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Abstract - This paper re-examines some of the usual the power rating becomes higher, the rotor speeds become
assumptions in deploying synchronous machines in multi- lower, but the diameters grow. Arkkio suggests that the rotor tip
megawatt, high-speed applications. A viable design is speed of 250 m/s to be the upper limit for applying PM
presented with a focus on rotor capability and cooling system machines in favor of solid rotor induction machines. While
performance that can operate at common gas turbine speeds Arkkio recommends a design value for sleeve stress, he does
and power ratings. The models used in the analysis are not directly connect the tip speed to the sleeve stress. Certain
validated with a similar topology machine, albeit a higher speed design choices, in particular magnet thickness and rotor
and lower power than the proposed design. construction, can influence the sleeve stress dramatically but
have no effect on tip speed. For this reason, it is the sleeve
Index Terms — Permanent magnet, high speed, stress that determines the limit of rotor containment (and
synchronous, motor, generator ultimate speed) and the tip speed should only be used as a
parametric indicator or rule-of-thumb.
I. INTRODUCTION The high-speed, sleeved PM machine has an intrinsically
larger magnetic air-gap than the unsleeved PM machine due to
High-speed electric motors with variable speed drives have the sleeve thickness and the increased magnet thickness
been shown to have an advantage over gas turbines as a prime required to force an equivalent amount of flux through the larger
mover for natural gas compressor applications when both magnetic gap. This larger magnetic gap provides better
environmental and economic factors are considered [1] [2]. demagnetization protection, especially under short-circuit
Both synchronous and asynchronous systems have been conditions. The potential of PM machines to demagnetize is
considered for these applications, however there are significant often used as a factor in dismissing them for applications where
differences among synchronous systems that warrant robustness is required. The machine design presented here
discussion. benefits from a relatively large magnetic gap and the near
The synchronous machines discussed by LaGrone [2] were immunity to demagnetization.
discounted because of the complex rotor construction typical of High-speed machines are operated at frequencies at least an
wound-field synchronous machines. Permanent magnet (PM) order of magnitude above line frequency. This high-speed
machines do not suffer from many of the same difficulties, as operation allows the machines to be smaller than conventional
they do not have field winding and a rotating rectifier. In machines in the same power rating which yields a significantly
addition, the modern synchronous PM machine designed for higher power density machine than the conventional alternative.
high speed and high power applications differs from its lower However, with the higher power density and frequency also
power brethren, such as the machine topologies studied by come higher loss density. Special attention must then be paid
Melfi [3]. to the choice of lamination material, coil construction, and
High-speed PM machines typically have surface-mounted cooling mechanism for what would otherwise be a typical stator
magnets and are sleeved. Laminated rotor cores and/or and housing design. In the case of a high-speed PM machine,
embedded magnets do not offer either the radial stiffness or temperature sensitivity of the magnet material is an additional
mass containment required for many applications. The sleeve factor. For this reason, samarium cobalt is often the choice to
provides the containment and a solid rotor core, or hub, realize higher temperature designs. In case of composite
provides stiffness. Common sleeve materials are non-magnetic sleeve machines, the maximum sleeve operating temperature
high-strength alloys, pre-molded graphite composite, and represents another design constraint.
wound-in-place carbon fiber. Of these, the carbon fiber winding
offers the highest strength while providing minimal conducting II. DESIGN SPECIFICATION
path for eddy currents induced by air-gap flux disturbances.
While Arkkio [4] was primarily focusing on high-speed The petrochemical industry would benefit from a high-speed,
applications not more than one or two megawatts, the medium-voltage PM machine to drive centrifugal compressors
observation that machines will require a larger diameter than an or be directly driven by gas turbines. The PM machine has
equivalent PM machine should not be lost on the reader. As reduced system weight, higher operating efficiency, and smaller
4 C. Rotor Containment
A. Electromagnetic Sizing
2
create the nodes connected by massless beams. The total each other with a two plane balancing scheme.
system model includes the rotor and bearings; however due to
the nature of magnetic bearings the main housing support
structure effect the rotor dynamic performance and therefore is Rotordynamic Bearing Load Plot
not included in the total system model. 8 MW PM Motor/Generator
Standard Operating Conditions
The magnetic bearings are modeled as dynamic supports Brg at Stn 6: SFD (K=12500,C=25)
[311.4
with variable stiffness and damping. The magnetic bearings 70
Bearing Load, lb pk
Max Load
loading of the coupled system. A coupling appropriate to the 178.0 40
Horz Load
machine size was chosen and is modeled as a cantilevered Vert Load
weight. 133.4 30
89.0 20
44.5 10
N] 0
0 5000 10000 15000 20000 25000 30000 35000
Rotor Speed, rpm
222.4 50
40 Max Load
Horz Load
Vert Load
The total rotor weight is over 900 kg and the bearing span is 133.4 30
254 10
5 10
15
15
15
20
20
20 25
30
A lumped parameter model is used to model the machine
0 0
5 30 37
35
40 geometry including rotor, stator, and cooling jacket to determine
correct magnitude of cooling system approach. A maximum
design temperature limit per coil insulation and carbon fiber
-254 -10
analysis was set at 150°C.
A separate aluminum cooling jacket with a press fit to the
-508 -20
stator back-iron extracts heat through a water/glycol cooling
flow. The interference fit is determined for structural integrity as
-762 -30
mm] 0 10 20 30 40 50 60 70 80
well as to reduce the insulating effects of a microscopic air gap,
[mm 254 508 762 1016 1270 1524 1778 2032] or contact resistance, between the cooling jacket and the stator
Axial Location, inches back iron.
