameter.
• Hydraulic PTO• Generators
• Squirrel Cage Induction Machine
Pelamis – power take off
Cylindrical sections connected by hinged joints
Motion of joints resisted by hydraulic rams, pumping high pressure oil through hydraulic motors via smoothing accumulators, ultimately driving induction machines
Power take off at each hinge
Power from all hinges fed into one sub-sea cable © Ocean Power Delivery
http://www.youtube.com/watch?v=F0mzrbfzUpM
Hydraulic Power Take Off
Aquamarine
Hydro Technology Pelton Turbine driving Synchronous
Machine© Aquamarine
Oyster – Testing at EMEC
© Aquamarine
Point Absorber: Archimedes Wave Swing
© AWS BV
Move with incident waves either in surge or heave mode and is veryMove with incident waves either in surge or heave mode and is very
small compared to the wavelength. small compared to the wavelength.
AWS Electrical Power Conversion
Linear PM synchronous machine Rating – 2MW Average – 400kW Stroke – 4 to 7m Velocity <= 2.2m/s Double sided Stator – 5.6m Translator – 8.4m Mass ?
© AWS BV
(Source: Dr. Henk Polinder, TU Delft)
Marine Current Turbines
Axial flow turbine SEAFLOW: 300 kW
unit; Lynmouth, North Devon Coast
SEAGEN: 1.2MW, Strangford Narrows, N. Ireland
Power take-off by geared induction generator
© Marine Current Turbines
Tidal Current Direct Drive:Open Hydro
Rim Generator Air-cored PM
generator Fully flooded 300kW device
tested at EMEC
ScotRenewables
Floating Turbine Hydraulic Power Take Off Induction Generator
Engineering Challenges
Low speed Wind: 1MW – 20rpm, 7MW – 10rpm Wave: recoprocating, 1-1.5 m/s peak Tidal Current: 1MW – 10rpm
Mechanical interface to step up speed Direct Drive
Physical size, weight, Permanent Magnet - Cost and Availability
June £77/kg, August £150/kg Environment – corrosion, vibration
Engineering Challenge
Variable prime mover Wave:
Challenge Example - Oyster
Diameter 6 m
Total Weight 118,6 t
Total Generator Cost £ 3,066k
Power Electronics Cost £ 116k
Total Cost £ 3,182k
Single Stage Gearbox
Direct Drive• Maximum Reliability• Larger generator mass & cost• Low utilization of magnetic material
(due to low speed)
Single Stage Gearbox• Reduced reliability
(but not as multi speed gearboxes)• Decreased generator mass & cost• Increased efficiency & electricity generation
Designs with Different Gear Ratios
Integrated Design
Wind speeddistribution
Wind turbinemodel
Generatormodel
Axial-flux
Electricalmodel
Structuralmodel
Criterioncalculation
Radial-flux
5 MW3 MW2 MW
Thermalmodel
Hydrodynamicmodel
Generatormodel
Electricalmodel
Structuralmodel
Criterioncalculation
Thermalmodel
DesignOptimisation
FinalDesign
Wave Energy Converter
Wave FrequencyDistribution
Structural Modelling of Direct Drive
2θ
R
R1Ro
hyr
What does this modelling tell us? Structural material is dominant
Optimal aspect ratios are larger
Optimal airgap lengths are larger
Stator
Rotor
Stator
Rotor
Structural Optimisation
Integrated Electromagnetic-Structural Optimization
A FEA optimisation tool was created to further decrease the weight of the direct drive generator
The FEA optimisation tool removes peaces of the predefined structure based on the major forces that apply on it
The rotating part was optimised separately from the stationery one
The new structures are up to 15% lighter compared to the original ones
Original Structure “New” StructurePartial FEA Optimisation
Induction Generator Modelling for OWCs -
Wavegen
Airflow and generator power recorded during OWC operation
Recorded casing and winding temperatures and 1 minute average generator power during operation
Solutions to Challenges
Power Density or Mass Transverse Flux Machine Air-cored Machines Novel Structures Superconducting Machines
Low speed Magnetic Gearing - SNAPPER
PM Magnets Switched Reluctance Machines
Armature
Translator
Springs
Copper Winding / Coil
Stack Length, ls
Magnetic Gearing: SNAPPER
Fdrive
Fspring
Fdrive
Fspring
Phase 1
Spring force is less than magnetic attraction force:
Translator and armature move in same direction.
Phase 2
Spring force matches magnetic attraction force:
Armature movement ceases
Phase 3
Armature becomes decoupled from translator and begins to move at high velocity relative to the translator.
Dry Testing
Dry Testing Video
Dry Testing video
Economic – PM availability
Switched Reluctance No permanent magnet material Coils on stator only. Rotor consists of iron laminations only. Versatile in terms of control. Requires grid connection for excitation Small airgaps required for high
performance.
Experimental Prototype20 kW at 100 rpm
Switched Reluctance with Segmental Rotor
Prof Barrie Mecrow, University of Newcastle
TOPOLOGIES FOR WOUND-FIELD THREE-PHASE SEGMENTED-ROTOR FLUX-SWITCHING MACHINES A. Zulu, B.C. Mecrow, M. Armstrong, IET PEMD, Brighton, 2010
Switched Reluctance with Segmental Rotor
65% improvement in Torque Density (Nm/kg) compared conventional.
“Optimised Segmental Rotor Switched Reluctance Machines with a Greater Number of Rotor Segments Than Stator
Slots” J.D. Widmer and B.C. Mecrow, IEEE IEMDC, Niagara, Canada, 2011.
Transverse Flux Machines
High Shear Stress at the airgap 200kN/m2 reported by Weh 4-5 times conventional PM synchronous
machine Construction is challenging Power Factor is an issue
Surface mounted TFM – pf ~0.2 Flux concentrating TFM - pf ~0.5
EEC
What type of TFPM machine ?A number of TFPM machine types have been proposed.
