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.

Konedirektiivin 2006/42/EY ja SFS-EN 1090- standardin vaatimukset ja soveltaminen teollisuuden kunnossapitotoiminnassa

Tässä diplomityössä tarkastellaan konedirektiivin 2006/42/EY ja SFS-EN 1090- teräsrakennestandardin vaatimuksia teollisuuden kunnossapitotoiminnalle, ja kuinka niitä täytyy soveltaa. Työssä käsitellään koneturvallisuuden perusasioita ja CE-merkintää niin koneissa kuin 1.7.2014 voimaantulleissa SFS-EN 1090 mukaisissa teräsrakenteissa ja rakennustuotteissa. Teoriaosuudessa selvitettiin ja koottiin yhteen muun muassa SFS-EN 1090 standardiin liittyviä vaatimuksia tilaajille, toimittajille ja niihin liittyviä vastuukysymyksiä. Samoin koneturvallisuuden kannalta selvitettiin muun muassa koneiden muuttamista ja valmistamista määrittäviä standardeja ja asetuksia. Työ sisälsi teräsrakenteita valmistaville toimijoille suunnatun haastattelun, jossa kysyttiin SFS-EN 1090 standardin tuomia vaatimuksia, standardin voimaan tuloon valmistautumista, standardin aiheuttamia kustannuksia tuotteiden hintoihin sekä yleisesti standardiin liittyvää tiedotuksen tasoa ja tietolähteitä. Haastattelut toteutettiin Kaakkois-Suomen alueella toimiville yhdeksälle yritykselle, jotka valittiin niiden toimimisestaan erään tilaajaorganisaation toimittajina. Saaduista vastauksista tutkittiin muun muassa yritysten valmistautumista SFS-EN 1090 standardin käyttöönottoon ja sertifiointiin. Valmistautuminen onnistui useiden yritysten kohdalta hyvin, vaikka se jäi monien osalta viimeisiin kuukausiin.

Eucalyptol, an essential oil, reduces contractile activity in rat cardiac muscle

Eucalyptol is an essential oil that relaxes bronchial and vascular smooth muscle although its direct actions on isolated myocardium have not been reported. We investigated a putative negative inotropic effect of the oil on left ventricular papillary muscles from male Wistar rats weighing 250 to 300 g, as well as its effects on isometric force, rate of force development, time parameters, post-rest potentiation, positive inotropic interventions produced by Ca2+ and isoproterenol, and on tetanic tension. The effects of 0.3 mM eucalyptol on myosin ATPase activity were also investigated. Eucalyptol (0.003 to 0.3 mM) reduced isometric tension, the rate of force development and time parameters. The oil reduced the force developed by steady-state contractions (50% at 0.3 mM) but did not alter sarcoplasmic reticulum function or post-rest contractions and produced a progressive increase in relative potentiation. Increased extracellular Ca2+ concentration (0.62 to 5 mM) and isoproterenol (20 nM) administration counteracted the negative inotropic effects of the oil. The activity of the contractile machinery evaluated by tetanic force development was reduced by 30 to 50% but myosin ATPase activity was not affected by eucalyptol (0.3 mM), supporting the idea of a reduction of sarcolemmal Ca2+ influx. The present results suggest that eucalyptol depresses force development, probably acting as a calcium channel blocker.

Apoptotic mimicry: an altruistic behavior in host/Leishmania interplay

Apoptosis is the most common phenotype observed when cells die through programmed cell death. The morphologic and biochemical changes that characterize apoptotic cells depend on the activation of a diverse set of genes. Apoptosis is essential for multicellular organisms since their development and homeostasis are dependent on extensive cell renewal. In fact, there is strong evidence for the correlation between the emergence of multicellular organisms and apoptosis during evolution. On the other hand, no obvious advantages can be envisaged for unicellular organisms to carry the complex machinery required for programmed cell death. However, accumulating evidence shows that free-living and parasitic protozoa as well as yeasts display apoptotic markers. This phenomenon has been related to altruistic behavior, when a subpopulation of protozoa or yeasts dies by apoptosis, with clear benefits for the entire population. Recently, phosphatidylserine (PS) exposure and its recognition by a specific receptor (PSR) were implicated in the infectivity of amastigote forms of Leishmania, an obligatory vertebrate intramacrophagic parasite, showing for the first time that unicellular organisms use apoptotic features for the establishment and/or maintenance of infection. Here we focus on PS exposure in the outer leaflet of the plasma membrane - an early hallmark of apoptosis - and how it modulates the inflammatory activity of phagocytic cells. We also discuss the possible mechanisms by which PS exposure can define Leishmania survival inside host cells and the evolutionary implications of apoptosis at the unicellular level.

