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.

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.

Vibrations in Rotating Machinery Arising from Minor Imperfections in Component Geometries

Vibrations in machines can cause noise, decrease the performance, or even damage the machine. Vibrations appear if there is a source of vibration that excites the system. In the worst case scenario, the excitation frequency coincides with the natural frequency of the machine causing resonance. Rotating machines are a machine type, where the excitation arises from the machine itself. The excitation originates from the mass imbalance in the rotating shaft, which always exists in machines that are manufactured using conventional methods. The excitation has a frequency that is dependent on the rotational speed of the machine. The rotating machines in industrial use are usually designed to rotate at a constant rotational speed, the case where the resonances can be easily avoided. However, the machines that have a varying operational speed are more problematic due to a wider range of frequencies that have to be avoided. Vibrations, which frequencies equal to rotational speed frequency of the machine are widely studied and considered in the typical machine design process. This study concentrates on vibrations, which arise from the excitations having frequencies that are multiples of the rotational speed frequency. These vibrations take place when there are two or more excitation components in a revolution of a rotating shaft. The dissertation introduces four studies where three kinds of machines are experiencing vibrations caused by different excitations. The first studied case is a directly driven permanent magnet generator used in a wind power plant. The electromagnetic properties of the generator cause harmonic excitations in the system. The dynamic responses of the generator are studied using the multibody dynamics formulation. In another study, the finite element method is used to study the vibrations of a magnetic gear due to excitations, which frequencies equal to the rotational speed frequency. The objective is to study the effects of manufacturing and assembling inaccuracies. Particularly, the eccentricity of the rotating part with respect to non-rotating part is studied since the eccentric operation causes a force component in the direction of the shortest air gap. The third machine type is a tube roll of a paper machine, which is studied while the tube roll is supported using two different structures. These cases are studied using different formulations. In the first case, the tube roll is supported by spherical roller bearings, which have some wavinesses on the rolling surfaces. Wavinesses cause excitations to the tube roll, which starts to resonate at the frequency that is a half of the first natural frequency. The frequency is in the range where the machine normally operates. The tube roll is modeled using the finite element method and the bearings are modeled as nonlinear forces between the tube roll and the pedestals. In the second case studied, the tube roll is supported by freely rotating discs, which wavinesses are also measured. The above described phenomenon is captured as well in this case, but the simulation methodology is based on the flexible multibody dynamics formulation. The simulation models that are used in both of the last two cases studied are verified by measuring the actual devices and comparing the simulated and measured results. The results show good agreement.

Kestomagneettiavusteisen synkronireluktanssikoneen soveltuvuus autokäyttöihin

Työn tavoitteena on tehdä kirjallisuuskatsaus kestomagneettiavusteisesta synkronireluktanssikoneesta ja tarkastella sen soveltuvuutta sähköauton voimantuottoon. Lisäksi työssä tehdään katsaus tämänhetkisiin sähköautoihin ja niissä esiintyviin koneratkaisuihin ja esitetään esimerkkilaskelma moottorin voimantarpeesta auton eri toiminta-alueilla. Tarkasteluissa selvisi, että kestomagneettiavusteinen synkronireluktanssikone on varteenotettava moottoriratkaisu sähköautoissa. Tämänhetkisissä sähköautoissa pääosin esiintyviin epätahtikoneeseen ja kestomagneettitahtikoneeseen verrattuna kestomagneettiavusteisella synkronireluktanssikoneella on muutamia ominaisuuksia, jotka autokäytössä ovat erityisesti sen vahvuuksia. Epätahtikoneeseen verrattuna kestomagneettiavusteisella synkronireluktanssikoneella on etuina huomattavasti pienempi paino ja synkronisuus ja kestomagneettitahtikoneeseen verrattuna sillä on paremmat kentänheikennysominaisuudet ja näin laajempi nopeusalue käytettävissä.

Hysteresis Losses in Sintered NdFeB Permanent Magnets in Rotating Electrical Machines

Permanent magnet materials are nowadays widely used in the electrical machine manufacturing industry. Eddy current loss models of permanent magnets used in electrical machines are frequently discussed in research papers. In magnetic steel materials we have, in addition to eddy current losses, hysteresis losses when AC or a rotating flux travels through the material. Should a similar phenomenon also be taken into account in calculating the losses of permanent magnets? Actually, every now and then authors seem to assume that some significant hysteresis losses are present in rotating machine PMs. This paper studies the mechanisms of possible hysteresis losses in PMs and their role in PMs when used in rotating electrical machines.

