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.

Alternative Energy Conversion Systems for a Micro Scale Wind Turbine

This Master's thesis deals with a Micro Scale Wind Wind Turbine application. The thesis consists of nine chapters. The first chapter is an introduction to the philosophy of a small scale wind turbine application. The second defines concepts, and lists the requirements. The third presents the whole application for an On-Grid , and for an Off-Grid arrangement, with main concentration on lighting, heating, and energy storage. The fourth deals with the Inverter's technology, which are used for the conversion of the produced power. The fifth chapter presents the available storage technology and it's possibilities. The sixth deals with the system, and the technological means used for the implementation. The seventh presents the PLC device, which was used as the controller for the management of the whole application. The eighth deals with the concept and the control application philosophy that the PLC involves. And the final chapter presents conclusions and ideas for further considerations.

Technical Wind Energy Potential in Russia

The goal of the master's thesis is a detailed research of the technical wind energy potential in Russian Federation: the distribution of the potential all over the territory of the country and the possibility of the application of the potential for power supply of various objects. The main attention of the thesis is devoted to the assessment of wind energy resources (potential) of Russian Federation, both for the territory of country in whole and for every region. Theoretical basic wind energy concepts and the scheme of transformation of kinetic energy of a wind into electric energy by modern wind turbines are given in the work. Also the costs of energy, stimuli of development of wind-engineering and obstacles which impact the industry development are analyzed. The review of existent and projected wind power plants in Russia is carried out.

Small wind energy

Master thesis represents the literature overview of small wind energy. I have given the description of principles of work wind turbines, the description of the types of wind turbines, their advantages and disadvantages, the characteristics of small wind turbines, have shown how to count the payback period, have given an overview of currently market wind turbines and the future forecast.

Utilization of a Time Domain Simulator in the Technical and Economic Analysis of a Wind Turbine Electric Drive Train

The amount of installed wind power has been growing exponentially during the past ten years. As wind turbines have become a significant source of electrical energy, the interactions between the turbines and the electric power network need to be studied more thoroughly than before. Especially, the behavior of the turbines in fault situations is of prime importance; simply disconnecting all wind turbines from the network during a voltage drop is no longer acceptable, since this would contribute to a total network collapse. These requirements have been a contributor to the increased role of simulations in the study and design of the electric drive train of a wind turbine. When planning a wind power investment, the selection of the site and the turbine are crucial for the economic feasibility of the installation. Economic feasibility, on the other hand, is the factor that determines whether or not investment in wind power will continue, contributing to green electricity production and reduction of emissions. In the selection of the installation site and the turbine (siting and site matching), the properties of the electric drive train of the planned turbine have so far been generally not been taken into account. Additionally, although the loss minimization of some of the individual components of the drive train has been studied, the drive train as a whole has received less attention. Furthermore, as a wind turbine will typically operate at a power level lower than the nominal most of the time, efficiency analysis in the nominal operating point is not sufficient. This doctoral dissertation attempts to combine the two aforementioned areas of interest by studying the applicability of time domain simulations in the analysis of the economicfeasibility of a wind turbine. The utilization of a general-purpose time domain simulator, otherwise applied to the study of network interactions and control systems, in the economic analysis of the wind energy conversion system is studied. The main benefits of the simulation-based method over traditional methods based on analytic calculation of losses include the ability to reuse and recombine existing models, the ability to analyze interactions between the components and subsystems in the electric drive train (something which is impossible when considering different subsystems as independent blocks, as is commonly done in theanalytical calculation of efficiencies), the ability to analyze in a rather straightforward manner the effect of selections other than physical components, for example control algorithms, and the ability to verify assumptions of the effects of a particular design change on the efficiency of the whole system. Based on the work, it can be concluded that differences between two configurations can be seen in the economic performance with only minor modifications to the simulation models used in the network interaction and control method study. This eliminates the need ofdeveloping analytic expressions for losses and enables the study of the system as a whole instead of modeling it as series connection of independent blocks with no lossinterdependencies. Three example cases (site matching, component selection, control principle selection) are provided to illustrate the usage of the approach and analyze its performance.

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.

Doubly fed wind turbine performance in variable grid conditions

Wind turbines based on doubly fed induction generators (DFIG) become the most popular solution in high power wind generation industry. While this topology provides great performance with the reduced power rating of power converter, it has more complicated structure in comparison with full-rated topologies, and therefore leads to complexity of control algorithms and electromechanical processes in the system. The purpose of presented study is to present a proper vector control scheme for the DFIG and overall control for the WT to investigate its behavior at different wind speeds and in different grid voltage conditions: voltage sags, magnitude and frequency variations. The key principles of variable-speed wind turbine were implemented in simulation model and demonstrated during the study. Then, based on developed control scheme and mathematical model, the set of simulation is made to analyze reactive power capabilities of the DFIG wind turbine. Further, the rating of rotor-side converter is modified to not only generate active rated active power, but also to fulfill Grid Codes. Results of modelling and analyzing of the DFIG WT behavior under different speeds and different voltage conditions are presented in the work.

