Tuulivoimalan staattoripakan puristusrakenteen kehittäminen

Diplomityössä tutkittiin voidaanko tuulivoimalan generaattorin staattoripakan puristamisessa hyödyntää komposiittista rakenneratkaisua. Tyypillisesti generaattorissa staattorin teräslevyt puristetaan erilaisilla teräsrakenteilla toisiaan vasten. Tavoitteena oli selvittää, voidaanko puristavan komposiittirakenteen osana hyödyntää liimaliitosta tai laminoitua liitosta. Tarkoitus oli etsiä rakenteeseen soveltuva liima ja liimaliitoksen arvot tai laminoitu rakenne ja sille soveltuvat materiaalit ja suoritustapa. Työssä on perehdytty erilaisiin tuulivoimalatyyppeihin, sekä niissä käytettäviin kesto- ja vierasmagnetoituihin generaattorityyppeihin. Tämän lisäksi on tarkasteltu niissä käytettävien staattorien valmistusvaihtoehtoja ja syitä miksi niissä olevat teräslevyt on puristettava toisiaan vasten. Samalla on luotu katsaus nykyisin käytössä oleviin rakenteisiin, joilla puristus voidaan toteuttaa. Liimauksesta on käsitelty perusteoriaa, sekä seikkoja jotka vaikuttavat liimaliitoksen kestoon. Työssä tutkittavaan liitokseen soveltuvien liimojen ominaisuuksia on käsitelty. Myös laminoituun liitokseen jo aiemmin kovettuneeseen komposiittiin on perehdytty. Tutkittavaan rakenteeseen soveltuvia hartsi- ja lasikuitutyyppejä on esitelty. Komposiittien mekaaniseen liittämiseen on lyhyesti perehdytty. Työssä suoritettiin useita vetokokeita, joilla selvitettiin puristusrakenteen tutkimista varten valmistettujen koekappaleiden suurin vetokuormankesto. Vetokokeiden perusteella voitiin valita soveltuvin rakenne staattorin puristamiseksi.

Tuulivoimalan lapojen huolto ja tarkastukset

Uusiutuva energia elää voimakasta kasvukautta ja hallituksen tekemien tukipäätösten vuoksi tuulivoimaa tullaan rakentamaan huomattavasti lisää tulevien vuosien aikana. Tuuligeneraattorin siipien huolto- ja tarkastustoiminta on uusi ja kehittyvä toimiala. Tämä diplomityö onkin tehty oppaaksi helpottamaan tuulivoimaa omistavien, rakentavien, tai tuulivoimapuiston perustamista harkitsevien tahojen huoltosuunnitelmien tekemistä varten. Diplomityössä käydään läpi yleisimmät tuulivoimaloiden lapojen vikaantu-miset, sekä työskentelytavat ja käytettävät laitteistot voimaloiden lapojen huoltoja ja tarkastuksia tehtäessä.

Sähköverkosta irti olevan pienhybridijärjestelmän toteutus

Lappeen siniset –partiolippukunnalla on käytössään leiripaikka Humaljärvellä, Lappeenrannassa. Leiripaikalla ei ole liityntää sähköverkkoon, joten leiripaikalle on asennettu kaksi erillistä aurinkovoimalla toimivaa sähköjärjestelmää. Leiripaikan sähköistetyt rakennukset ovat pääkämppä ja saunan sekä vanhan kämpän muodostama kokonaisuus. Aurinkopaneeleilla tuotettu sähköenergia varastoidaan akustoihin. Lippukunta on havainnot käytössä, ettei talvella tuotettu aurinkoenergia riitä kattamaan pääkämpän sähkönkulutusta, joten leiripaikalle on päätetty hankkia tuulivoimala lisäämään tuotantoa. Tässä kandidaatin työssä esitellään hybridijärjestelmään kuuluvien aurinko- ja tuulivoiman toimintaperiaatteita sekä näiden komponentteja. Aurinko- ja tuulivoimalla tuotetulle sähköenergialle lasketaan arviot, joita verrataan leiripaikan sähköjärjestelmän arvioituun kulutukseen. Leiripaikalle tulevaa tuuliturbiinia ja sen lataussäädintä testataan laboratoriossa, jotta varmistutaan niiden soveltuvuudesta sekä toimivuudesta kohteeseen. Testausten ja laitteiden datalehtien avulla suunnitellaan leiripaikalle toimiva hybridijärjestelmä, joka kattaa leiripaikan ympärivuotisen sähkönkulutuksen.