Conversor CA-CA de elevado fator de potência para aplicações com geradores de Ímã permanente

This paper proposes and describes a high power factor AC-AC converter for naval applications using Permanent Magnet Generator (PMG). The three-phase output voltages of the PMG vary from 260 Vrms (220 Hz) to 380 Vrms (360 Hz), depending on load conditions. The proposed converter consists of a Y-/ΔY power transformer, which provides electrical isolation between the PMG and remaining stages, and a twelve-pulse uncontrolled rectifier stage directly connected to a single-phase inverter stage, without the use of an intermediary DC-DC topology. This proposal results in more simplicity for the overall circuitry, assuring robustness, reliability and reduced costs. Furthermore, the multipulse rectifier stage is capable to provide high power factor and low total harmonic distortion for the input currents of the converter. The single-phase inverter stage was designed to operate with wide range of DC bus voltage, maintaining 120 Vrms, 60 Hz output. The control philosophy, implemented in a digital signal processor (DSP) which also contains protection routines, alows series connections between two identical converters, achieving 240 Vrms, 60 Hz total output voltage. Measured total harmonic distortion for the AC output voltage is lower than 2% and the input power factor is 0.93 at 3.6kW nominal load. © 2010 IEEE.

Bancada experimental para ensaios em geradores elétricos utilizados em aerogeradores de pequeno porte

Este trabalho apresenta uma bancada para testes em geradores elétricos, utilizados em aerogeradores de pequeno porte. O sistema é composto basicamente por um motor de indução trifásico, que simula um rotor eólico, acoplado mecanicamente ao gerador elétrico submetido ao ensaio; um inversor de frequência, usado para variação da velocidade do motor; transdutores de grandezas elétricas, que efetuam a medição dos parâmetros de interesse (tensões e correntes instantâneas) na saída do gerador; um sensor de velocidade angular, para medição da rotação que é fornecida ao eixo do motor; um microcomputador, para monitoração e armazenamento dos parâmetros medidos, e controle do inversor de frequência, por meio de um programa computacional desenvolvido; e uma placa de aquisição de dados, que serve como interface entre os transdutores/sensores e o microcomputador. A velocidade angular fornecida ao gerador em ensaio pode ser variada conforme valores fornecidos de velocidades de vento, as quais são associadas a valores correspondentes de rotação, a fim de simular o comportamento de um rotor eólico. Dessa forma, é possível traçar a curva de potência (potência versus velocidade de vento) do gerador ensaiado e analisar seu desempenho. Apresenta-se também neste trabalho os resultados de medições realizadas na bancada, referentes aos ensaios de um gerador comercial de pequena potência (1 kW) e de outro desenvolvido em projeto de pesquisa, ambos do tipo de imã permanente com fluxo axial.

A Comparison of Induction Motor Starting Methods Being Powered by a Diesel-Generator Set

Starting induction motors on isolated or weak systems is a highly dynamic process that can cause motor and load damage as well as electrical network fluctuations. Mechanical damage is associated with the high starting current drawn by a ramping induction motor. In order to compensate the load increase, the voltage of the electrical system decreases. Different starting methods can be applied to the electrical system to reduce these and other starting method issues. The purpose of this thesis is to build accurate and usable simulation models that can aid the designer in making the choice of an appropriate motor starting method. The specific case addressed is the situation where a diesel-generator set is used as the electrical supplied source to the induction motor. The most commonly used starting methods equivalent models are simulated and compared to each other. The main contributions of this thesis is that motor dynamic impedance is continuously calculated and fed back to the generator model to simulate the coupling of the electrical system. The comparative analysis given by the simulations has shown reasonably similar characteristics to other comparative studies. The diesel-generator and induction motor simulations have shown good results, and can adequately demonstrate the dynamics for testing and comparing the starting methods. Further work is suggested to refine the equivalent impedance presented in this thesis.

Nondetection Index of Anti-Islanding Passive Protection of Synchronous Distributed Generators

Synchronous distributed generators are prone to operate islanded after contingencies, which is usually not allowed due to safety and power-quality issues. Thus, there are several anti-islanding techniques; however, most of them present technical limitations so that they are likely to fail in certain situations. Therefore, it is important to quantify and determine whether the scheme under study is adequate or not. In this context, this paper proposes an index to evaluate the effectiveness of anti-islanding frequency-based relays commonly used to protect synchronous distributed generators. The method is based on the calculation of a numerical index that indicates the time period that the system is unprotected against islanding considering the global period of analysis. Although this index can precisely be calculated based on several electromagnetic transient simulations, a practical method is also proposed to calculate it directly from simple analytical formulas or lookup tables. The results have shown that the proposed approach can assist distribution engineers to assess and set anti-islanding protection schemes.

