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Diseño y simulación de generadores síncronos para aplicaciones de

energía eólica

Ing. Ismael González Salas Grupo SSC

• Introducción

• Soluciones de ANSYS Electromagnetics

• Turbinas eólicas y aplicaciones de energía

renovable.

• Caso de estudio: Diseño y simulación multi-física

de un generador de imanes permanentes de 3kW.

Agenda

• Fundada en 1970

• Visión con objetivos a largo plazo

• Inversión consistente de 15-20% en Investigación y

desarrollo

• Presencia global

• Grande y prestigiosa base de clientes

• 40,000+ clientes

• Adquisiciones inteligentes y estratégicas

EVOLUTIONARY ENGINEERING

ANSYS - Resumen

RF & Microwave

IC Design & Verification Electromechanical Analysis

Signal & Power Integrity & EMI

EBU Segmentos de aplicación

Niveles de abstracción - Electrónica

Naturaleza

Leyes de la física

Componentes digitales y análogicos

Reloj

Modelo parámetros concentrados

Lógica combinacional Software

Lenguajes programación

ANSYS Simplorer Circuit/System Design

PP := 6

ICA:

A

A

A

GAIN

A

A

A

GAIN

A

JPMSYNCIA

IB

IC

Torque JPMSYNCIA

IB

IC

Torque

D2D

SCADE Suite Control Systems

Model order Reduction

Co-simulation

Field Solution

FE Model Generation

Embedded Design

Push Back Excitations

Xprts Machine Design (RM) Power Electronics (PE)

ANSYS CFD Thermal

HF/SI

HFSS, Q3D, SIWave

RLCG Parasitics

ANSYS Mechanical Thermal/Stress

Optimetrics/DX DOE, Optimization, DSO

ANSYS Maxwell 2D/3D Magnetic FEA Analysis

Motor-CAD

ANSYS Sistemas electromecánicos

Turbinas eólicas

y

energía renovable

Agenda

Por qué es importante la simulación?

• Consideraciones Eléctricas

Si la potencia del aire es aumentada, el voltaje y la frecuencia del sistema

se ven afectados, necesitando un sistema eléctrico robusto y controlado.

• Aspectos Mecánicos y de Dinámica de Fluidos

Los generadores aumentan de tamaño, numero, y eficiencia aerodinámica,

el construir soportes y estructuras resistentes así como identificar

vibraciones presentes se convierte en un aspecto muy importante.

• Reducir Riesgo / Aumentar confiabilidad

Evaluar el desempeño del sistema antes de que ocurran problemas.

Motivación

drive signal forthe converter(voltage)

Q Current Controller

D Current Controller

drive signal forthe converter(voltage)

Actual ID

Ref ID

converter

regulator

regulator

converter

Ref IQ

actual IQ

regulator

Ref Q

Actual Q

regulator

Q Power Controller

P Power Controller

Actual P

Ref P

0

0

0

0

0

0

A1

B1

C1

N1

A2

B2

C2

N2

ROT1

ROT2

w+W

+

WM1

W

+

WM2

W

+

WM3

W

+

WM4W

+

WM5

W

+

WM6

w

+

ICA:

