Design Preliminaries for Direct Drive under Water Wind Turbine Generator

Krisztina Leban, Ewen Ritchie, Alin Argeseanu

Abstract This paper focuses on the preliminary design process of a 20 MW electric generator. The application calls for an offshore, vertical axis, direct drive wind turbine. Arguments for selecting the type of electric machine for the application are presented and discussed. Comparison criteria for deciding on a type of machine are listed. Additional constraints emerging from the direct drive, vertical axis concepts are considered. General rules and a preliminary algorithm are discussed for one of the machine selected to be most suitable for the imposed conditions. Index TermsAC machines; direct drive; generators; rotating machines; wind energy

TFPM - Transverse Flux PM Generator Tgenom Nominal torque p - pole pitch s - stator slot pitch II. INTRODUCTION

FFSHORE wind turbines are becoming more

I.

NOMENCLATURE

AFPM Axial Flux PM Generator EESG - Electrically Excited Synchronous Generator ( RF) PMSG - PM Synchronous Generator(RF) SCIG - Squirrel Cage Induction Generator( RF) Ag - Air gap area Bg - Peak flux density in the air-gap bp - Rotor pole width bs - Stator slot width bt - Stator tooth width DFIG Doubly Fed Induction Generator(RF) Dg - airgap diameter Ds - stator diameter E - RMS value of no-load voltage hry - Rotor yoke height hs - Stator slot height hsy - Stator yoke height Isnom - Nominal current Krad - aspect ratio coefficient of the machine lg - air gap length lm- magnet length ls - axial length of the machine m - number of phases Ncslot - Number of conductors per slot N rotor speed p - number of pole pairs q - slot per pole per phase RF - radial flux
This work was supported by the Deep Wind FP7 project, Grant agreement no: 256769

appealing than onshore ones due to better cost efficiency [1], [2]. The work presented in this paper was carried out in connection with the DeepWind FP7 project. Research in this project aims to develop design rules for a 20MW direct drive, vertical axis, offshore wind turbine [1],[3]. The main constraints of the Deep wind project state that: -the turbine must be a floating, offshore construction -the generator should be direct drive (gear ratio to be optimised: [4] geared 1:x could be 1:1) -the turbine should be rated at a high power (5-20MW; the aim is for the 20MW generator; preliminary designs of lower power are needed to study the implications of up scaling). -as a consequence of being direct drive, the rotational speed of the generator is extremely low (max 10 rpm) -Darrieus turbine (vertical axis) Fig. 1 depicts the Deep Wind concept. The turbine is to be installed offshore, in deep waters and anchored to the sea bed. The generator will be installed under water and will float together with the turbine.

Fig. 1 Deep Wind project concept [3]

Krisztina Leban is with the Department of Energy Technology, Aalborg University, Denmark (e-mail: kle@et.aau.dk ). Ewen Ritchie is with the Department of Energy Technology, Aalborg University, Denmark (e-mail: aer@et.aau.dk). Alin Argeseanu is with Politehnica University of Timisoara, Romania (e-mail: alin_argeseanu@yahoo.com ).

This paper reviews previously reported direct drive wind turbine generators in the megawatt class. It goes on to present a preliminary consideration of design rules and preliminary design predictions. This is considered in relationship to the challenges presented by the DeepWind application. The DeepWind research project aims for the 20MW generator. To achieve this goal, small scale machines will be first studied. The 5 and 10 MW generators are regarded as steps towards the final 20MW machine.
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978-1-4673-0141-1/12/$26.00 2012 IEEE

III. THE DIRECT DRIVE GENERATOR SYSTEM The direct drive concept requires that the generator be directly connected to the hub of the turbine rotor. This means that the generator rotates at a low speed, which makes it necessary to produce a high torque. As a result, the generator will have a relatively large diameter. Relatively large wind turbine generators are usually designed with a large diameter and a small pole pitch in order to increase the efficiency of the system, reduce the active mass and to keep the end winding losses small.[5], [6]. The estimated torque on the 5MW wind turbine shaft as a function of rotational speed is presented in Fig. 2. Here it is seen that the torque developed by the wind turbine increases as a function of the shaft speed until the speed reaches 4.4 rpm. When the speed reaches 4.4 rpm, the torque increases (as the wind speed increases), up to around 10.9 MNm.

