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Design and Performance Analysis of a 5 MW Medium-Speed Brushless DFIG drive-train

Design and Performance Analysis of a 5 MW Medium-Speed Brushless DFIG drive-train. Peter Tavner Wind Technologies Ltd Past President of European Academy of Wind Energy. Overview. Wind Technologies Brushless DFIG propositions History of the Brushless DFIG

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Design and Performance Analysis of a 5 MW Medium-Speed Brushless DFIG drive-train

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  1. Design and Performance Analysis of a 5 MW Medium-Speed Brushless DFIG drive-train Peter Tavner Wind Technologies Ltd Past President of European Academy of Wind Energy

  2. Overview • Wind Technologies Brushless DFIG propositions • History of the Brushless DFIG • Wind Technologies progress in machine sizes • Design of a 5 MW brushless DFIG generator • Comparison of different wind turbine drive-trains • Conclusions.

  3. Brushless DFIG drive-train Generator DFIG Gearbox x3 Partially-rated AC/AC Generator B’DFIG Gearbox x1 or x2 Partially-rated AC/AC

  4. Brushless DFIG Operation • Synchronous mode operation • Converter controls • Real power • Reactive power Synchronous speed

  5. Why is Brushless Better?

  6. History of the Brushless DFIG • 1902- Siemens patent based on Lydall , 2 WRIM with connected rotors; • 1907 & 1914- First Hunt papers, 2 WRIM incorporated in a frame with 1 rotor winding; • 1920s- Integration into 1 machine in 1 frame realised commercially in Germany & UK; • 1930s- Practical cascade-mode BDFM machines produced for rock-crushing and ship propulsion applications in UK , Germany & USA; • 1970- Broadway paper design analysis for the integrated machine, nested loop rotor winding & synchronous mode of operation; • 1980s- Weier proposed and installed a cascade-mode BDFM for limited range variable speed wind turbine with a small size converter; • 1990s-Introduction of large rating IGBT Voltage Source Converters; • 1990s-Some work in Brazil by WEG; • 2000s-Wind Technologies at Cambridge University and later Durham University started to develop synchronous-mode BDFIG with IGBT VSC, specifically to replace DFIG but retain partially-rated converter in large wind turbines, 44 papers published; • 2010-Wind Technologies IP consists of 3 Patents & 50 man-years work covering Electromagnetic design of the BDFIG and control of its partially-rated Converter

  7. Wind Technologies Progression in Brushless DFIG sizes

  8. 20 kW Brushless DFIG Wind Turbine 20 kW 12.5 m 11 m Brushless DFIG 2 stage helical Grid –connected, partially-rated Free yaw, down-wind Rated power Hub height Rotor diameter Generator Gearbox Converter Yaw West Cambridge Site, Cambridge In operation from March 2009

  9. Manufacturing process for 250 kW Brushless DFIG 2 winding stator, 4 pole & 8 pole 1 winding rotor, 6 pole

  10. Assembled 250 kW Brushless DFIG

  11. Proposed 5 MW Brushless DFIG Design Specification

  12. Initial Specification Equivalent Circuit Analysis Finite Element Analysis Discussion with machine manufacturer Final Design Design Process For Brushless DFIG Analytical Design Software Thermal Modelling Coupled Circuit Analysis System Dynamics LVRT & Grid Connection Controller Optimization

  13. Equivalent Circuit

  14. Finite Element Analysis – Flux Distribution

  15. 5 MW Brushless DFIG Design

  16. Drive-train Technologies

  17. Comparison of different wind turbine drive-trains *Data taken from UpWind

  18. Comparison of different wind turbine drive-trains *Data taken from UpWind

  19. Efficiency Comparison

  20. Comparison of conventional high-speed DFIG with medium-speed Brushless DFIG in a 5 MW Nacelle 2 stage gearbox Cooling system Brushless DFIG Fractionally Rated Converter No slip rings Smaller Gearbox

  21. Conclusions Brushless DFIG steadily developed by Wind Technologies. Brushless DFIG is in operation in a 20 kW Wind Turbine at Cambridge. 250 kW Brushless DFIG built and tested with successful rated and fault ride-through results. Two medium-speed 5MW Brushless DFIGs designed to fit into medium-speed drive-trains with 1- or 2-stage gearboxes. Performance of these drive-trains compared against high- & medium-speed geared and direct architectures. Medium-speed Brushless DFIG drive-train is competitive with alternative designs in respect of weight, cost and efficiency and reduces drive-train CAPEX A large scale Brushless DFIG is practicable and scalable from current designs BDFIG drive-train appeared in Eize de Vries’ article ‘Products of 2012’ in January Issue of Wind Power Monthly ranked 2nd in Top Turbines for 2012 in competition alongside GE Wind, Winergy, Emerson & Romax.

  22. Thank you

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