Energy Systems Research at Oregon State...

Oregon State University, School of Electrical Engineering and Computer Science

Energy Systems Research at Oregon State University

Annette von Jouanne, Ph.D., P.E.School of Electrical Engineering and Computer Science

Oregon State University


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Outline• Brief Overview of OSU’s main Energy Systems Lab –

The Motor Systems Resource Facility (MSRF)-Capabilities-Example Recent Research and Testing Projects

• Current Main Research Thrusts-NAVY LCAC (Landing Craft, Air Cushion) Hovercraft-Ocean Energy Research-Hybrid Electric Tank Power Quality


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Motor Systems Resource Facility (MSRF)

A Machines, Drives, Power Electronics, Renewables and Power Quality Research and Testing Laboratory at OSU

Fully operational since 1996

Founding Sponsors:– Electric Power Research Institute (EPRI)– Bonneville Power Administration (BPA)– US Department of Energy (USDOE)– Pacific Gas & Electric (PG&E)

Co-Directed by Drs. A. Wallace and A. von Jouanne


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Create a unique research and testing facility where our students can obtain an enhanced, hands-on industrial experience, while meeting the needs of the Energy Systems Industry. Highly flexible capabilities:

– converters, drives, power supplies, filters and controllers– motors, generators and renewables (can regenerate)– wide power and speed range

Highly efficient: only system losses dissipated.

OBJECTIVES OF THE MSRF


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MSRF CAPABILITIES

750 kVA Adjustable Power Supply Variable voltage input (0-600 VAC), 600 A rating Three phase adjustment while loaded (balanced or unbalanced)

Testbeds for Motors, Generators and Controllers up to 300 hp Four Quadrant Dynamometer Converter

Programmable Torque & Speed Modes Vector Control for dynamic testing over the full speed range

(0-4000 rpm, bi-directional) 120 kVA Three-Phase Programmable Source (solid state

amplifier) Vph_max = 392V, VL_max = 680Vrms (transient) Vph_max = 306V, VL_max = 530Vrms (steady-state) Peak phase current, 166A Frequency range, 45Hz to 2kHz

Controllable Pulse Generator Power Supply 0-10kV, 0-10kHz, up to 30A Controllable rise-time down to 10ns, and pulse-width Modular with DC power supply, function generator, power switch

modules (cascaded IGBTs) and rise-time filters


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Schematic of the Main Testbeds in the MSRF

LockedRotor 500 hp 350 hp 250 hp 125 hp 50 hp 30 hp

Con

trol C

ircui

t Auto 480V: 0 to 600VTransformer

MotorStarter

MotorStarter

MCC-1

MCC-2

(500 hp) (50 hp)

MotoracDyno Drive

Torque/SpeedTransducer System Under Test

300 hp Test Bed

300 hpConverter

dc supplyor resistive

load

Motor dcDynoDrive

Torque/SpeedTransducerSystem Under Test

15 hp Test Bed

120kVAProgrammable

Source

Test Loads(ASDs,

motors, etc.)

DedicatedUtility Supply (750 kVA)

PQTest

Platform

BuildingPower

EmergencyS/D

JUNCTIONBOX

DATAACQUISITIONCOMPUTER

CONTROL ROOM

DYNAMOMETERCONTROL

COMPUTER

MOTOR START/STOP BUTTONS


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MSRF – Partial Aerial View


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MSRF 300 hp Test Bed (with Hybrid Electric Vehicle Generator)


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EXAMPLE RECENT MSRF PROJECTS Landing Craft, Air Cushion (LCAC Hovercraft), 2003- (U.S. Navy) Ocean Energy Extraction, 2003-2005, (NSF, Oregon Sea Grant) Hybrid Tank Power Quality Issues, 2003-4, (United Defense) Motor Controller/Escalator Testing, 2003-4, (Power Eff. Corp.) Escalator Reliability, 2003, (Kone Elevator) Motor Efficiency Estimators, Summer 2003, (NEEA) Electric Propulsion Coil Testing, 2001-03, (U.S. Navy) Piezoelectric-based Micro Power Generator, 2001-03, (DARPA) 50kVA Multilevel Inverter providing DC-Link Balancing, Ride-

Through Enhancement and Common-Mode Voltage Elimination,2000-2002, (NSF)