Doubly fed induction generator versus direct drive permanent magnet synchronous generator in wind power applications

The objective of this master's thesis is to compare two different generator systems for wind turbines. It is the doubly fed induction generator system with three stage gearbox and the direct drive permanent magnet generator system. The comparison of generator systems is based on annual energy production for a given wind climate. For comparison a 3 MW, 15 rpm wind turbine is used. Modelling of a turbine rotor, gearbox and converters were done. Design of two generators was done and their performance was examined.

Design of a 1 kW 150 rpm permanent-magnet synchronous generator for stand-alone wind-power applications

A program for calculating low-speed low-power synchronous machine is presented. A permanent-magnet synchronous generator for 1 kW 150 rpm is designed. Optimization of magnet’s and coil’s dimensions was made.

Wind Turbine Direct-Drive Permanent-Magnet Generator with Direct Liquid Cooling for Mass Reduction

Today’s electrical machine technology allows increasing the wind turbine output power by an order of magnitude from the technology that existed only ten years ago. However, it is sometimes argued that high-power direct-drive wind turbine generators will prove to be of limited practical importance because of their relatively large size and weight. The limited space for the generator in a wind turbine application together with the growing use of wind energy pose a challenge for the design engineers who are trying to increase torque without making the generator larger. When it comes to high torque density, the limiting factor in every electrical machine is heat, and if the electrical machine parts exceed their maximum allowable continuous operating temperature, even for a short time, they can suffer permanent damage. Therefore, highly efficient thermal design or cooling methods is needed. One of the promising solutions to enhance heat transfer performances of high-power, low-speed electrical machines is the direct cooling of the windings. This doctoral dissertation proposes a rotor-surface-magnet synchronous generator with a fractional slot nonoverlapping stator winding made of hollow conductors, through which liquid coolant can be passed directly during the application of current in order to increase the convective heat transfer capabilities and reduce the generator mass. This doctoral dissertation focuses on the electromagnetic design of a liquid-cooled direct-drive permanent-magnet synchronous generator (LC DD-PMSG) for a directdrive wind turbine application. The analytical calculation of the magnetic field distribution is carried out with the ambition of fast and accurate predicting of the main dimensions of the machine and especially the thickness of the permanent magnets; the generator electromagnetic parameters as well as the design optimization. The focus is on the generator design with a fractional slot non-overlapping winding placed into open stator slots. This is an a priori selection to guarantee easy manufacturing of the LC winding. A thermal analysis of the LC DD-PMSG based on a lumped parameter thermal model takes place with the ambition of evaluating the generator thermal performance. The thermal model was adapted to take into account the uneven copper loss distribution resulting from the skin effect as well as the effect of temperature on the copper winding resistance and the thermophysical properties of the coolant. The developed lumpedparameter thermal model and the analytical calculation of the magnetic field distribution can both be integrated with the presented algorithm to optimize an LC DD-PMSG design. Based on an instrumented small prototype with liquid-cooled tooth-coils, the following targets have been achieved: experimental determination of the performance of the direct liquid cooling of the stator winding and validating the temperatures predicted by an analytical thermal model; proving the feasibility of manufacturing the liquid-cooled tooth-coil winding; moreover, demonstration of the objectives of the project to potential customers.

Lightweight, liquid-cooled, direct-drive generator for highpower wind turbines: motivation, concept, and performance