FML_INIT1

EQU

FML4

STATE_1140

SET: SWA1:=0

SET: SWB1:=0SET: SWC1:=0

STATE_1139

SET: SWA1:=1


STATE_1138

SET: SWA1:=1


STATE_1137

SET: SWA1:=1


STATE_1136

SET: SWA1:=1


STATE_1135

SET: SWA1:=0


STATE_1134

SET: SWA1:=1


STATE_1133

SET: SWA1:=0


STATE_1132

SET: SWA1:=0


STATE_1131

SET: SWA1:=1


STATE_1130

SET: SWA1:=1


STATE_1129

SET: SWA1:=1


STATE_1128

SET: SWA1:=0


STATE_1127

SET: SWA1:=0


STATE_1126

SET: SWA1:=0


STATE_1125

SET: SWA1:=0


STATE_1124

SET: SWA1:=0


STATE_1123

SET: SWA1:=1


STATE_1122

SET: SWA1:=0


STATE_1120

SET: SWA1:=0


STATE_1119

SET: SWA1:=0


STATE_1118

SET: SWA1:=0SET: SWB1:=1

SET: SWC1:=0

STATE_1117


SET: SWC1:=0

STATE_1116


SET: SWC1:=1

STATE_1115


SET: SWC1:=1

STATE_1114


SET: SWC1:=1

STATE_1113


SET: SWC1:=0

STATE_1112


SET: SWC1:=0

STATE_1111


SET: SWC1:=0

STATE_1110


SET: SWC1:=0

STATE_119


SET: SWC1:=0

STATE_114


SET: SWC1:=1

STATE_113


SET: SWC1:=0

STATE_2_2


SET: SWC1:=0

STATE_1121


SET: SWC1:=0

STATE_1_8STATE_1_7STATE_1_6STATE_1_5STATE_1_4STATE_1_3STATE_1_2

STATE_118

STATE_117

STATE_116

STATE_115

STATE_2_1

STATE_1_1

STATE_Flexible1

2L3_GTOS

g_r1

g_r2

g_s1

g_s2

g_t1

g_t2

TWO_LVL_3P_GTO1

C2

B6U

D1 D3 D5

D2 D4 D6

B6U1

+

V

VM1

A

B

C

G(s)

gs4

G(s)

gs3

G(s)

gs2

G(s)

gs1

I

GAIN

sum3

sum2

GAIN

I

sum5

GAIN

I

G(s)

gs5

G(s)

gs6

I

GAIN

sum8

0.00 100.00 200.00 300.00 400.00 500.00 600.00Time [ms]

-400.00

-200.00

-0.00

200.00

307.39

Y1

Curve Info

rotor_current_dTR

rotor_current_qTR

target_rotor_current_DTR

target_rotor_current_QTR

0.00 100.00 200.00 300.00 400.00 500.00 600.00Time [ms]

-50.00

-25.00

0.00

25.00

43.09

Y1

[k]

Curve Info

PTRintgain='2' pgain='0.9'

QTRintgain='2' pgain='0.9'

PRTRintgain='2' pgain='0.9'

QRTRintgain='2' pgain='0.9'

Controladores Electrónica de Potencia Diseño Mecánico

Diseño de Generador

Power Lines Transformadores Terminales HV

Interacción Fluido – Estructura

(FSI)

Simulación Multi-física

Caso de estudio

Simulación de un Generador Síncrono de Flujo

Axial de Imánes Permanentes de 3 kW para

aplicaciones de energía eólica

Analytical Pre-design

𝒑 =𝟏𝟐𝟎𝒇𝒏𝒐𝒎

𝒏𝒏𝒐𝒎

Rated speed: 297 rpm Rated frequency: 50 Hz

𝟎. 𝟓 =𝟐𝑸

𝟑𝒑

𝑩𝒎𝒈 =𝑩𝒓

𝟏 + 𝝁𝒓𝒓𝒆𝒄(𝒈 + 𝟎. 𝟓𝒕𝒘)

𝒉𝒎𝒌𝒔𝒂𝒕

𝒕𝒘 = 𝟐𝒉𝒎 − 𝟐𝒈

«Axial Flux Permanent Magnet Generator Design

for Low Cost Manufacturing of Small Wind

Turbines»

K.C. Latoufis, G.M. Messinis, P.C. Kotsampopoulos and N.D.

Hatziargyriou, WIND ENGINEERING

Volume 36, No. 4, 2012, pp. 411-442

Experimental data from:

Design Parameters

Parameter Value

Nominal Power 3 kW

Nominal Frequency 50 Hz

Pole pairs (p) 20

Coil number (Q) 15

Rotor Thickness 12 mm

Outer Radius 238.26 mm

Inner Radius 207.05

Magnet Thickness 10 mm

Radial Width 46 mm

Active lenght 30 mm

Pole Arc 0.659

Coil Thickness 13.76 mm

Turns per coil 337

Coil leg width 31.54 mm

Conductor Size 0.95 mm

• Automatic 3D Model creation from RMxprt template

• Imported geometry from CAD software

• User Defined Primitives and simple CAD operations

with the Maxwell integrated 3D Modeler

Modeling

Why not 2D? Not possible to analyze it in 2D - XY plane like

radial flux machines due to intersection between

magnets, coils and rotors. Unless simplified like

a linear generator.

