Dutch Wind Workshops, October 2010

COST OPTIMIZATION OF PERMANENT

MAGNET DIRECT DRIVE GENERATORS
Ir. Anoop J assal, Dr. H Polinder, TU Delft
EPP
Electrical Power Processing
CONTENTS
I ntroduction
Motivation
New Design Approach
Challenges
Solution
Conclusion
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Electrical Power Processing
1.
Introduction
EPP
Electrical Power Processing
More energy from wind required in near future
Energy Generators Many Types Possible
INTRODUCTION
DFIG Cheap/ need gear box/ partial converter
Synchronous No gearbox/ expensive/ full converter/ losses
PMDD Efficient/ reliable/ big and expensive/ full converter
Offshore ! !
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Electrical Power Processing
REQUIREMENTS FOR OFF-SHORE
Large single units Cost control
Low maintenance Accessibility
Cost effectiveness
DIRECT DRIVE
ENERGY
CONVERSION
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Electrical Power Processing
2.
Motivation
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Electrical Power Processing
MOTIVATION
di stri buti on of costi ng
29%
10%
1%
3%
0%
3%
12%
25%
15%
2%0%
rotor :
drivetrain:
hydraulic:
nacelle:
cover :
yaw mechanism:
tower:
generator:
E-system/converter:
transformer :
auxiliary equipment:
Generator
forms a big
part of the
cost
Source www.elkraft.ntnu.no/norpie/10956873/Final%20Papers/068%20-%20Norpie%20paper.pdf
An Indicative Cost distribution in a Wind Turbine with PMDD
Generator
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Electrical Power Processing
MOTIVATION
Distributed Winding
Distributed Winding: Large
number of coils
-Large Overhangs: Copper Losses
-Insulation is laborious
-High manufacture cost
Source:http://i170.photobucket.com/albums/u260/ben_eberle/IMG_0960.jpg
* PM Magnets are also very expensive
* Research focus on only Winding part
Most Conventional machines use distributed windings
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Electrical Power Processing
3.
New Design Approach
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Electrical Power Processing
SOME EXISTING CONCEPTS
Ironless Stator
Newgen Stator
Clipper concept
Magnetic Bearings
Dewind Variable speed Gearbox
Unison Multibrid
Enercon Direct Drive (Electromagnets)
Zephyros Direct Drive
(Permanent Magnets)
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Electrical Power Processing
DESIGN APPROACHES
COST
REDUCTION
Magnetic
Bearings
Reduce
Weight
Modular
Machine
New Gen
Concept
Ironless
Stator
Concentrated
Windings
Clipper Concept,
more no. of small
standard generators
Cooling
Maintenance,
reliability
- Large Sizes Difficult to make
- Heat dissipation
- Futuristic
- Cost not evaluated
- Maintenance issues
- Reliability
Concentrated windings can be promising ! !
EPP
Electrical Power Processing
1) Shorter overhangs - Less Copper needed and Low Copper Losses.
2) Low Number of slots - Lamination cutting reduced.
3) Winding Process automatic - Faster manufacture.
4) Modular windings Faster Assembly
5) Rugged Design
WHY CONCENTRATED WINDINGS ???
Magnets
Rotor
back Iron
Stator
Winding
Coil Holder (before
winding)
View of coil inside the stator.
Coil is preformed, Slides on to
each tooth
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Electrical Power Processing
DESIGN APPROACH
Change from Distributed Windings to Concentrated Winding Scheme
Distributed Winding
Concentrated Winding
Source:http://www.theinventory.orconhosting.net.nz/smartdrives/D
SC02061_2.J PG
Source:http://i170.photobucket.com/albums/u260/ben_eberle/I
MG_0960.jpg
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Electrical Power Processing
4.
Challenges
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Electrical Power Processing
Cogging because of wider teeth (Less slots).
- Machine fails to start
- Torque Ripple
Eddy Current Losses in PM Rotor back Iron.
- Excessive Heating
- Danger of Demagnetization
Cooling of Machine
- If good, Gain More Power for Same Size
- If bad, overheating, reduced life, failure
WHAT DO WE PAY ??
Research Challenges with Concentrated Windings
Research Issue
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Electrical Power Processing
COGGING : PM Edge interacts with a tooth, experiences a pull,
giving rise to Cogging Torque
Stator Teeth
PM Edge
Movement
Cogging
Torque
Element
Rotor
Net Cogging Torque is sum
of these cogging torque
elements
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Electrical Power Processing
EDDY CURRENT LOSSES : Harmonics and Sub-Harmonics
generated by currents in concentrated windings.
Non-Sinusoidal MMF - High Harmonic Content ! !
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Electrical Power Processing
5.
Solution