Naudanlanta biokaasulaitosraaka-aineena, käsittely ja logistiikka

Maatalouden lietelannasta saatavien ravinteiden talteenotto ja kierrätys ovat viime aikoina nousseet yhä tärkeämmäksi tavoitteeksi. Ravinteiden tehokas kierrätystapa saadaan ai-kaiseksi käsittelemällä lietelantaa. Lannan käsittelyketjuja on monenlaisia; tässä työssä naudan lannan käsittelyketju muodostuu separoinnista ja mädätyksestä. Tämän diplomityön tarkoituksena oli selvittää naudan lannan mekaanisen separoinnin ja logistiikan kannattavuus märkämädätys- ja kuivamädätyskäsittelyketjussa. Käsittelyketju-jen kannattavuus tai kannattamattomuus on esitetty eri skenaarioissa muodostettujen kus-tannuslaskentojen perusteella. Skenaarioiden kustannuslaskelmat ovat toisiinsa verratta-vissa, jolloin ne voidaan asettaa niin ikään paremmuusjärjestykseen. Viides skenaario ei ole suoraan verrattavissa muihin skenaarioihin, koska siinä lannankäsittelyketjua on tar-kasteltu eri näkökulmasta, keskittämällä suurimmalle maatilalle. Mekaanisista separaattoreista tarkasteltiin työssä ruuvipuristinta, dekantterilinkoa ja ul-koistettua separointipalvelua. Lannan logistiikkakustannuksissa huomioitiin lannan kulje-tusta traktori- ja säiliöautolla tai traktorilla. Separoinnin kustannus liitettiin osaksi logis-tiikkakustannusta. Työn tuloksien perusteella voidaan todeta dekantterilingon separointi-kustannuksen olevan taloudellisesti kannattamattomin johtuen pienestä lantakapasiteetista ja separaattorin korkeasta investointihinnasta. Ravinteiden osalta linko osoittautui tehok-kaimmaksi menetelmäksi erottamaan ravinteet eri jakeisiin. Lannan käsittely separointipalvelulla oli edullisin skenaario, jonka vuosittaiseksi kustan-nukseksi saatiin säiliö- ja kuorma-autolla lantaa kuljetettaessa 58 700 € ja traktorilla kul-jetettaessa 60 400 €. Kallein lannan käsittely oli dekantterilingolla, jonka vuosittaiseksi kustannukseksi saatiin lantaa säiliö- ja kuorma-autolla kuljetettaessa 121 000 € ja trakto-rilla kuljetettaessa 123 300 €. Lannan separointi maatilalla osoittautui kannattavammaksi kuin käsittelemättömän lietteen kuljetus biokaasulaitokselle.

Advanced biofuel production: Engineering metabolic pathways for butanol and propane biosynthesis.

