4bis Tessarolo

Experiences with electric machines
for wind power generation
Alberto Tessarolo
Engineering and Architetcture Dept.
University of Trieste, Italy
Sesto, 25 giugno 2013
Montebello, Italy
AC & DC LV Drives
Center of Excellence for
Metals – Long products
Ropeway transportation
System Integration
System Automation
Dusseldorf, DE
Metal Systems
Sales & Service
Integration
Roche-Moliere, FR
Metal Systems
Sales & Service
Integration
Genoa, Italy
Center of Excellence for Metals
– Flat products
Artics Platform Develop.
Marine Systems
Milan, Italy
MV Drives
Drive systems
Power Supply
Monfalcone, Italy
AC & DC Motors
Generators
Special Machines
OIL & GAS
Oil & Gas Extraction, Transportation & Storage,
Processing and Refining
METALS
Hot rolling mills for long and flat products, Cold mills,
Non ferrous Metals applications, Iron & steel Making,
Aluminium smelters, E-Chem
MARINE
Offshore, Navy, Transport and Passenger Vessels
applications,
Electric Propulsion, Power Generation systems,
Complete Package Solutions
ENERGY
Power Generation & Distribution, Desalination,
Alternative Energy
ENVIRONMENT
Ventilation and smoke extraction system, HVAC,
Drinking water, Pumping stations, Water
transportation
ROPEWAY
Complete automation systems, drive systems, supervision
& monitoring systems
“CARNIVAL LIBERTY” CARNIVAL CRUISE LINES (Hull 6111)
Supply:
N.6 x 14MVA Diesel Generator feeding two main 11kV
Switchboards + n. 6 thruster motors 1720kW - 11kV, 1187
r/min, 60 Hz
N.3 NEW CARNIVAL CORP. CRUISE LINERS (Hull 6129, 6130,
6135)
Supply:
N.6 x 21 MW LCI water-cooled converters for Electric
Propulsion
N.6 x 14MVA Diesel Generator feeding two main 11kV
Switchboards + n. 6 thruster motors 1720kW - 11kV, 1187
r/min, 60 Hz
MEDIUM VOLTAGE from 690 up to 13800 Volts
LOW VOLTAGE from 230 up to 690 Volts
DC CONVERTERS
IGBT/IGCT Based
SILCOVERT
TN – IGBT
SILCOVERT
– IGCT
SILCOVERT
SILCOVERT
TN – IGBTGN
GN
– IGCT
3,3
3,3kV
kV
3,3
3,3 kV
kV
Traditional
Thyristor based
SILCOVERT
- 1,5-10,0
kV kV
SILCOVERTS –S LCI
– LCI
- 1,5-10,0
SILCOVERT
– Cycloconverter
SILCOVERTC C
– Cycloconverter
GT
GT SERIES
SERIESLVLV
DRIVES
DRIVES
– IGBT
– IGBT
230-690
230-690
V
V
SILCOPAC
V DC
SILCOPACDD380-750
380-750
V DC
3
10
100
SILCO
kVkV
DCDC
SILCO400-1,5
400-1,5
200
800
1,000
5,000
10,000
30,000 75,000
Power: kW
Synchronous
motor
45 MW
7.2 kV
3000 rpm
12 phases
Oil and Gas
Industry
Synchronous
generator
2 MVA
1.2 kV
750 Hz
22000 rpm
12 phases
Shipboard
applications
Axial flux motor
123 kW
1400 rpm
Automotive
650 kW
10.000 giri/min
700 kW
14 giri/min
2012 – Motore
superveloce a magneti
superficiali ad array di Halbach con levitazione
magnetica
2010 – Generatore eolico a magneti permanenti interni con
architettura “full fault tolerant”.
Structural analysis tools
EM Analysis tools
Optimization design tool
Thermal analysis tools
Fluid dynamic
analysis tools
Industry
University
20 MW generator
14 rpm
Micro-wind
applications
20 kW generator
1200 rpm
Off-shore wind
applications
m
m
10
00
slot
pole
How many poles?
How many slots?