Material Assignment

Permanent Magnets

• NdFeB N38H

Back iron disks

• Steel 1010

Coils

• Copper

Stator and rotor protection

• Epoxy Resin

Steel 1010 BH Curve

PM Properties definition

PM Polarization

North pole

direction

Caso de estudio 1:

Deformación axial de los discos

rotóricos debido a las fuerzas de

los imanes permanentes

Mesh created by

adaptive meshing

algorithm

ANSYS Maxwell

Magnetostatic Analysis

Case Study 1:

Axial deformation analysis

Excitations:

• Permanent Magnets

• No currents

Force calculation setup

Case Study 1:


Material definition

Mechanical Link

Parametric Setup

Maxwell – Mechanical

coupling in ANSYS

Workbench

Case Study 1:


Force mapping on disks

and magnets

Supports definition

Case Study 1:


Design Points Extra Thickness

[mm] Total Thickness

[mm] Axial Deformation

[mm]

DP 1 -5 5 0.7524

DP 2 -2.5 7.5 0.2720

DP 3 -1 9 0.1757

DP 4 (nominal) 0 10 0.1279

DP 5 1 11 0.0960

DP 6 2 12 0.0776

DP 7 3 13 0.0568

DP 8 4 14 0.0478

DP 9 5 15 0.0392

Parametric

Analysis Results

Case Study 1:


Axial deformation for

DP 6 (Thickness=12 mm)

Axial deformation: 0.077 mm

7.7% of mechanical clearance gap

Equivalent Stress plot

Case Study 1:


Caso de estudio 2:

Análisis transitorio del

Generador AFPM

Case study 2:

Transient Analysis

XY plane Symmetry

Periodic Behavior

(72 degrees)

Symmetry conditions

Boundary conditions

Symmetry Even

(Flux Normal)

Master/Slave with Symmetry

Multiplier

1/10th of the full

model

Case study 2:

Transient Analysis

Coil Terminals definition

Stranded coils:

337 conductors per coil

Case study 2:

Transient Analysis

0

LPhaseA

LPhaseB

LPhaseC

8.9ohm

R5

8.9ohm

R6

8.9ohm

R7

LabelID=IVoltmeter20

107.46ohm

R22

107.46ohm

R23

107.46ohm

R24



0

LPhaseA

LPhaseB

LPhaseC

8.9ohm

R5

8.9ohm

R6

8.9ohm

R7

D11D12D13

D14 D15 D16

100ohm

R17

220uF

C18

Model

Diode1


LabelID=VAmmeter21

Winding definition

Three cases:

• Open voltage (No load)

• Ohmic load in wye connection

• DC Rectifier and ohmic load

Case study 2:

Transient Analysis

Motion Setup Two Cases

Rated speed: 297 RPM

Low speed (cut-in): 111 RPM

Case study 2:

Transient Analysis

Open Voltage (No load) Results

Rated Speed (297 rpm) Low Speed (111 rpm)

372 Vpk 139.13 Vpk

Case study 2:

Transient Analysis

Ohmic load at Rated speed

Simulation Results Experimental Data

359 Vpk

Case study 2:

Transient Analysis

Distorted waveform due to attached rectifier bridge

Simulation Results Experimental Data

346 Vpk at Rated speed

Case study 2:

Transient Analysis

Phase currents with

attached rectifier

Phase currents with

Ohmic load

Results at rated speed

3.34 Arms 2.13 A

rms

Case study 2:

Transient Analysis

DC Output at Nominal Speed (297 RPM)

453.91 VDC

Case study 2:

Transient Analysis

Current density Vector

Field Animation Gradient of B at nominal Speed

With bridge rectifier attached

Case study 2:

Transient Analysis

Induced Eddy currents at nominal speed

Case study 2:

Transient Analysis

Copper losses

Steady State Average loss

8.2089 Watts

Steady State Average loss

18.2382 Watts

Ohmic load Full wave Rectifier

Case study 2:

Transient Analysis

Ohmic loss at rated speed - Animation

Case study 2:

Transient Analysis

Caso de estudio 3:

Análisis térmico de estado estable

Object Total Loss Scaling Factor CoilA 18.2438W 0.997425

CoilB 18.2824W 0.998005

CoilC 18.2882W 0.997932

CoilA_1 18.2864W 0.997956

CoilA_2 18.2767W 0.997672

CoilA_3 18.2955W 0.997962

CoilA_4 18.2872W 0.998252

CoilB_1 18.292W 0.997869

CoilB_2 18.274W 0.996142

CoilB_3 18.2973W 0.994436

CoilB_4 18.2438W 0.997315

CoilC_1 18.2749W 0.996835

CoilC_2 18.2819W 0.996722

CoilC_3 18.2696W 0.996404

CoilC_4 18.2944W 0.996356

Natural convection analysis

CFD Analysis needed to account

for the rotors ventilating effects

Case study 3:

Thermal analysis

Object Total Loss Scaling Factor CoilA 8.18425W 0.997273

CoilB 8.19896W 0.997556

CoilC 8.18588W 0.996386

CoilA_1 8.1873W 0.996389

CoilA_2 8.1929W 0.997967

CoilA_3 8.19003W 0.997189

CoilA_4 8.18319W 0.997465

CoilB_1 8.2052W 0.996189

CoilB_2 8.18468W 0.998582

CoilB_3 8.19016W 0.996848

CoilB_4 8.18882W 0.997117

CoilC_1 8.18214W 0.996953

CoilC_2 8.17387W 0.998343

CoilC_3 8.19136W 0.998056

CoilC_4 8.1873W 0.997052

Temperature dependent Heat

Transfer Coefficient for

Stagnant Air.

Worst case scenario

Case study 3:

Thermal analysis

Tmax = 107.22°C

18.23 W Avg loss

Case study 3:

Thermal analysis

Tmax = 65.2°C

8.2 W Avg loss

Caso de estudio 4:

Analysis de Sistema:

Co-simulación entre

Maxwell – Simplorer

Maxwell Component in

Simplorer

Case study 4:

System analysis

Full wave rectifier bridge and 3 level inverter with Low Pass LC filter

0

3LH_NSAMP

3 level natural sampling (single-phase)

_3LH_NSAMP1

C=0.01farad

C1

3LH_GTOS

g_11

g_14

g_21

g_24

g_12

g_13

g_22

g_23

_3LH_GTOS1

C=0.01farad

C2

+

V

VM1

PhaseA_in

PhaseB_in

PhaseC_in

MotionSetup1_in

PhaseA_out

PhaseB_out

PhaseC_out

MotionSetup1_out

w+

V_ROTB1

D1 D2 D3

D4 D5 D6

R2

R3

R4 C=220uF

C3

S1

TRANS1STATE_01_1

SET: cs:=0

STATE_01_2

SET: cs:=1

L1

C4 load

S2

S3

0.00 10.00 20.00 30.00 40.00 50.00 60.00 70.00Time [ms]

-5.00

-2.50

0.00

2.50

5.00

loa

d.I

[A

]

-501.13

-400.00

-200.00

0.00

200.00

400.00

523.13

Y2

[V

]

Curve Info Y Axis max

VM1.VTR Y2 454.1963

load.VTR Y2 476.5704

load.ITR load.I 4.4349

0.00 10.00 20.00 30.00 40.00 50.00 60.00 70.00Time [ms]

0.00

100.00

200.00

300.00

400.00

500.00

C3

.V [

V]

Curve Info

C3.VTR

Case study 4:

System analysis

Freq: 60 Hz

Voltage waveforms (filtered

and unfiltered)

Current waveform through

load

Case study 4: System analysis

• ANSYS enables multi-physics approach.

• Complex coupled circuits and system

analysis for generator design.

• Capacity to analyze a wide range of aspects

for wind energy applications.

• Concepts and analysis useful to design other

devices.

• That was just the beginning…

Conclusions

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