It is necessary to find the most suitable type. How?
PM
Core
Winding
Secondary part
Primary part
Core
EEC
PM
Core
Winding
Secondary part
Primary part
Core
CorePM
Winding
Secondary part
Primary part
Core
PM
Core
Winding
Primary part
Core
Secondary part
PM
Core
Winding
Primary part
Core
Secondary part
a) RFPM machine b) TFPM machine-1 c) TFPM machine-2
d) TFPM machine-3 e) TFPM machine-4
Comparative design of PM machines
EEC
Generator parameter
Generator power, P 5.56 MW
Rotational speed, rpm 12
Number of phase, m 3
Nominal current, is 675 A
No-load voltage, ep 2746 V
Air gap length, lg 6.14 mm
Air gap diameter, Dg 6.14 m
Material parameter
Remanent flux density of the magnets (T)
1.2
Recoil permeability of the magnets 1.06
Resistivity of copper at operating temperature (μΩm)
0.025
Cost modeling
Laminations cost (€/kg) 3
Copper cost (€/kg) 15
Magnet cost (€/kg) 25
Design parameters
EEC
PM
Core
Winding
Secondary part
Primary part
Core
CorePM
Winding
Secondary part
Primary part
Core PM
Core
Winding
Primary part
Core
Secondary part
PM
Core
Winding
Primary part
Core
Secondary part
Comparison
EEC
PM
Core
Winding
Secondary part
Primary part
Core
CorePM
Winding
Secondary part
Primary part
Core
PM
Core
Winding
Primary part
Core
Secondary part
PM
Core
Winding
Primary part
Core
Secondary part
a) RFPM machine b) TFPM machine-1 c) TFPM machine-2
d) TFPM machine-3 e) TFPM machine-4
Comparative design of PM machines
PM Air-cored Machines
Stator winding contains no iron. Elimination of magnetic attraction
forces between stator and PM rotor Benefits in terms of
Machine structural mass Assembly and manufacture
PM machines
Copper
Steel
PM
Stator
Rotor
Rotor
Iron-cored machines:
High flux density and shear stress
Large attractive forces between rotor and stator
Air-cored machines:
Lower flux density and shear stress
No attractive forces between rotor and stator
Air cored PM: SLIM & Goliath
Goliath – 250kW
Spoked Structure Airgap Winding, steel surrounding
winding
Open Hydro
Air-cored Machines:C-GEN
Mild steel C-core
Magnets
C-GEN modular assemblyC-GEN modular assembly
Rotor
Stator
C-GEN final assemblyC-GEN final assembly
• PM GeneratorsPM Generators– Assembly is difficult and Assembly is difficult and
dangerousdangerous– Large forces of attraction Large forces of attraction
between rotor and statorbetween rotor and stator
• C-GEN stator can be C-GEN stator can be simply and easily simply and easily lowered into placelowered into place– No forcesNo forces– Assembles with an engine Assembles with an engine
hoisthoist– Production savings for Production savings for
large generatorslarge generators
C-GEN Mk I: 20 kW C-GEN Mk I: 20 kW Prototype ResultsPrototype Results
80%
85%
90%
95%
100%
0 5 10 15 20 25
Power (kW)
Eff
icie
ncy
100rpm90rpm80rpm70rpm60rpm50rpm
PowerPower 21.5 kW21.5 kW Outer radiusOuter radius 502 mm502 mm
EfficiencyEfficiency 93 %93 % Machine Machine lengthlength
500 mm500 mm
SpeedSpeed 100 rpm100 rpm Total massTotal mass 949 kg949 kg
C-GEN MkII: 15kW C-GEN MkII: 15kW resultsresults
85
90
95
100
0 200 400 600 800 1000 1200
Torque (Nm)
50
96
107
115
120
rpm
Linear C-GEN for Wave
50kW (pk) Vpk = 2m/s Machine Length =
3m Stroke = 2m
High Temperature Superconducting Machines
American Superconductor Coorp
36.5 MW, 120 rpm (U.S. Navy, AMSC)
HTS Context
Larger Offshore Wind Turbines (>5MW)
Gearboxes unfeasible Direct Drive
Low Speed – High Torque More Reliable High Generator Mass
• High Installation Cost
M. Lesser, J. Müller, “Superconductor Technology – Generating the Future of Offshore Wind Power,”
Types of HTS Machines
Rotating DC Superconducting Field Most Common Type Transient Torques on HTS wire Cryocooler Coupler + Brushes
Low Reliability Cooling Times
Magnetized Bulk HTS Very Difficult to Handle Demagnetization
All Superconducting Machines AC Losses on HTS wire
HTS Machines – Claw Pole
Stationary HTS coil to provide field excitation
Air-cored winding Claw Pole Rotor
steel construction modulates the
field
Claw Pole HTS Generator
Future
Low speed Direct Drive Single Stage Gear Box
Direct Drive HTS, Air-cored machines, Novel Support
Structures Permanent Magnet Issue
Switched reluctance segmented rotor machine Integrated Design Tools
Electromagnetic, structural, thermo-fluid Operational Environment Design for Reliability
Acknowledegements
Scottish Enterprise The Carbon Trust npower juice EPSRC Supergen Marine EU FP6 UPWIND EU FP7 SNAPPER Project NGenTec Fountain Design Ltd, TUV NEL, & Hopewell Wind Ltd PhDs & RAs
Ozan Keysan, Richard Crozier, Alasdair McDonald, Aris Zavvos
Professor Ed Spooner (Goliath & Open Hydro) Dr. Henk Polinder (TU Delft)