diameter demands a large mass of inactive material [7]. TABLE I shows the relationship between the power rating and the active, inactive and total mass of the direct drive PMSG as found in the literature.
TABLE I MASS OF 2, 3 AND 5MW PMSG DIRECT DRIVE GENERATORS [5], [6] 2MW Active Mass[ton] Inactive Mass [ton] Total Mass[ton] 14.6 10.4 25 3MW 22.4 19.6 42 5MW 39.9 50.1 90 10MW

65 260 325

Fig. 2 Torque on the turbine shaft as a function of rotational speed (5MW generator)

This imposes corresponding requirements on the generator. The relationship between shaft torque and speed for 5MW shaft power is shown in Fig. 3. The input torque to the generator is 10.9 Nm at 4.4 rpm. This defines the rated working point of the generator. It may be seen from Fig. 3 that a reduction in shaft speed will require more torque at the generator shaft, and an increase of speed will reduce the torque requirement. It is important to recognise this, as the rated torque has a decisive influence on the size of the generator.

Direct drive low speed generators have the following disadvantages [5] and peculiarities that require attention during the design process. -require high torque to be produced -A higher torque implies larger size of the generator. [8] -large diameter of the generator causes manufacturing and transport difficulties -heavy mass the structural mass increases faster than the active mass increases [5]-see TABLE I -high cost compared to the generator used in a geared construction - direct-drive low speed and high torque generators have a large number of poles. This implies a large diameter in order to maintain a reasonable pole pitch [8] For larger direct-drive generators, a higher torque also requires a larger volume machine, as the torque density cannot be further significantly increased. [8] (Considering that the current loading is limited by the temperature rise and the air-gap flux density is limited by saturation of the iron parts of the magnetic circuit). When approaching the problem of designing the generator for such a turbine, the following issues must be addressed: - Selecting a generator type that is most suitable for the application - Identification of additional constraints (e.g. manufacturing issues, insulation, corrosion, diagnostics of machine faults) - Preliminary design algorithm-list of main design elements to consider In the following the upper listed issues are addressed. A. Generator type selection Considered generator types for the application as suggested in the bibliography [5], [6], [8], [9], [10], [11] are: SCIG - Squirrel Cage Induction Generator (RF) DFIG Doubly Fed Induction Generator (RF) EESG - Electrically Excited Synchronous Generator (RF) PMSG - PM Synchronous Generator (RF) TFPM - Transverse Flux PM Generator AFPM Axial Flux PM Generator Comparison criteria suggested by [12], [13],[6] are: -outer diameter power/volume -total length torque/volume -total volume power/mass -efficiency torque/mass -torque density power/cost -force density torque/cost -active material weight

Fig. 3 Required torque as a function of shaft speed for 5MW shaft power

The electromagnetic - direct-drive generator is designed with a large air gap diameter and small pole pitches to increase the efficiency, to reduce the active mass and to keep the end winding losses small. To generate high power at low speed, high torque is demanded. High torque results in high tangential force and large air gap diameter of the generator. A large air gap

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. The AFPM Axial Flux PM Generator was rejected due to the disadvantages it would bring. [5], [8], [6]. The advantages and disadvantages of the remaining machines were reviewed to determine if they might be suitable for the Darrieus wind turbine application. Further analysis was needed to narrow down the list of candidates. For this purpose the method of SWOT analysis was employed. The following factors should be considered [6]: -the design of electric machines usually aims to optimise one or more of the previously mentioned criteria -it is important to identify the optimising potential of each machine. -Suitability of the EESG and PMSG depends on the price of PM and converters Fig. 4 depicts the world market share of yearly installed power for different wind turbine generator types as well as their tendency. DFIGs seem to be the dominant type. The EESG and PMSG show a constant level of exploitation.

To better outline the difference between the radial flux and transversal flux machines, sketches of the main flux paths for the two machine categories are presented in Fig.5 and Fig 6.

Fig. 5 Longitudinal Orientation.

[14]

Fig. 6 Transverse Orientation. [14]

Fig. 4 World Market Share For Yearly Installed Power For Different Wind Turbine Generator Types [6]

-due to physical, functional and manufacturing restraints, a compromise must be reached in order to increase the specified design values without diminishing the other parameters. -for wind turbines, the rotational speed is further reduced when increasing the power rating. The mass of electrical machines depends on their torque rating. - As a consequence, the torque rating (more precisely the torque to mass ratio) may be a useful criterion for choosing the most suitable machine for the 20 MW turbines. - COST: material (mass of the generator) and manufacturing cost (chosen geometry). In [6], large direct-drive wind PM turbines were assessed for their active mass-competitiveness. Machines selected by [6] to be the most suitable from a mass assessment point of view: RFPM machine: Slotted surface-mounted RFPM machine with inner rotor and rare earth magnets (R1: RFSM-ST-IR-NdFeB) TFPM machine: Flux-concentrating TFPM machine with single windings; the best candidates are TFPMG-U: single-sided, single winding flux-concentrating TFPM generator with U-core and TFPMG-C: double-sided, single winding flux-concentrating TFPM generator with C-core [13].