Accurate Loss Prediction
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Electrical Power Processing
Machine Field Modeling
analytically and then verification
with Finite Element Method
Eddy Current loss modeling with
FE method and Measurement of
these losses For Comparison
Application on various designs
and optimize for cost.
- Cost Comparison with a
reference machine
PROCEDURE
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Electrical Power Processing
ANALYTICAL MODEL
Magnets
Rotor
back Iron
Stator
Winding
X
Y
Z
Region 2; Air with Permeability 2
b
B2
B4
B5
Region 1; Iron with Permeability 1
Region 4; Iron with Permeability 4
B1
B3
l
Region 3; Magnet region Permeability 3 and Remanant Flux Density of 1.2 T
B6
B7
ASSUMPTIONS
-Slot less Stator
-Winding =Current Sheet
-No Saturation
-No end effects
ADVANTAGES
-Very Fast
-Good for short-listing
potential designs

( , ) cos( ) A x t A kx t e =
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Electrical Power Processing
ANALYTICAL MODEL
1 1 2 2
cosh sinh 0 0 0 0 0
3 3 3 3
cosh sinh cosh sinh 0 0 0
4 4 4 4
3 3 3 3
sinh cosh sinh cosh
4 4 4 4
0 0 0
0 0 cosh sinh cosh
2 2 2
nkb nkb
nkb nkb nkb nkb
nkb nkb nkb nkb
nkb nkb nkb

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\ . \ . \
2 2 3 3
3 3 4
sinh 0
2
sinh cosh sinh cosh
2 2 2 2
0 0 0
0 0 0 0 cosh sinh sinh
4 4 4
sinh cosh cosh
4 4 4
0 0 0 0
nkb
nkb nkb nkb nkb
nkb nkb nkb
nkb nkb nkb


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1
1
2
2
3 2
3
3
3 2
4
0
0
0
(2 )4
0
(2 )4
0
r
r
g
h
g
n B
h
n k
g
h
n B
h
n k
t
t
t
t
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Solve some Nasty Equations ! ! !
Analytical Model Cross-Checked with Finite Element Method ! !
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Electrical Power Processing
COMPARISON FOR VALIDATION
Flux Lines
Distance along x-axis
D
i
s
t
a
n
c
e

a
l
o
n
g

y
-
a
x
is
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
Analytical
Finite Element
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Electrical Power Processing
ANALYTICAL RESULTS
Quantity Analytical COMSOL Error
Magnet Loss [W] 3224 3193 0.97 %
Back Iron Loss [W] 765 764.6 0.05 %
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Electrical Power Processing
FINITE ELEMENT (FE) MODEL
-Using COMSOL
MULTIPHYSICS 3.5a as FE
solver
-Complicated Geometries
Possible
-Motion Possible
-Material Saturation Possible
-Closer to real world scenario
TIME CONSUMING !!
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Electrical Power Processing
EXPERIMENTAL WORK
-Compare FE Models with the actual machines for model validation
-Check if we can predict losses with analytical calculation
Test Bench
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Electrical Power Processing
FUTURE WORK
Conducting Experiments
Comparison between Analytical-FE-Experimental
results
Derivation of a cost model
Estimate of cost saving achievable by using new
winding topology
Some design proposals based on research work
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Electrical Power Processing
6.
Conclusions
EPP
Electrical Power Processing
PMDD machines are efficient and reliable but
expensive.
One way to lower costs is using concentrated
windings.
Eddy current losses in solid parts of these
machines are primary concern. Research
needed for accurate prediction of these
losses.
If designed properly, PMDD generator can be
made cheaper than the conventional Direct
Drive generators.
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Electrical Power Processing
STATEMENTS
- In many ways policy makers and economists decide which
product(s) dominates the market.
- Cost is of great importance when technology competes.
- Technically best product might not be the most useful product.
Thank you for your kind attention ! !