design and development of a 10 kw permanent magnet ... · design and development of a 10 kw...

Design and development of a 10 kW permanent magnet synchronous generator prototype

for a grid connected low wind speed wind turbine!

Asst.Prof.Dr.Chawin Chantharasenawong, Dr.Cherdchai Prapanavarat and Mr. Anon Pliensakul !

Department of Mechanical Engineering, Faculty of Engineering !

King Mongkut’s University of Technology Thonburi, Thailand !

1!

Renewable energy !

Carbon Emission

Electricity !

Introduction !

1. The carbon emission form combustion processes is considered harmful to the Earth’s atmosphere. 2. Costs of these fuels have been steadily increasing. !

Coal

Oil

Natural Gas

2!

0

10

20

30

40

50

2005

2006

2007

2008

2009

2010

2011

2012

Price (Bah

t/Litre)

!

Year !

Oil Prices in Thailand !Gasoline 95

Gasoline 91

Gasohol 95

Gasohol 91

E20

E85

Diesel

NGV

Power Plant !

Introduction !

Renewable energies !

Wind Energy !

Hydrogen Energy !

Solar Energy !

Hydro Energy !Bio Energy !

Wind energy is one of the renewable energies that have been focused. !

3!

Traditional Fuel Replacement !

Generating Capacity in EGAT’s Renewable Energy Development Plan !

PDP2010, Electricity Generating Authority of Thailand (EGAT) !

Wind energy will form part of the country’s power production in the future. !

Introduction !4!

5.778 MW capacity of wind turbines had been installed in Thailand, 2010 (*Annual Report 2010, Department of Alternative Energy Development and Efficiency) !

Air mass !

Kinetic energy !

Mechanical energy !

Electricity energy !

The wind turbine generator can be classified Into Permanent Magnet Synchronous Generator (PMSG) !

SWOT Analysis !S (strengths) •  No additional power supply for the magnet field excitation. •  Higher reliability due to the absence of mechanical components as slip rings.

W (weaknesses) •  High cost of PM. •  Difficulties to handle in manufacture.

O (opportunities) •  The Electricity Generating Authority of Thailand (EGAT) has a power development plan for power renewable energy.

T (Threats) •  Low wind speed in Thailand.

Introduction !5!

Scopes !Design procedure and development processes of a 10 kW Permanent Magnet Synchronous Generator (PMSG) prototype for HAWT (Grid connected).

6!

-Testing the generator by driving it using an 11 kW AC motor to determine its characteristics.

Analysis of the generator test results and the wind turbine integration. !

Generator Design Processes !

Wind Energy Conversion !

The power produced by the wind turbine rotor is given by !

31 ( )2 p t nP C A A vρ= −

Wind turbine permanent magnet synchronous generator design!

Q = LCoD2ns

120s

fnp

=

(1) !

(2) !

Relationships between the generator diameter and its rotation speed !

(3) !

7!

Q = kVA Rating of machine !L = Stator core length !

oC2D

= Output coefficient != Stator Bore (m) !

sn = Synchronous speed (rps)!f = Frequency (Hz) !p = Amount of pole!

Wind Energy Conversion !

The power produced by the wind turbine rotor is given by !

Wind turbine Induction generator !

Wind turbine Permanent magnet generator !

31 ( )2 p t nP C A A vρ= − (3) !

The turbine rotor swept area !( )tA

The generator cross section

area !( )nA

Generator Design Processes !8!

Larger area !

Data Reduction !

The relationship between the PMSG diameter, rotation sped and material cost estimates !

Stator Diameter

(m)

Generator speed (rpm)

%Remaining Area (m2)

Cost Estimated

(Baht) 0.5 366 99.7 113,960 1.0 130 98.6 415,611 1.5 71 96.9 987,384 2.0 46 94.5 1,742,902 2.5 33 91.3 2,710,013 3.0 25 87.5 3,888,312 3.5 20 83.0 5,277,501

Cost! Raw Material !

Machining

1 meter of stator diameter was selected due to manufacturing and budget constraints. !

%Remaining area !

9!

10 kW wind turbine generator prototype (grid connected design)

Parameters and characteristics of the designed 10 kW PMSG for HAWT !