Greenhouse gases emitted from energy production and transportation are dramatically changing the climate of Planet Earth. As a consequence, global warming is affecting the living conditions of numerous plant and animal species, including ours. Thus the development of sustainable and renewable liquid fuels is an essential global challenge in order to combat the climate change. In the past decades many technologies have been developed as alternatives to currently used petroleum fuels, such as bioethanol and biodiesel. However, even with gradually increasing production, the market penetration of these first generation biofuels is still relatively small compared to fossil fuels. Researchers have long ago realized that there is a need for advanced biofuels with improved physical and chemical properties compared to bioethanol and with biomass raw materials not competing with food production. Several target molecules have been identified as potential fuel candidates, such as alkanes, fatty acids, long carbon‐chain alcohols and isoprenoids. The current study focuses on the biosynthesis of butanol and propane as possible biofuels. The scope of this research was to investigate novel heterologous metabolic pathways and to identify bottlenecks for alcohol and alkane generation using Escherichia coli as a model host microorganism. The first theme of the work studied the pathways generating butyraldehyde, the common denominator for butanol and propane biosynthesis. Two ways of generating butyraldehyde were described, one via the bacterial fatty acid elongation machinery and the other via partial overexpression of the acetone‐butanol‐ethanol fermentation pathway found in Clostridium acetobutylicum. The second theme of the experimental work studied the reduction of butyraldehyde to butanol catalysed by various bacterial aldehyde‐reductase enzymes, whereas the final part of the work investigated the in vivo kinetics of the cyanobacterial aldehyde deformylating oxygenase (ADO) for the generation of hydrocarbons. The results showed that the novel butanol pathway, based on fatty acid biosynthesis consisting of an acyl‐ACP thioesterase and a carboxylic acid reductase, is tolerant to oxygen, thus being an efficient alternative to the previous Clostridial pathways. It was also shown that butanol can be produced from acetyl‐CoA using acetoacetyl CoA synthase (NphT7) or acetyl‐CoA acetyltransferase (AtoB) enzymes. The study also demonstrated, for the first time, that bacterial biosynthesis of propane is possible. The efficiency of the system is clearly limited by the poor kinetic properties of the ADO enzyme, and for proper function in vivo, the catalytic machinery requires a coupled electron relay system.

Ohuiden päällystyskerrosten applikointi puukuitupohjaisille materiaaleille

Työn aiheena oli tutkia vaahdon soveltuvuutta ohuiden päällystyskerrosten applikointiin paperin tai kartongin pinnalle. Paperia ja kartonkia päällystetään teollisessa mittakaavassa eri menetelmillä, mutta niille kaikille yhteistä on päällystyspastan laimentaminen vedellä ennen applikointia ja laimennusveden haihduttaminen applikoinnin jälkeen päällysteen asettamiseksi. Laimennus on tärkeää pastan komponenttien tasaisen levittämisen vuoksi, mutta veden haihduttaminen kuluttaa valtavasti energiaa. Tekstiiliteollisuudessa on saavutettu merkittäviä säästöjä kuivausenergiassa korvaamalla laajalti vedellä laimentaminen vaahdottamisella. Diplomityön kirjallisessa osassa käytiin läpi vaahdon kemiallisia ja fysikaalisia ominaisuuksia sekä selvitettiin mitä kemikaaleja ja laitteita vaahdotukseen käytetään. Lisäksi luotiin katsaus vaahtoprosessien käyttöön tekstiiliteollisuudessa ja muilla aloilla. Kokeellinen osa koostui esikokeista, joissa selvitettiin pastan koostumuksen vaikutuksia vaahtoamiseen, ja pilot-mittakaavan koeajoista, joissa esikokeiden tuloksia hyödynnettiin. Esikokeissa huomiota kiinnitettiin varsinkin eri polyvinyylialkoholien (PVA) seosten erinomaiseen vaahtoavuuteen. Pilot-koeajoissa vaahtopäällystys vaikutti lupaavalta menetelmältä, joskaan täysin tyydyttävää päällystystulosta ei saavutettu. Suurimpana ongelmana esiintyi ilman pääseminen pohjapaperin ja päällysteen väliin ja siitä seuraava huono päällystejälki. Toisen ongelmakokonaisuuden muodostivat päällysteeseen jäävät reiät. Vaahtopäällystys vaikuttaa lupaavalta tekniikalta ohuiden päällystekerrosten applikointiin, mutta pastareseptejä tulee optimoida ja ratkaista päällysteen alle pääsevän ilman ongelma.

Myosin Va is developmentally regulated and expressed in the human cerebellum from birth to old age