Wind turbine indirect ice detection and operational analysis

Wind energy is one of the most promising and fast growing sector of energy production. Wind is ecologically friendly and relatively cheap energy resource available for development in practically all corners of the world (where only the wind blows). Today wind power gained broad development in the Scandinavian countries. Three important challenges concerning sustainable development, i.e. energy security, climate change and energy access make a compelling case for large-scale utilization of wind energy. In Finland, according to the climate and energy strategy, accepted in 2008, the total consumption of electricity generated by means of wind farms by 2020, should reach 6 - 7% of total consumption in the country [1]. The main challenges associated with wind energy production are harsh operational conditions that often accompany the turbine operation in the climatic conditions of the north and poor accessibility for maintenance and service. One of the major problems that require a solution is the icing of turbine structures. Icing reduces the performance of wind turbines, which in the conditions of a long cold period, can significantly affect the reliability of power supply. In order to predict and control power performance, the process of ice accretion has to be carefully tracked. There are two ways to detect icing – directly or indirectly. The first way applies to the special ice detection instruments. The second one is using indirect characteristics of turbine performance. One of such indirect methods for ice detection and power loss estimation has been proposed and used in this paper. The results were compared to the results directly gained from the ice sensors. The data used was measured in Muukko wind farm, southeast Finland during a project 'Wind power in cold climate and complex terrain'. The project was carried out in 9/2013 - 8/2015 with the partners Lappeenranta university of technology, Alstom renovables España S.L., TuuliMuukko, and TuuliSaimaa.

Merituulivoiman kannattavuus Kokkolan seudun rannikolla

Tässä diplomityössä selvitetään teollisen mittakaavan merituulipuistojen taloudellisia ja osin myös teknisiä rakentamisedellytyksiä Kokkolan seudun rannikolla. Lisäksi työssä tarkastellaan erilaisten tukitoimien vaikutusta tuulivoiman kannattavuuteen sekä selvitetään lyhyesti merituulivoiman hallinnollisia ja oikeudellisia edellytyksiä. Esimerkkikohteina tarkastellaan viittä Kokkolan edustalle suunniteltua merituulipuistoa, joiden tehot ovat 20 – 100 MW ja yksikkökoot 1,8 – 5 MW. Tuulipuistojen tuuliolot on arvioitu läheisten mittauspisteiden tietojen perusteella ja niiden pohjalta on laskettu puistojen energiantuotto. Tuulivoimaloiden huipunkäyttöajoiksi on saatu noin 2400 – 2500 h/a. Puistojen investointikustannukset ovat noin 6 500 –10 200 mk/kW: itse turbiinin lisäksi suurimpia kustannuseriä ovat perustukset ja sähköverkkoliitäntä. Vuosittaisten käyttö- ja kunnossapitokustannusten suuruudeksi on arvioitu noin 3 % investointikustannuksista. Kannattavuustarkastelut on suoritettu 5 % laskentakorolla ja 25 vuoden pitoajalle. Tuotantokustannukset ovat ilman tukia noin 27 – 38 p/kWh. Kun sähkön hintana on 150 mk/MWh, ei taloudellista kannattavuutta voida saavuttaa edes nykyisin käytössä olevan investointi- ja tuotantotuen avulla. Tuulisähköstä saatava mahdollinen ”vihreän sähkön lisä” tai päästökaupan aloittaminen voisivat mahdollistaa tuulivoiman taloudellisen kannattavuuden myös silloin, kun sähkön hintataso on matala. Kannattavuutta voitaisiin parantaa myös tukijärjestelmällä, joka painottaa nykyistä enemmän tuotantoa.

Literature review on permanent magnet generators design and dynamic behavior

This paper is a literature review which describes the construction of state of the art of permanent magnet generators and motors constructing and discusses the current and possible application of these machines in industry. Permanent magnet machines are a well-know class of rotating and linear electric machines used for many years in industrial applications. A particular interest for permanent magnet generators is connected with wind mills, which seem to be becoming increasingly popular nowadays. Geared and direct-driven permanent magnet generators are described. A classification of direct-driven permanent magnet generators is given. Design aspects of permanent magnet generators are presented. Permanent magnet generators for wind turbines designs are highlighted. Dynamics and vibration problems of permanent magnet generators covered in literature are presented. The application of the Finite Element Method for mechanical problems solution in the field of permanent magnet generators is discussed.