10 kW wind turbine generator design Power output (P) 10 kW

Line Voltage 400 V Frequency 50 Hz

Phase 3 Synchronous speed 130 rpm

Inner Stator bore (D) 1000 mm Stator Length (L) 67 mm

Pole type Salient Pole Amount of poles 46 Air gap length 1 mm

10!

PMSG Construction!The 10 kW PMSG consists of the following main parts !

Stator !

Rotor !Silicon steel sheets are cut using laser in order to satisfy this high precision requirement !

*1 USD = 30.84 Baht (Bank of Thailand, Feb. 2011) !

Item Quality Price Working time

Stator and Rotor 134 sheets 199,727 Baht

(6,465.31 USD*) Feb. - Mar.

2011

11 !


Items ! Quantities ! Prices! Working time !

Stator and Rotor! 134 sheets!

199,727 Baht (6,465.31 USD)!

Feb. - Mar. 2011!

Pole Shoe! 6,164 sheets!80,506 Baht

(2,637.31 USD*)!Mar. – Apr.

2011!

*1 USD = 30.5258 Baht (Bank of Thailand, March. 2011) !

1 Sheet!

134 Sheets were assembled for 1 pole. !Stamping process !

12!


Item ! Quality ! Price ! Working time !


199,727 Baht (6,465.31 USD)!

Feb. - Mar. 2011!

Pole Shoe! 6,164 sheets!80,506 Baht (2,637.31 USD)!

Mar. – Apr. 2011!

Magnet ! 46 pieces!37,205 Baht

(1,218.81 USD*)! Mar. 2010 !

*1 USD = 30.5258 Baht (Bank of Thailand, March. 2011) !

The NdFeB permanent magnet contains 15 pieces per 1 pole.

Magnets are arranged in a specially prepared polyxymethylene (POM) block.

13!




199,727 Baht (6,465.31 USD)!

Feb. - Mar. 2011!


Mar. – Apr. 2011!

Magnet ! 46 pieces!37,205 Baht (1,218.81 USD)! Mar. 2011 !

Generator Frame !

1 piece !80,250 Baht

(2660.95 USD*)!Apr. – May

2011!Cold-rolled and welded at the end to from a tubular shape. !

Be turned on a lathe. !

*1 USD = 30.1584 Baht (Bank of Thailand, April. 2011) !

14!




199,727 Baht (6,465.31 USD)!

Feb. - Mar. 2011!


Mar. – Apr. 2011!


Generator Frame !

1 piece !80,250 Baht (2,660.95 USD)!

Apr. – May 2011!

Copper winding!

1 piece !69,550 Baht

(2,288.82 USD*)!May – Jun.

2011!

*1 USD = 30.3868 Baht (Bank of Thailand, May. 2011) !

The copper winding was outsourced. !

15!


Item ! Quality ! Cost! Working time !


199,727 Baht (6,465.31 USD)!

Feb. - Mar. 2011!


Mar. – Apr. 2011!


Generator Frame !

1 piece !80,250 Baht (2,660.95 USD)!

Apr. – May 2011!

Copper winding!

1 piece !69,550 Baht (2,288.82 USD)!

May – Jun. 2011!

Assembly! 1 piece ! No Wage* ! Jul. 2011 !

Total Cost! 467,238 Baht (15,271.2 USD)!

*The assembly processes were Completed at KMUTT mechanical workshop.!

16!

PMSG Testing Procedure!

Synchronizing board Grid

PMSG for wind turbine!

Oscilloscope

Watt and P.F. meter

Amp. meter

Wave Form Voltage

Power output

Power Factor

P.F.

W

Current

Output!

Data Record !

Input!11 kW AC Motor!

Gear ratio 6.55 : 1 !Inverter !

17!

Relationship between the shaft rotating speed and the phase voltage. (Before Connected Grid) !

Results and Discussions !

50 Hz!

18!

240V !

The generator rotation speed at 130 rpm!

240 Voltage (Line – Neutral) !

50 Hz!

Generator can connected the grid !

Results and Discussions !The PMSG power output is controlled by the grid connection electronics

to match the Electricity Generation Authority of Thailand (EGAT). !

Maximum power output 6.8 kW !

Armature reaction !