Myosin Va functions as a processive, actin-based motor molecule highly enriched in the nervous system, which transports and/or tethers organelles, vesicles, and mRNA and protein translation machinery. Mutation of myosin Va leads to Griscelli disease that is associated with severe neurological deficits and a short life span. Despite playing a critical role in development, the expression of myosin Va in the central nervous system throughout the human life span has not been reported. To address this issue, the cerebellar expression of myosin Va from newborns to elderly humans was studied by immunohistochemistry using an affinity-purified anti-myosin Va antibody. Myosin Va was expressed at all ages from the 10th postnatal day to the 98th year of life, in molecular, Purkinje and granular cerebellar layers. Cerebellar myosin Va expression did not differ essentially in localization or intensity from childhood to old age, except during the postnatal developmental period. Structures resembling granules and climbing fibers in Purkinje cells were deeply stained. In dentate neurons, long processes were deeply stained by anti-myosin Va, as were punctate nuclear structures. During the first postnatal year, myosin Va was differentially expressed in the external granular layer (EGL). In the EGL, proliferating prospective granule cells were not stained by anti-myosin Va antibody. In contrast, premigratory granule cells in the EGL stained moderately. Granule cells exhibiting a migratory profile in the molecular layer were also moderately stained. In conclusion, neuronal myosin Va is developmentally regulated, and appears to be required for cerebellar function from early postnatal life to senescence.

Effects of melatonin on DNA damage induced by cyclophosphamide in rats

The antioxidant and free radical scavenger properties of melatonin have been well described in the literature. In this study, our objective was to determine the protective effect of the pineal gland hormone against the DNA damage induced by cyclophosphamide (CP), an anti-tumor agent that is widely applied in clinical practice. DNA damage was induced in rats by a single intraperitoneal injection of CP (20 or 50 mg/kg). Animals received melatonin during the dark period for 15 days (1 mg/kg in the drinking water). Rat bone marrow cells were used for the determination of chromosomal aberrations and of formamidopyrimidine DNA glycosylase enzyme (Fpg)-sensitive sites by the comet technique and ofXpf mRNA expression by qRT-PCR. The number (mean ± SE) of chromosomal aberrations in pinealectomized (PINX) animals treated with melatonin and CP (2.50 ± 0.50/100 cells) was lower than that obtained for PINX animals injected with CP (12 ± 1.8/100 cells), thus showing a reduction of 85.8% in the number of chromosomal aberrations. This melatonin-mediated protection was also observed when oxidative lesions were analyzed by the Fpg-sensitive assay, both 24 and 48 h after CP administration. The expression of Xpf mRNA, which is involved in the DNA nucleotide excision repair machinery, was up-regulated by melatonin. The results indicate that melatonin is able to protect bone marrow cells by completely blocking CP-induced chromosome aberrations. Therefore, melatonin administration could be an alternative and effective treatment during chemotherapy.

Vibration analysis of a power take-off line

Gear rattle is a phenomenon that occurs when idling or lightly loaded gears collide due to engine’s torque fluctuations. This behaviour is related to vibration behaviour of the transmission system. Aim of this master’s thesis is to evaluate Adams and Adams/Machinery as a simulation tools for modelling the rattle e ect in a transmission system. A case study of tractor’s power take-o driveline, suspected to be prone to rattle, is performed in this work. Modelling methods used by Adams in this type of study are presented in the theory section while simulation model build with the software during this work is presented in the results. The Machinery toolbox is used to create gears and bearings while other model components are created with standard Adams tool set. Geometries and excitations are exported from other softwares. Results were obtained from multiple variations of a base model. These result sets and literature review suggest that Adams/Machinery may not be the most suitable tool for rattle analysis. While the system behaviour was partially captured, for accurate modelling user-written routines must be used which may be more easily performed with other tools. Further research about this topic is required.

Tuottavuuden ja investointitehokkuuden parantaminen kunnallisteknisissä töissä

Tutkimuksen tavoitteena oli selvittää keinoja parantaa tuottavuutta ja investointitehokkuutta kunnallisteknisissä töissä. Tutkimusmenetelmäksi valittiin konstruktiivinen tutkimusmenetelmä, jossa käytännölliseen ongelmaan luodaan teoriapohjan kautta ratkaisuehdotus. Työn teoriaosuus käsittelee palveluiden tuottavuutta ja sen mittaamista. Työn tuloksena syntyi excel-työkalu, jonka avulla on mahdollista tarkastella palveluntuottajan konekannan aiheuttamia kustannuksia ja tuottoja. Työkalu laskee konekohtaiset kustannukset ja tuotot, joiden avulla palveluntuottajalle on mahdollista osoittaa aiempien investointien kannattavuus. Työkalu laskee kustannus- ja tuottoarvion myös vaihtoehtoiselle konekannalle, jossa alhaisen käyttöasteen koneita korvataan monipuolisemmalla kalustolla. Palveluntuottajan konekannan hallinta ja kustannusrakenteen tarkka määrittely ovat tärkeässä roolissa tuottavuuden ja kannattavuuden kehittämisessä. Työkalu mahdollistaa myös eri kustannuserissä tapahtuvien muutosten vaikutusten arvioinnin, mikä auttaa palveluntuottajia toiminnan pitkäjänteisessä kehittämisessä.