Consideration of Multi-Phase Criterion in the Differential Protection Algorithm for High-Impedance Grounded Synchronous Generators

The generator differential protection is one of the most important electrical protections of synchronous generator stator windings. Its operation principle is based on the comparison of the input current and output current at each phase winding. Unwanted trip commands are usually caused by CT saturation, wrong CT selection, or the fact that they may come from different manufacturers. In generators grounded through high impedance, only phase-to-phase or three-phase faults can be detected by the differential protection. This kind of fault causes differential current to flow in, at least, two phases of the winding. Several cases of unwanted trip commands caused by the appearance of differential current in only one phase of the generator have been reported. In this paper multi-phase criterion is proposed for generator differential protection algorithm when applied to high impedance grounded generators.

Validation Study of the Use of Matlab/Simulink Synchronous-Machine Block for Accurate Power-Plant Stability Studies

This paper presents results of the validity study of the use of MATLAB/Simulink synchronous-machine block for power-system stability studies. Firstly, the waveforms of the theoretical synchronous-generator short-circuit currents are described. Thereafter, the comparison between the currents obtained through the simulation model in the sudden short-circuit test, are compared to the theoretical ones. Finally, the factory tests of two commercial generating units are compared to the response of the synchronous generator simulation block during sudden short-circuit, set with the same real data, with satisfactory results. This results show the validity of the use of this generator block for power plant simulation.

Development and improvement of protection-system algorithms for ground-fault detection and location in synchronous machines

Uno de los defectos más frecuentes en los generadores síncronos son los defectos a tierra tanto en el devanado estatórico, como de excitación. Se produce un defecto cuando el aislamiento eléctrico entre las partes activas de cualquiera de estos devanados y tierra se reduce considerablemente o desaparece. La detección de los defectos a tierra en ambos devanados es un tema ampliamente estudiado a nivel industrial. Tras la detección y confirmación de la existencia del defecto, dicha falta debe ser localizada a lo largo del devanado para su reparación, para lo que habitualmente el rotor debe ser extraído del estator. Esta operación resulta especialmente compleja y cara. Además, el hecho de limitar la corriente de defecto en ambos devanados provoca que el defecto no sea localizable visualmente, pues apenas existe daño en el generador. Por ello, se deben aplicar técnicas muy laboriosas para localizar exactamente el defecto y poder así reparar el devanado. De cara a reducir el tiempo de reparación, y con ello el tiempo en que el generador esta fuera de servicio, cualquier información por parte del relé de protección acerca de la localización del defecto resultaría de gran utilidad. El principal objetivo de esta tesis doctoral ha sido el desarrollo de nuevos algoritmos que permitan la estimación de la localización de los defectos a tierra tanto en el devanado rotórico como estatórico de máquinas síncronas. Respecto al devanado de excitación, se ha presentado un nuevo método de localización de defectos a tierra para generadores con excitación estática. Este método permite incluso distinguir si el defecto se ha producido en el devanado de excitación, o en cualquiera de los componentes del sistema de excitación, esto es, transformador de excitación, conductores de alimentación del rectificador controlado, etc. En caso de defecto a tierra en del devanado rotórico, este método proporciona una estimación de su localización. Sin embargo, para poder obtener la localización del defecto, se precisa conocer el valor de resistencia de defecto. Por ello, en este trabajo se presenta además un nuevo método para la estimación de este parámetro de forma precisa. Finalmente, se presenta un nuevo método de detección de defectos a tierra, basado en el criterio direccional, que complementa el método de localización, permitiendo tener en cuenta la influencia de las capacidades a tierra del sistema. Estas capacidades resultan determinantes a la hora de localizar el defecto de forma adecuada. En relación con el devanado estatórico, en esta tesis doctoral se presenta un nuevo algoritmo de localización de defectos a tierra para generadores que dispongan de la protección de faltas a tierra basada en la inyección de baja frecuencia. Se ha propuesto un método general, que tiene en cuenta todos los parámetros del sistema, así como una versión simplificada del método para generadores con capacidades a tierra muy reducida, que podría resultar de fácil implementación en relés de protección comercial. Los algoritmos y métodos presentados se han validado mediante ensayos experimentales en un generador de laboratorio de 5 kVA, así como en un generador comercial de 106 MVA con resultados satisfactorios y prometedores. ABSTRACT One of the most common faults in synchronous generators is the ground fault in both the stator winding and the excitation winding. In case of fault, the insulation level between the active part of any of these windings and ground lowers considerably, or even disappears. The detection of ground faults in both windings is a very researched topic. The fault current is typically limited intentionally to a reduced level. This allows to detect easily the ground faults, and therefore to avoid damage in the generator. After the detection and confirmation of the existence of a ground fault, it should be located along the winding in order to repair of the machine. Then, the rotor has to be extracted, which is a very complex and expensive operation. Moreover, the fact of limiting the fault current makes that the insulation failure is not visually detectable, because there is no visible damage in the generator. Therefore, some laborious techniques have to apply to locate accurately the fault. In order to reduce the repair time, and therefore the time that the generator is out of service, any information about the approximate location of the fault would be very useful. The main objective of this doctoral thesis has been the development of new algorithms and methods to estimate the location of ground faults in the stator and in the rotor winding of synchronous generators. Regarding the excitation winding, a new location method of ground faults in excitation winding of synchronous machines with static excitation has been presented. This method allows even to detect if the fault is at the excitation winding, or in any other component of the excitation system: controlled rectifier, excitation transformer, etc. In case of ground fault in the rotor winding, this method provides an estimation of the fault location. However, in order to calculate the location, the value of fault resistance is necessary. Therefore, a new fault-resistance estimation algorithm is presented in this text. Finally, a new fault detection algorithm based on directional criterion is described to complement the fault location method. This algorithm takes into account the influence of the capacitance-to-ground of the system, which has a remarkable impact in the accuracy of the fault location. Regarding the stator winding, a new fault-location algorithm has been presented for stator winding of synchronous generators. This algorithm is applicable to generators with ground-fault protection based in low-frequency injection. A general algorithm, which takes every parameter of the system into account, has been presented. Moreover, a simplified version of the algorithm has been proposed for generators with especially low value of capacitance to ground. This simplified algorithm might be easily implementable in protective relays. The proposed methods and algorithms have been tested in a 5 kVA laboratory generator, as well as in a 106 MVA synchronous generator with satisfactory and promising results.

