Permanent Magnet Synchronous Generator Design Solution for Large Direct-Drive Wind Turbines


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Abstract


Turbine power generation in the range of 8-12 MW and beyond will be needed to accelerate the global growth of wind energy production and meet renewable energy targets. Described here is a theoretical framework for a compact, high-power, direct-drive permanent magnet synchronous generator (DD PMSG) that uses direct liquid cooling (LC) of the stator windings to efficiently manage generator cooling, and therefore the temperature of the windings and permanent magnets. Direct liquid cooling enables a significantly lighter weight generator, and this lower mass design promises reliable and efficient power generation at substantially lower cost. It is clear that much improved cooling will become a necessity for DD-PMSGs targeting wind turbine applications as power ratings continue to grow. Discussed first here is the analysis of air gap tangential stress and its effect on generator torque density and efficiency. Major LC DD-PMSG design issues are presented along with a suggested integrated design solution in the form of an 8 MW example. Next, a fabricated, instrumented, and tested cooling loop is described. This prototype features a pair of typical LC tooth coils embedded in a lamination stack attached to a forced recirculation liquid cooling loop. Finally, operating characteristics are evaluated for a large wind turbine equipped with the proposed 8 MW LC DD-PMSG revealing annual energy output and load factor calculated for typical North Sea wind conditions. Ultimately, the higher partial load efficiency inherent in the LC DD PMSG design results in more efficient total electricity production.
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Keywords


Directly Cooled Winding; Permanent Magnet; Synchronous Generator; Wind Turbine

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