Thesis: A liquid-cooled, direct-drive, permanent-magnet, synchronous generator with helical, double-layer, non-overlapping windings formed from a copper conductor with a coaxial internal coolant conduit offers an excellent combination of attributes to reliably provide economic wind power for the coming generation of wind turbines with power ratings between 5 and 20MW. A generator based on the liquid-cooled architecture proposed here will be reliable and cost effective. Its smaller size and mass will reduce build, transport, and installation costs. Summary: Converting wind energy into electricity and transmitting it to an electrical power grid to supply consumers is a relatively new and rapidly developing method of electricity generation. In the most recent decade, the increase in wind energy’s share of overall energy production has been remarkable. Thousands of land-based and offshore wind turbines have been commissioned around the globe, and thousands more are being planned. The technologies have evolved rapidly and are continuing to evolve, and wind turbine sizes and power ratings are continually increasing. Many of the newer wind turbine designs feature drivetrains based on Direct-Drive, Permanent-Magnet, Synchronous Generators (DD-PMSGs). Being low-speed high-torque machines, the diameters of air-cooled DD-PMSGs become very large to generate higher levels of power. The largest direct-drive wind turbine generator in operation today, rated just below 8MW, is 12m in diameter and approximately 220 tonne. To generate higher powers, traditional DD-PMSGs would need to become extraordinarily large. A 15MW air-cooled direct-drive generator would be of colossal size and tremendous mass and no longer economically viable. One alternative to increasing diameter is instead to increase torque density. In a permanent magnet machine, this is best done by increasing the linear current density of the stator windings. However, greater linear current density results in more Joule heating, and the additional heat cannot be removed practically using a traditional air-cooling approach. Direct liquid cooling is more effective, and when applied directly to the stator windings, higher linear current densities can be sustained leading to substantial increases in torque density. The higher torque density, in turn, makes possible significant reductions in DD-PMSG size. Over the past five years, a multidisciplinary team of researchers has applied a holistic approach to explore the application of liquid cooling to permanent-magnet wind turbine generator design. The approach has considered wind energy markets and the economics of wind power, system reliability, electromagnetic behaviors and design, thermal design and performance, mechanical architecture and behaviors, and the performance modeling of installed wind turbines. This dissertation is based on seven publications that chronicle the work. The primary outcomes are the proposal of a novel generator architecture, a multidisciplinary set of analyses to predict the behaviors, and experimentation to demonstrate some of the key principles and validate the analyses. The proposed generator concept is a direct-drive, surface-magnet, synchronous generator with fractional-slot, duplex-helical, double-layer, non-overlapping windings formed from a copper conductor with a coaxial internal coolant conduit to accommodate liquid coolant flow. The novel liquid-cooling architecture is referred to as LC DD-PMSG. The first of the seven publications summarized in this dissertation discusses the technological and economic benefits and limitations of DD-PMSGs as applied to wind energy. The second publication addresses the long-term reliability of the proposed LC DD-PMSG design. Publication 3 examines the machine’s electromagnetic design, and Publication 4 introduces an optimization tool developed to quickly define basic machine parameters. The static and harmonic behaviors of the stator and rotor wheel structures are the subject of Publication 5. And finally, Publications 6 and 7 examine steady-state and transient thermal behaviors. There have been a number of ancillary concrete outcomes associated with the work including the following. X Intellectual Property (IP) for direct liquid cooling of stator windings via an embedded coaxial coolant conduit, IP for a lightweight wheel structure for lowspeed, high-torque electrical machinery, and IP for numerous other details of the LC DD-PMSG design X Analytical demonstrations of the equivalent reliability of the LC DD-PMSG; validated electromagnetic, thermal, structural, and dynamic prediction models; and an analytical demonstration of the superior partial load efficiency and annual energy output of an LC DD-PMSG design X A set of LC DD-PMSG design guidelines and an analytical tool to establish optimal geometries quickly and early on X Proposed 8 MW LC DD-PMSG concepts for both inner and outer rotor configurations Furthermore, three technologies introduced could be relevant across a broader spectrum of applications. 1) The cost optimization methodology developed as part of this work could be further improved to produce a simple tool to establish base geometries for various electromagnetic machine types. 2) The layered sheet-steel element construction technology used for the LC DD-PMSG stator and rotor wheel structures has potential for a wide range of applications. And finally, 3) the direct liquid-cooling technology could be beneficial in higher speed electromotive applications such as vehicular electric drives.

Permanent magnet synchronous generator design solution for large directdrive wind turbines: Thermal behavior of the LC DD-PMSG

Wind is one of the most compelling forms of indirect solar energy. Available now, the conversion of wind power into electricity is and will continue to be an important element of energy self-sufficiency planning. This paper is one in a series intended to report on the development of a new type of generator for wind energy; a compact, high-power, direct-drive permanent magnet synchronous generator (DD-PMSG) that uses direct liquid cooling (LC) of the stator windings to manage Joule heating losses. The main param-eters of the subject LC DD-PMSG are 8 MW, 3.3 kV, and 11 Hz. The stator winding is cooled directly by deionized water, which flows through the continuous hollow conductor of each stator tooth-coil winding. The design of the machine is to a large degree subordinate to the use of these solid-copper tooth-coils. Both steady-state and timedependent temperature distributions for LC DD-PMSG were examined with calculations based on a lumpedparameter thermal model, which makes it possible to account for uneven heat loss distribution in the stator conductors and the conductor cooling system. Transient calculations reveal the copper winding temperature distribution for an example duty cycle during variable-speed wind turbine operation. The cooling performance of the liquid cooled tooth-coil design was predicted via finite element analysis. An instrumented cooling loop featuring a pair of LC tooth-coils embedded in a lamination stack was built and laboratory tested to verify the analytical model. Predicted and measured results were in agreement, confirming the predicted satisfactory operation of the LC DD-PMSG cooling technology approach as a whole.