Direct current ripple compensation for multi-phase fault-tolerant machines

A second-harmonic direct current (DC) ripple compensation technique is presented for a multi-phase, fault-tolerant, permanent magnet machine. The analysis has been undertaken in a general manner for any pair of phases in operation with the remaining phases inactive. The compensation technique determines the required alternating currents in the machine to eliminate the second-harmonic DC-link current, while at the same time minimising the total rms current in the windings. An additional benefit of the compensation technique is a reduction in the magnitude of the electromagnetic torque ripple. Practical results are included from a 70 kW, five-phase generator system to validate the analysis and illustrate the performance of the compensation technique.

Application of calorimetric method for loss measurement of a SynRM drive system

Synchronous reluctance motors (SynRMs) are gaining in popularity in industrial drives due to their permanent magnet-free, competitive performance, and robust features. This paper studies the power losses in a 90-kW converter-fed SynRM drive by a calorimetric method in comparison of the traditional input-output method. After the converter and the motor were measured simultaneously in separate chambers, the converter was installed inside the large-size chamber next to the motor and the total drive system losses were obtained using one chamber. The uncertainty of both measurement methods is analyzed and discussed.

ADDITIVE MANUFACTURING: tecnologia innovativa per l'ottimizzazione di macchine elettriche

Lo scopo di questa tesi è quello di mostrare le potenzialità e le possibili soluzioni dell’Additive Manufacturing per l’ottimizzazione di macchine elettriche in risposta al problema delle terre rare. Nel primo capitolo viene presentato lo stato dell’arte dell’Additive Manufacturing mostrando una rapida panoramica delle sue caratteristiche principali, le potenzialità future e i settori di utilizzo. Il secondo capitolo propone le principali tecniche di Stampa 3D per la realizzazione di oggetti evidenziando di ognuna i pregi e i difetti. All’interno del terzo capitolo, viene illustrata la struttura di una macchina elettrica mostrando le varie componenti e presentando delle possibili ottimizzazioni realizzate tramite Additive Manufacturing. Nel quarto capitolo vengono presentati esempi di macchine elettriche complete realizzate attraverso le tecniche dell’Additive Manufacturing. Nel quinto capitolo vengono confrontati un Interior Permanent Magnets motor e un Synchronous Relectance Machine.