Number of poles
Number
of slots
Best slot – pole combinations
Importance and advantages of
micro-wind generation
• Simple installation
• Possible installation in hurban
environments
• Small size Little aesthetical impact
• Very silent operation
• Exploitation of wind energy at almost
any speed
Connection to the grid
Funded applied research project for
micro-wind turbine realization
Percent of the time
Wind speed distribution over time (year)
Mechanical characteristic required
Power / Voltage
Cut-in speed
Rated speed
Most probable speed
Cut-off speed
torque
Mean torque
Mean torque
time
SLOTTED STATOR
SLOTOLESS STATOR
torque
torque
time
Past design experience
time
No reference design
Slotless machine design for
optimization
DESIGN VARIABLES
Deterministic
MULTI-OBJECTIVE
OPTIMIZATION
CONSTRAINTS
OPTIMIZATION
ALGORITHM
Stochastic
OBJECTIVE FUNCTION
Design variables
Number of poles : 2p
Constraints
Objective functions
• Total permanent-magnet weight (to
minimize)
• Torque to current ratio (to minimize)
• Efficiency (to maximize)
modeFrontier Work Flow
Desgin variables
Optimization algorithm
Computation node
Objective functions
Computation node
THERMAL FINITE-ELEMENT
ANALYSIS TOOL
E. M. FINITE-ELEMENT
ANALYSIS TOOL
Post-processing
Too large
Pareto frontier
Inclusion of efficiency constraint
η > 97%
New Pareto frontier
Smaller Pareto
frontier
Torque over current ratio
Inclusion of T/I constraint
Design ID
Inclusion of T/I constraint
T/I constraint
η constraint
Magnet mass
minimization
Convergence of design variables to
optimal values
Number of poles
Winding height
PM height
28
7.5 mm
12 mm
Electromagnetic analysis
voltage
current
Efficiency
Total losses
Iron losses
Copper losses
Additional losses
Cogging torque verification
Rated torque = 160 Nm
Structural analysis
Generator manufacturing
Pictures during manufacturing
Aluminium
frame
Stator slotless core
(silicon iron laminations)
Winding spacers
Coil assembly
Stator impregnation
Completely incapsulated
winindg
Rotor assembly
Glued permanent magnets
Insulating
spacers
Rotor wrapping with polyglass tape
Rotor placed in
the stator bore
Frame closed
with end shields
Generator test
generator
torquemeter
DC motor drive
Test results
• Direct efficiency measurement 97.2%
• Measurement of the cogging torque (< 0.2Nm)
• Voltage drop < 10% at full load
Conclusions
• The application of mF optimization tool has been
reported for the design of a slotless micro-wind
generator
• The use of mF highly simplified the design process by
shorting the development time
• The Pareto frontier has been progressively reduced by
transforming objective functions into constraints single-objective optimization pareto frontier = single
design
• The optimal design has been implemented in the
actual generator which has been manufactured and
tested.
• Test results have confirmed the effectiveness of the
design approach.
THANKS FOR THE ATTENTION
Generator cosφ ≅ 1
Generator
phasor diagram
High phase inductance
Load
increase
Large voltage drop
Low phase inductance
Load
increase
Low voltage drop
Phase inductance must be very small
Modeling for optimization
Induction Machines
• Power Ratings:
150 - 25,000 kW
• Voltage:
up to 15 kV
• Mass:
1,500 - 120,000 kg
• Frame Sizes:
315 mm through 1120, 10, 11, 12,13
Available Cooling Systems
CR = IC 81W (TEWAC)
CT = IC 611 (TEAAC)
W = IC 01 (WPI & WPII)
N = IC 01 (ODP)
CB = IC 31 (TEPV)
HORIZONTAL OR VERTICAL MOUNTING AVAILABLE
Strengths: 2 pole stiff shaft
API 541
Explosion Proof Machines (ET, CAD)
• Power Ratings:
150 - 4,500 kW
• Voltage:
up to 15,000 V
• Mass:
1,500 - 20,000 kg
• Frame Sizes:
300 - 800 mm
• No. of Poles:
2 - 36
• Type of Cooling:
IC 511, IC 411
• Standard Protection:
IP55 - EExd II B T3
Antifriction or Sleeve Bearings - Horizontal and Vertical Mounting,
2 pole stiff shaft
Types of flame proof “d” protection available gas groups:
Group IIA:
Group IIB+H2:
Group IIC:
Temperature Classes:
Methane, xthane, butane, propane
ethylene, cyclopropane, hydrogen
acetylene
T1 - T6
Other types of protection available: Pressurized “p”, increased safety “e”,
non sparking “n”
Synchronous Machines
• Power Ratings:
1,000 - 55,000 kVA
• Voltage:
380 to 15,000 V
• Mass:
3,500 - 250,000 kg
• Frame Sizes:
450 mm through 1320, 11, 12, 13
• No. of Poles:
4 - 36
• Excitation:
Brushless or Static with Slip Rings
HORIZONTAL AND VERTICAL MOUNTING
API 546
Series GH
• Power Ratings:
2 - 6,000 kW (at 150 RPM)
• Voltage:
up to 1,000 V
• Mass:
100 - 110,000 kg
• Shaft Height:
80 - 1,120 mm
• Mounting Arrangement:
Horizontal/Vertical
• Type of Cooling:
IC06, IC00, IC666,
IC86W, IC37
Significant experience in Marine, Metals & Plastics