To compare the candidates, Strong points(S- maximum value desired), Weak points (W-minimum value desired), Opportunities (O- maximum value desired) and Threats (T-minimum value desired) were assessed for the machines proposed by the existing literature. The importance of each feature was quantified by a grade. By adding the grades, a number was obtained for each SWOT element and for each machine. TABLE II shows the evaluation of the results. The cells containing the desired maximum values are coloured green (and bold). The desired minimum values are outlined using orange. In this way, the machines could be compared and the fittest candidates could be picked.
TABLE II S.W.O.T. ANALYSIS RESULT S MAX SCIG DFIG EESG PMSG TFPM 7.3 W MIN 7.0 8.8 6.5 6.3 4.7 O max T min 5 5 6 8.5 5 X X X Chosen

9.3
0

9 7.8 9.0 9

8 8.7
8

The machine types chosen to be the most suitable candidates based on the SWOT analysis are EESG, PMSG, and TFPM Fig. 7 shows the active mass/torque of PM machines as a function of torque rating

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The classical design algorithm is presented below:

Start Machine design

Input:Power,Phase voltage, frequency, cos fi, rotational speed, efficiency, short circuit reactance,other

Derive main quantities: Phase Current, Phase(star) voltage, number of poles

Preliminary repartisation of losses: mechanical, suplimentary, Pcu,Pfe

Choosing of main dimensions

Method I Cs-machine constant

MethodII KA-utilisation constant 1. KA-calculated 2. Calculation volume of machine 3. Pole pitch/ideal length chosen 4.Bore diameter-calculated. 5.ideal length calculated, pole pitch chosen 6.Real length(with vent channels)-calculated

Fig. 7 Active Mass/Torque of PM Machines as a Function of Torque Rating [6]

1.Cs chosen 2.Pole pitch, ideal machine length, bore diameter Calculated

Conclusions from Fig. 7[6] TFPM are lighter than RFPM machines for low torque ratings (under 50 kNm). RFPM machines are the lighter for large torque ratings (over 100 kNm). Active mass/torque ratios of the machines in Fig. 7decrease when the torque rating increases. B. Additional Issues for the Generator The harsh offshore conditions bring additional constraints for the generator design approach. -sealing-the generator must withstand the outside environment water, salt and other chemicals, sea-life. -corrosion-machine parts e.g. magnets, insulation and bearings must withstand fouling and corrosion. -insulation-must be effective in deep sea conditions, under the expected electrical, mechanical and chemical stresses. -monitoring and diagnosis are extremely important as servicing the generator will prove a very difficult task-as deep water is generally a long way offshore. In case of a fault, early warning of incipient faults would facilitate planned servicing of the machine. An advantage arising from the deep sea environment might be the possibility to increase the magnetic and electric loading due to the cooling provided by the abundant sea water. C. Preliminary Design Algorithm The design algorithm proposed contains the following: SOA-SWOT: decide on the machine type First Estimations-Generator Diameter and massto serve as an input for the turbine design; get an idea about the expected values Analytical design first iteration Finite Element Machine Model analysis of the calculated geometry Optimisation- using the analytical model, optimisation algorithms e.g. genetic or particle swarm may be employed Second analytical iteration Suggestions for software to be used: - Matlab for analytic design and optimisation - C++ - for analytic design and optimisation - Opera VF 14 - finite element and optimisation - Design Verification: thermal: MOTOR CAD

Stator slot design

Determination of stator winding and number of slots: 1.number of turns/phase 2.winding type 3.slots/pole and phase 4.winding step 5.tooth pitch 6.cording factor 7.winding factor

Determination of stator winding and number of slots: 1.number of turns/phase 2.winding type 3.slots/pole and phase 4.winding step 5.tooth pitch 6.chording factor 7.winding factor 8.slot fill factor

Machine exterior diameter 1. Exterior diameter of machine 2.Airgap diameter and length 3 Carter Coefficient Rotor Dimensions (Wound Rotor) 1. Width of the pole piece 2.Press plates-calculation 3.Length of the pole piece