Grounding in a wind power application

The subject of this master’s thesis is to research grounding in a particular wind power application. The aim is to define how the grounding from different points effects to the function of the whole system. The investigated subjects are generator voltage spikes, ground currents and system fault situations. The first part of this thesis represents power electronics, which is commonly used in wind power systems. The second part concentrates more to the grounding, electrical safety demands and potential fault situations. The object of the simulations is to investigate voltage spikes and fault situations. Measurements will be made with small-scale setup and in the last part simulation and measurement results are compared to each other and to a full-scale system.

Overvoltage Mitigation Techniques in Wind Power Generators

Advancements in power electronic semiconductor switching devices have lead to significantly faster switching times. In motor and generator applications, the fast switching times of pulse width modulated (PWM) inverters lead to overvoltages caused by voltage reflections with shorter and shorter cables. These excessive overvoltages may lead to a failure of the electrical machine in a matter of months. In this thesis, the causes behind the overvoltage phenomenon as well as its different mitigation techniques are studied. The most suitable techniques for mitigating the overvoltage phenomenon in wind power generator applications are chosen based on both simulations and actual measurements performed on a prototype. An RC filter at the terminals of the electrical machine and an inverter output filter designed to reduce the rise and fall times of voltage pulses are presented as a solution to the overvoltage problem. The performance and losses of both filter types are analysed.

Simulation model of wind turbine gearbox and lubrication system

As increasing efficiency of a wind turbine gearbox, more power can be transferred from rotor blades to generator and less power is used to cause wear and heating in the gearbox. By using a simulation model, behavior of the gearbox can be studied before creating expensive prototypes. The objective of the thesis is to model a wind turbine gearbox and its lubrication system to study power losses and heat transfer inside the gearbox and to study the simulation methods of the used software. Software used to create the simulation model is Siemens LMS Imagine.Lab AMESim, which can be used to create one-dimensional mechatronic system simulation models from different fields of engineering. When combining components from different libraries it is possible to create a simulation model, which includes mechanical, thermal and hydraulic models of the gearbox. Results for mechanical, thermal, and hydraulic simulations are presented in the thesis. Due to the large scale of the wind turbine gearbox and the amount of power transmitted, power loss calculations from AMESim software are inaccurate and power losses are modelled as constant efficiency for each gear mesh. Starting values for simulation in thermal and hydraulic simulations were chosen from test measurements and from empirical study as compact and complex design of gearbox prevents accurate test measurements. In further studies to increase the accuracy of the simulation model, components used for power loss calculations needs to be modified and values for unknown variables are needed to be solved through accurate test measurements.

Sähkökoneen staattorikäämityksen kehittäminen

Tämä insinöörityö tehtiin ABB:n Pitäjänmäen konetehtaalle Tahtikoneet-tulosyksikölle. Työssä tutkittiin mahdollisuuksia valmistaa murtovakovyyhtejä kestomagneettituuligeneraattoreihin, joissa vakoluku on alle yhden. Työ tehtiin tutustumalla aluksi Pitäjänmäen konetehtaan käytössä oleviin vyyhden valmistus- ja käämintämenetelmiin. Lisäksi tutkittiin erilaisia mahdollisia murtovakovyyhden valmistusmenetelmiä, joista lupaavimpia myös kokeiltiin. Saatujen kokemusten pohjalta valittiin vyyhden valmistusmenetelmä, jonka mukaan valmistettiin koe-erä. Koe-erälle suoritettiin mittauksia, joilla varmistettiin niiden sähköinen kestävyys Työn tuloksena valitulla valmistusmenetelmällä valmistettiin vyyhdet prototyyppi tuuligeneraattorin.

Factors affecting the snow and wind induced damage of a montane secondary forest in northeastern China

Abstract