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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

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
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.
brushless dfig drive train
Brushless DFIG drive-train

Generator

DFIG

Gearbox

x3

Partially-rated

AC/AC

Generator

B’DFIG

Gearbox

x1 or x2

Partially-rated

AC/AC

brushless dfig operation
Brushless DFIG Operation
  • Synchronous mode operation
  • Converter controls
    • Real power
    • Reactive power

Synchronous speed

history of the brushless dfig
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
slide8

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

manufacturing process for 250 kw brushless dfig
Manufacturing process for 250 kW Brushless DFIG

2 winding stator,

4 pole & 8 pole

1 winding rotor,

6 pole

design process for brushless dfig

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

comparison of conventional high speed dfig with medium speed brushless dfig in a 5 mw nacelle
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

conclusions
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.

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