Damper windings-if needed

Magnetisation Characteristics 1.Flux linkage-calculation 2.Induction in the air gap 3.inductions in the teeth 4. Induction in the yoke 5. Magnetomotive forces

Magnetomotive forces at rated load and rated power factor 1.Determination of the stator winding leakage reactance 2.Checking of the short circuit reactance

Excitation Design

Calculation of weights(Cu,Fe) Usage of active materials

Efficiency, Losses calculation Machine Time Constants Short circuit currents

Thermal analysis

Finished First Analytical Iteration

Fig. 8 Flowchart of generator design approach- EESG example [15]

A general approach for the EESG design was presented in Fig. 8. A detailed design including analytical formulas can be found in [15] D. Estimates for the 20MW generator TABLE III presents the parameters given in the literature for 5 and 10 MW machines. The ratio of the 10 MW/5MW was calculated and the 20 MW features estimated from
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this. A linear dependency was assumed for the largest machine. In this way the figures presented for the 20 MW machine are purely representative estimates.
TABLE III DIMENSIONS, CURRENT, AIR GAP FLUX DENSITY AND NO LOAD VOLTAGE RFPMG FOR 5 MW AND 10MW DIRECT DRIVE WIND TURBINES [13]+ORIGINAL 20 MW Parameter Speed Nominal Torque Aspect ratio of the generator Air gap diameter (Generator rotor diameter) Axial length of generator Air gap length Magnet height Stator diameter Number of phases Stator slot pitch Number of slots per pole per phase Pole pitch, p t [mm] Number of pole pairs Rotor pole width Stator slot width Stator tooth width Stator slot height Stator yoke height Rotor yoke height Air gap area Nominal current Number of conductors per slot Peak flux density in the air-gap RMS value of no-load voltage Force density Symbol Formula N Tnom Krad=ls/Dg Dg ls Lg lm Ds m s q p P bp bs bt hs hsy hry Ag(=Dgls) Isnom Ncslot Bg(=Bpm) E [] [rpm] [MNm] [-] [m] [m] [mm] [mm] [m] [-] [mm] [-] [mm] [-] [mm] [mm] [mm] [mm] [mm] [mm] [m2] [A] [turns] [T] [V] 5MW 12.1 4.38 0,27 6,36 1,72 6,36 15,9 6,37 3 33 1 100 100 80 15 18 80 40 40 34,29 606,2 3,35 0,97 3057,3 10MW 8.6 12.38 0,3 8,68 2,61 8,68 21,7 8,699 3 33 1 99,7 137 80 14,96 18 80 40 40 71,04 551,9 3,35 1,07 6716,1 20MW estimated 6.11 34.99 0,33 11,85 3,96 11,85 29,62 11,88 3,00 33,00 1 99,40 187,69 80,00 14,92 18,00 80,00 40,00 40,00 147,18 502,46 3,35 1,18 14753,54

With this in mind optimization tools and new solutions will be studied and improved, to increase the torque density of the generator. V. CONCLUSIONS

This paper, presents the preliminary design process for a 20 MW electric generator for a direct drive vertical axis wind turbine. To decide on a machine type to be used in the application, radial and transverse flux machines were compared using the SWOT analysis technique. The most suitable candidates were found to be the EESG, PMSG, and TFPM. Arguments for selecting the type of electric machine for the application were presented and discussed. Comparison criteria for deciding on a particular type of machine are listed. Additional constraints emerging from the direct drive, vertical axis concepts are considered. General rules and a preliminary algorithm are discussed for the machine selected to be most suitable for the imposed conditions.