Tuulivoiman verkkomääräykset Euroopassa ja Yhdysvalloissa sekä niiden kehittyminen tulevaisuudessa älykkäiden sähköverkkojen kannalta

Tuulivoimatekniikan nopea kehitys on lisännyt tuulivoimakapasiteetin määrää sähköverkoissa. Eri maiden siirtoverkko-operaattorit ovatkin julkaisseet tuulivoimaloille omat verkkomääräyksensä. Työssä tutkitaan tuulivoimaloiden tekniikkaa, eri maiden verkko-operaattoreiden asettamia verkkomääräyksiä tuulivoimalle sekä arvioidaan näiden kehitystä tulevaisuudessa. Tutkittaviksi alueiksi on valittu maita, joiden siirtoverkot ovat rakenteeltaan erilaisia ja joissa tuulivoimaloille asetetut vaatimukset sekä asennetun tuulivoimakapasiteetin määrät vaihtelevat. Verkkomääräyksiä käsitellessä on keskitytty vain tärkeimpiin teknisiin vaatimuksiin. Eri verkkomääräykset eroavat toisistaan rakenteeltaan sekä vaatimuksiltaan ja ne ovat tiukentuneet tuulivoiman osuuden kasvaessa kokonaisenergiantuotannosta. Tämä on vaikeuttanut sähköverkoissa toimivien osapuolien operointia. Verkkomääräyksien harmonisoinnille ja kehittämiselle onkin tarvetta verkon kaikkien osapuolien toimintaedellytyksien parantamiseksi. Tuulivoimaloiden sisältämän tehoelektroniikan ja älykkäiden sähköverkkojen kehityksen myötä voidaan tuulivoimalla saavuttaa myös monia etuja esimerkiksi muihin tuotantotapoihin verrattuna.

Switching components for medium voltage drives

Nowadays power drives are the essential part almost of all technological processes. Improvement of efficiency and reduction of losses require development of semiconductor switches. It has a particular meaning for the constantly growing market of renewable sources, especially for wind turbines, which demand more powerful semiconductor devices for control with growth of power. Also at present semiconductor switches are the key component in energy transmission, optimization of generation and network connection. The aim of this thesis is to make a survey of contemporary semiconductor components, showing difference in structures, advantages, disadvantages and most suitable applications. There is topical information about voltage, frequency and current limits of different switches. Study tries to compare dimensions and price of different components. Main manufacturers of semiconductor components are presented with the review of devices produced by them, and a conclusion about their availability was made. IGBT is selected as a main component in this study, because nowadays it is the most attractive component for usage in power drives, especially at the low levels of medium voltage. History of development of IGBT structure, static and dynamic characteristics are considered. Thesis tells about assemblies and connection of components and problems which can appear. One of key questions about semiconductor materials and their future development was considered. For the purpose of comparison strong and weak sides of different switches, calculation of losses of IGBT and its basic competitor – IGCT is presented. This master’s thesis makes an effort to answer the question if there are at present possibilities of accurate selection of switches for electrical drives of different rates of power and looks at future possible ways of development of semiconductor market.

Tuulivoimageneraattorin konseptisuunnittelu

Tämä diplomityö käsittelee tuulivoimageneraattorin konseptisuunnittelua. Työssä käydään läpi tuulivoimateollisuuden, -markkinoiden ja -turbiinien historiaa, nykyhetkeä ja tulevaisuuden ennusteita. Tuulivoimaturbiineista esitellään yleisimmät tyypit ja teknologiat, joita vertaillaan keskenään. Lisäksi selvitetään tarkemmin suoravetoisten tuuliturbiinigeneraattoreiden teknologiaa ja teknisiä rakenteita joita myös vertaillaan keskenään. Työn pääasiallisena tarkoituksena on luoda selkeä konseptisuunnitteluprojektin toimintamalli, jota noudattamalla projekti voidaan hoitaa johdonmukaisesti läpi. Lopuksi työssä vielä käydään läpi suoravetoisen kestomagneettigeneraattorin todellinen konseptisuunnitteluprojekti, jossa ei ole ollut käytössä selkeää toimintamallia.

Hybridikomposiittien hyödyntäminen tuulivoimalan rakenteissa

Diplomityön tarkoituksena oli tutkia hybridikomposiittien soveltuvuutta tuulivoimalan osien tai osakokonaisuuksien rakennemateriaaliksi. Lähtökohtana oli selvittää erityisesti luonnonkuitukomposiitin materiaaliteknisten ominaisuuksien, etenkin lujuusominaisuuksi-en soveltuminen tuulivoiman rakenteisiin. Työn johdanto-osuudessa esitellään tuulivoiman rooli tämän päivän energiantuotannossa, yksittäisen tuulivoimalalaitoksen rakenne, rakenteiden suunnittelussa huomioitavat seikat, voimalan eri osien kuten tornin, lapojen ja nasellin yleisimmät valmistusmenetelmät, sekä muovien ja eri lujitteiden ohella puumuovikomposiitin materiaaliominaisuudet, valmistus-menetelmät ja yleisimmät käyttökohteet. Hybridikomposiittien lujuusominaisuuksia tutkittiin Lappeenrannan teknillisen yliopiston puutekniikan laboratoriossa suoritetuissa mittauksissa. Saatuja tuloksia verrattiin referens-situlosten ohella myös tällä hetkellä tuulivoimalan rakenteissa yleisesti käytettävien lasi- ja hiilikuidun, sekä teräksen ominaisuuksiin. Mittaustulosten perusteella bambu- ja lasikuitu-lujitteiset puumuovikomposiitit soveltuvat parhaiten tuulivoimalarakenteisiin, mutta niiden valmistaminen ekstruusiomenetelmällä on melko haasteellista.