Yrityskohtainen ilmansuojelulaitteiden vaatimustenmukaisuuden arviointi SFS-EN 1090-1 periaatteiden mukaisesti

Rakennustuotteena käytettävien teräskokoonpanojen lisääntyneet CE- merkintävaatimukset ovat aiheuttaneet runsaasti hämmennystä alan toimijoiden keskuudessa. Tämän tutkimuksen tavoitteena oli selvittää teräskokoonpanojen SFS-EN 1090-1 standardin soveltamisala suhteessa konedirektiiviin sekä kartoittaa mahdollisen muutoksen aiheuttamat toimenpiteet ilmansuojelulaitetoimituksissa. Työssä tutustuttiin asetusten teoreettiseen viitekehykseen, standardeihin sekä alan kirjallisuuteen. Teoriaa sovellettiin tulevaisuudentutkimuksen Delfoi- menetelmään, jossa asiantuntijahaastatteluiden perusteella arvioitiin asetuksen soveltamisalaa ja vaatimuksia. Tutkimuksen avaintuloksia ovat standardin SFS-EN 1090-1 vaatimuksenmukaisuuteen vaikuttavien tekijöiden tunnistaminen ja niiden perusteella laaditut ehdotukset yritystoiminnan kehittämiseksi.

Press forming of paperboard – advancement of converting tools and process control

Press forming is nowadays one of the most common industrial methods in use for producing deeper trays from paperboard. Demands for material properties like recyclability and sustainability have increased also in the packaging industry, but there are still limitations related to the formability of paperboard. A majority of recent studies have focused on material development, but the potential of the package manufacturing process can also be improved by the development of tooling and process control. In this study, advanced converting tools (die cutting tools and the press forming mould) are created for production scale paperboard tray manufacturing. Also monitoring methods that enable the production of paperboard trays with enhanced quality, and can be utilized in process control are developed. The principles for tray blank preparation, including creasing pattern and die cutting tool design are introduced. The mould heating arrangement and determination of mould clearance are investigated to improve the quality of the press formed trays. The effect of the spring back of the tray walls on the tray dimensions can be managed by adjusting the heat-related process parameters and estimating it at the mould design stage. This enables production speed optimization as the process parameters can be adjusted more freely. Real-time monitoring of pressing force by using multiple force sensors embedded in the mould structure can be utilized in the evaluation of material characteristics on a modified production machinery. Comprehensive process control can be achieved with a combination of measurement of the outer dimensions of the trays and pressing force monitoring. The control method enables detection of defects and tracking changes in the material properties. The optimized converting tools provide a basis for effective operation of the control system.

Control of multi-actuator system by an electrically driven hydraulic pump-motor

The awareness and concern of our environment together with legislation have set more and more tightening demands for energy efficiency of non-road mobile machinery (NRMM). Integrated electro-hydraulic energy converter (IEHEC) has been developed in Lappeenranta University of Technology (LUT). The elimination of resistance flow, and the recuperation of energy makes it very efficient alternative. The difficulties of IEHEC machine to step to the market has been the requirement of one IEHEC machine per one actuator. The idea is to switch IEHEC between two actuators of log crane using fast on/off valves. The control system architecture is introduced. The system has been simulated in co-simulation using two different software. The simulated responses of pump-controlled system is compared to the responses of the conventional valve-controlled system.

The death and resurrection of 'economics with psychology': remarks from a methodological standpoint

One of the merits of contemporary economic analysis is its capacity to offer accounts of choice behavior that dispense with details of the complex decision machinery. The starting point of this paper is the concern with the important methodological debate about whether economics might offer accurate predictions and explanations of actual behavior without any reference to psychological presuppositions. Inspired by an exercise of rational reconstruction of ideas, I aim to offer an interpretation of the process of freeing economic analysis from psychology at the end of the 19th century and the contemporary resurrection of behavioral approaches in the late 1980s.