VI. ACKNOWLEDGMENT The authors would like to thank the FP7 Deep Wind Project for financial support. VII. REFERENCES

[1] Deep Wind project Team. Deep wind call-Future Deep Sea Wind Turbine Technologies THEME [ENERGY.2010.10.2-1][Future Emerging Technologies for Energy Applications (FET)] Grant agreement for: Collaborative project* Annex I - "Description of Work"Grant agreement no: 256769; Date of preparation of Annex I (latest version): 2010-07-15 Date of last change: 2010-07-15 . [2] Bilgili M, Yasar A, Simsek E. Offshore wind power development in Europe and its comparison with onshore counterpart. Renewable and Sustainable Energy Reviews 2011;15:905-15. [3] Vita L, Schmidt Paulsen U, Friis Pedersen T. A novel floating offshore wind turbine concept: new developments. 2010. [4] Deep Wind. Future Deep Sea Wind Turbine Technologies DeepWind Collaborative Project Small or medium-scale focused research project ENERGY.2010.10.2-1: Future Emerging Technologies for Energy Applications (FET) Appendix B. [5] Bang D, Polinder H, Shrestha G, Ferreira J. Review of generator systems for direct-drive wind turbines. 2008:1-11. [6] BANG D. Design of Transverse Flux PM Machines for Large Direct-Drive Wind Turbines.. Busan, Korea : Master of Engineering, Pukyong National University, 2010. ISBN 978-90-5335-336-3. [7] Deok-je Bang HP. RESEARCH REPORT on Rough Design of 10 and 20 MW Direct-drive Generators (Deliverable No.: D 1B2.b.hp1, 2008). [8] Li H, Chen Z. Overview of different wind generator systems and their comparisons. Renewable Power Generation, IET 2008;2:123-38. [9] J. Marques, H. Pinheiro, H. A. Grndling, J. R. Pinheiro and H. L. Hey. A SURVEY ON VARIABLE-SPEED WIND TURBINE SYSTEM. [10] Xiang D, Ran L, Tavner PJ, Yang S. Control of a doubly fed induction generator in a wind turbine during grid fault ride-through. Energy Conversion, IEEE Transactions on 2006;21:652-62. [11] Hansen AD, Michalke G. Fault ride-through capability of DFIG wind turbines. Renewable Energy 2007;32:1594-610. [12] Chen Y, Pillay P, Khan A. PM wind generator topologies. Industry Applications, IEEE Transactions on 2005;41:1619-26. [13] Deok-je Bang HP. Electromagnetic Optimization of Direct-drive generators.. s.l. : Project UpWind, 2010. Deliverable No.: D 1B2.b.hp2. .

Fd

[kN/m2]

40,16

40,16

40,16

IV. DISCUSSION Serious challenges are presented by the application, in particular the sub-sea conditions and the low speed of the Darreius wind turbine. This means that usually applied design rules must be reviewed and revised where possible. New or unusual materials must be considered and evaluated for use in this application. New techniques must be developed and studied for adoption with a view to reducing the mass/torque ratio.

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[14] Dubois M. Optimized permanent magnet generator topologies for direct-drive wind turbines. PhD, Delft University 2004;142:143-82. [15] I.M. Postnikov. Design of electrical machines-translated from Russian .

Biographies
Krisztina Leban was born in Timisoara, Romania, on March, 28, 1983. She received the B. Sc. Degree from Faculty of Electrical and Power Engineering of Politehnica University of Timisoara, Romania and MSc degree from Aalborg University, Denmark where she was employed as a Research Assistant. Currently, she is a PhD student with the Department of Energy Technology, Aalborg University, Denmark. Scientific interests include electrical drives, interdisciplinary engineering and innovation. She is currently working with renewable energy systems, electric vehicles, ferrofluids applications in actuators and electrical machines. Ewen Ritchie was born in 1943, B.Tech. (Hons.) from University of Bradford, England 1966. Employed as Development Engineer at English Electric Co. Bradford England, Special Machines & Equipment Division 1966-73, Scragg Power Drives, Macclesfield, England, 1973-76. Development Engineer at Thrige-Titan, Aalborg, Denmark 1976-79, ASEA, Aalborg,

Denmark 1979-83, Electrolux Elmotor, Aalborg, Denmark 1983-87, External lecturer at Aalborg University 1986, Associate Professor at Aalborg University 1987-. Member of Energy Sector Study Board 1987-89, & 19962000, Faculty Study Board 1987-89, Seconded to Ondo State University, Ado Ekiti, Nigeria, April-June 1991. Member of Board of the Faculty of Engineering and Science, 1993-2001. Hon. Treasurer,Danish Magnetic Association, 1994-2000. Chairman Danish Magnetic Association 20052007. He is currently employed at the Department of Energy Technology Aalborg University, Denmark as Associate Professor. His research interests include all aspects of design, application and fault diagnosis of electrical machines. Alin Argeseanu was born in Hunedoara, Romania, on September, 09, 1959. He received the B. Sc. Degree and the Ph. D. degree from the Politehnica University of Timisoara, Romania. He is currently lecturer of the Politehnica University of Timisoara, Faculty of Electrical and Power Engineering. He is single author or co-author of over 50 publications in the field of sensors, drives, optimal control and renewable energy. Also, he is the author of two books and six patents. He is currently involved in renewable energy systems and ferrofluids applications in actuators and electrical machines.

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