Fig. 4 First Forward Bending Mode with Geometry Plot Curtain-air flow pulls heat out of the end turns without being
Overlaid choke-limited by the radial air-gap size. Although the wound-
carbon-fiber sleeve acts as a thermal insulator, cooling flow
The magnetic bearing control circuit design depends heavily through the radial air-gap minimally cools the rotor as well as
on the expected system load response at the location of the cooling the stator tooth tips. Therefore cooling air flow is
support bearing actuators. The response plots shown, coupled actively blown through a mid-stator-stack vent and into the
end bearing (Figure 5) and non-coupled end bearing (Figure 6), radial air-gap and out over the stator end-turns (Figure 7). Loss
are based on the maximum allowable imbalance per ISO inputs are determined and allocated per the electromagnetic
1940/1-1986 machine category G2,5 180º out of phase with analysis tools discussed in IV. B.
3
adjusting the magnet material-properties, both in the drawing
tolerance and in the electromagnetic model.
Electromagnetic aspects of the stator design are similar to or
no different than a conventional machine and so model
validation of stator quantities is of lesser concern and is not
presented here.
B. Thermal Model
Fig. 7 Machine Cross-Section Showing Cooling System Two HSA machines were coupled together in a back to back
configuration with one operating as a motor driving the other as
The 3-D model of the entire machine is generated based on a generator for testing purposes. In this configuration the
the cooling approach determined by the lumped parameter cooling system was adjustable and thoroughly instrumented.
model. A finite-difference (FD) analysis tool is utilized by using The HSA machines were run with different cooling and load
the actual 3-D modeled assembly. Losses are represented as combinations per Table II. Both the lumped parameter and FD
heat flux on the surface of the appropriate component, for models were refined based on these tests until they reasonably
example windage losses are modeled as heat flux on the matched the test data (Figure 9). In this way the lumped
surface of the rotor-containment sleeve. Cooling-flow inlets and parameter and FD models were verified.
outlets are defined; however the actual path and velocity of the The lessons learned from the HSA testing and modeling such
flows were calculated by the FD model (Figure 8). The as the significance of the heat lost to the ambient air and
conclusions of the lumped-parameter model were confirmed through the machine feet were incorporated into the 8 MW
and refined by the FD model analysis. machine thermal models.
TABLE II
Test Configuration for Cooling Model Validation
Test Load Liquid Air
Setup [kW] Cooling Cooling
1 450 Yes Yes
2 No Load Yes Yes
3 No Load Yes No
4 No Load No Yes
70
Temperature [C]
60
Measured upper
50 Lumped Parameter
Finite Difference
40
Measured lower
30
20
0 1 2 3 4 5 6 7
Fig. 8 Solid Model Results from Finite Difference Thermal
Location [fan/le ad end to driv e e nd]
Analysis of Machine
Fig. 9 Comparison Plot of Analytical Prediction and Test Data
IV. EXPERIMENTAL RESULTS AND MODEL VALIDATION
V. CONCLUSIONS
A. Electromagnetic Model
This paper presents a viable medium-voltage, high-speed
Nelson [6] presented the details of the two-megawatt high- PM machine design well suited for replacement of, or coupling
speed alternator (HSA) used to validate the electromagnetic with, a variety of gas turbines.
model. It was shown that the open-circuit voltage was linear The machines’ stator consists of thin, low loss silicon steel
with speed both before and after a sudden short-circuit test and laminations and multi-strand, multi-turn form-wound coils and
that no demagnetization was detected. The higher than was designed for high frequency operation using a
predicted rotor field strength reported by Nelson was taken into commercially available FEA program.
account when designing the eight-megawatt machine by The machine will be supported by one thrust and two radial
magnetic bearings with ball bearings used as touch down
4
bearings during start up and shut down. The rotor-dynamic power electronics and controls, respectively. He is currently the
analysis completed shows the machine to be running sub- Director of Technology for Direct Drive Systems and was
critical with a first forward bending mode 15% above the previously employed by Hamilton Sundstrand and General
overspeed condition and over 20% above the nominal Electric (concurrent with his advanced degrees). Throughout
operating speed. The response plots show a 30 lbs peak his 14 year career he has been involved in advanced
reaction force over the operating speed range, which is well electromagnetic design of electric machinery including new
within the magnetic bearing control capabilities. lamination and winding designs, design tools, and both
Cooling for the machine consists of cooling air entering prototype and product family development for commercial,
through a mid stator vent as well as independent cooling flows industrial and aerospace applications. Dr. Saban is a senior
over each of the end turn sections and a water/glycol cooling member of IEEE and a registered professional engineer in
flow through a pressed on cooling jacket over the stator back Indiana and Illinois.
iron. By independently blowing cooling air over the end turns Paulo Guedes-Pinto was graduated from the University of
the total flow rate is not restricted to the rotor air gap choke flow Sao Paulo in 1979 with a BSEE, majoring in electric machines.
and can be significantly increased to meet the thermal Paulo also pursued post-graduate studies in power systems
requirements of the machine. and quality engineering. He has over 15 years of experience in
The analytical tools used in the design have been validated the design and manufacture of motors and generators with
with existing hardware. Industrias Villares in Brazil and most recently with Direct Drive
Systems. Paulo is registered professional engineer in Ontario,
VI. REFERENCES Canada and is a member of IEEE.
VII. VITA