19!

Results and Discussions !The generator’s efficiency has been found to be in the region of 75%-84% depending on the power input. !

20!

0.75!

0.84!

0.8! 0.8! 0.79! 0.78! 0.78!

Generator Connected Wind Turbine !

Wind Gear !

Wind Speed !

Turbine RPM = 10 RPM !

PMSG Voltage!

PMSG

Gear Ratio 2 : 1 !

Gen. RPM = 20 RPM!

Example!

21!

0

100

200

300

400

500

600

0 1 2 3 4 5 6 7 8 9 10

Turb

ine

rota

tion

spee

ds (R

PM)

Wind speeds (m/s)

Gearless

Gear ratio 2:1

Gear ratio 3:1

Gear ratio 4:1

Gear ratio 5:1

Gear ratio 6.55:1 Synchronous speed 130 rpm

91.5!

183.0!

274.5!

366.0!

457.5!

549.0!

640.0!

732.0!

823.5!

915.0!

1006.5!

1098.0!

PMSG

Vol

tage

(V)!

Cut-in !

Having Gear !

No Power electronic !

Next Action plan !Grid connected point !


Wind Gear !

Wind Speed !

Turbine RPM = 10 RPM !

PMSG Voltage!

PMSG

Gear Ratio 2 : 1 !

Gen. RPM = 20 RPM!

Example!

21!

0

100

200

300

400

500

600

0 1 2 3 4 5 6 7 8 9 10

Turb

ine

rota

tion

spee

ds (R

PM)

Wind speeds (m/s)

Gearless

Gear ratio 2:1

Gear ratio 3:1

Gear ratio 4:1

Gear ratio 5:1


91.5!

183.0!

274.5!

366.0!

457.5!

549.0!

640.0!

732.0!

823.5!

915.0!

1006.5!

1098.0!

PMSG

Vol

tage

(V)!

Cut-in !

Having Gear !

No Power electronic !

Next Action plan !


PMSG

Grid Power

Electronic !

Wind Speed !

Turbine RPM !

PMSG Voltage!

Gearless !

22!

Example!

0

100

200

300

400

500

600

0 1 2 3 4 5 6 7 8 9 10

Turb

ine

rota

tion

spee

ds (R

PM)

Wind speeds (m/s)

Gearless

Gear ratio 2:1

Gear ratio 3:1

Gear ratio 4:1

Gear ratio 5:1


91.5!

183.0!

274.5!

366.0!

457.5!

549.0!

640.0!

732.0!

823.5!

915.0!

1006.5!

1098.0!

PMSG

Vol

tage

(V)!

Cut-in !

No Gear !

Having Power electronic !

Next Action plan !

Conclusions !23!

To achieve the power rating of 10 kW, a higher magnetic field intensity is required.

The large Cross section area of PMSG also causes flow blockage which reduces the rotor effective swept area.

The production is possible with technology in Thailand.

Thank you !

Q&A!Asst.Prof.Dr.Chawin Chantharasenawong,

Dr.Cherdchai Prapanavarat and Mr. Anon Pliensakul !Department of Mechanical Engineering, Faculty of Engineering !

King Mongkut’s University of Technology Thonburi, Thailand !

Results and Discussions !

0

0.2

0.4

0.6

0.8

1

0.6 1.8 2.6 3.6 4.4 5.2 6 6.6

Pow

er F

acto

r

Generator Power output (kW)

Lag Lead

At an output voltage of 240 grid connected !

The PMSG current output when power output up to 6.8 kW. !

The PMSG power factor ranges between 0.9 – 1.0 !

The power electronic devices efficiency and total Efficiency when connected power electronic device. !

Ma nufac ture r / Mod el Na me

Grid Inverter

E fficienc y

A verage Gene ra tor Efficiency

T otal E ffic ie ncy

W uxi m e te c M odel GW G -10 k5 00TL -T V

95% 79.5 % 75.5%

Yueqing Sandi Mod el SDS-10kw 97% 79.5 % 77.1%

Ginlong Mode l GCI-10k 97.5% 79.5 % 77.5%

*Information is taken from respective manufacturers’ websites. !

design and development of a 10 kw permanent magnet ... · design and development of a 10 kw...

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