Generator for Hybrid Electric Vehicles, 1999-2000, (Ford ) Resonant Adjustable Speed Drive, 2001, (Spellman High Voltage) Permanent Magnet Dynamometer Brake, 2000, (MagnaDrive Corp.) Rapid-Disconnect Permanent-Magnet Coupling, 2000, (MagnaDrive

Corp.) Permanent-Magnet Adjustable-Speed Coupling, Summer 1999,

(NEEA, MagnaDrive Corp.) Motor/ASD Application Issues, ongoing


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Students receive an enhanced, hand’s-on industrial experience Have Conducted Projects in a wide variety of areas in

Energy Systems High Power, High Quality Installation Highly Adaptable: Equipment and Personnel Good Reputation with our Industry Partners OSU Procedures in Place

STRENGTHS OF THE MSRF


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Navy STTR Phase I Contract: LCAC (Landing Craft Air Cushion) High Performance Hovercraft (with Chinook Power)

ObjectivesDevelop improved actuator systems for steering vanes in thrust engine exhausts, thus reducing the maintenance, complexity, and failure modes associated with conventional hydraulic systems.


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Existing Technology to be Replaced(High maintenance Hydraulics)

Solution:Replace hydraulic system with a Switched Reluctance Motor (SRM)/drive, operating as a linear actuator “screw”

Ave LCAC is 16,000hp, (8,000hp propulsion, 8,000hp lift)

Major Specs:1100lbs oper. thrust5.1 inches of travelSpeed: 5.5 inches/sWt: 12lbs w/out fluid


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Mock-up Installation

Drive electronics

mounted inside of nacelle leg

(for protection)

Note:

Vibration is a huge issue…

SRM/leadscrew actuator

Absolute resolver

(as a direct reading sensor, would give redundancy)

For fail-safe oper., would have “home sensor”, and two end-of-travel sensors


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SRM/leadscrew actuator

Thrust Shaft

SRM

Roller Nut

Roller Screw

See improvements in speed, thrust, maintenance, wear, lifetime and reliability when compared to the better known "power screw" and "ball screw" configurations


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Why Choice of SRM/Drive• Has ideal characteristics for the combat

environment– High power density– Robust Design (rotor is a simple stack of

laminations, without any windings or magnets)– Fault tolerant (limp home capability, e.g. during

loss of phase)


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MOTOR SYSTEM CLASS CANDIDATES

FEATURE LINEAR MOTORS

INDUCTION MOTORS

DC MOTORS

PERMANENTMAGNET MOTORS

RELUCTANCEMOTORS

POWER DENSITY

A A A A

ROBUSTNESS A A A DAMAGE

TOLERANCE A

CONTROLLABILITY A A A

A – Acceptable


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RELUCTANCE MOTOR COMPARISON

SYNCHRONOUSRELUCTANCE

FLUX-SWITCHING STEPPER

SWITCHEDRELUCTANCE

MAINTENANCE EXCELLENT EXCELLENT GOOD EXCELLENTPOWERDENSITY

FAIR GOOD ? EXCELLENT EXCELLENT

POSITIONHOLDING

GOOD FAIR ? FAIR EXCELLENT

POSITIONCONTROL

GOOD GOOD GOOD EXCELLENT

TORQUERIPPLE

EXCELLENT POOR POOR POOR

CONTROLS COMPLEX COMPLEX SIMPLE COMPLEX

TEMPERATURETOLERANCE

EXCELLENT EXCELLENT FAIR EXCELLENT

SHOCKTOLERANCE

EXCELLENT EXCELLENT GOOD EXCELLENT

DAMAGETOLERANCE

FAIR FAIR FAIR EXCELLENT

COST FAIR GOOD GOOD FAIR


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MOTOR & POWER ELECTRONICS

Vdc

-

+

A B C D

Salientsor poles

Rotor

A

A'

B

B'

C'

D'

C

D

8/6 SRM - When a stator phase is energized, the most adjacent rotor pole-pair is attracted towards the energized stator in order to minimize the reluctance of the magnetic path. Therefore, it is possible to develop constant torque in either direction of rotation by energizing consecutive phases in succession.

Classic Bridge Converter favored(importance of robustness/fault tolerance)


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DESIGN PROCESS FOR SRM

PerformanceSpecification

Basic Design(SRDaS)

Check/Refine(FEA)

MaterialPerturbations

DimensionPerturbations

Mechanical OuputRequirements

Electrical InputCapacity

"Optimal"NO NO

YES


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SRDaS (Switched Reluctance Design and Simulation) showing size/geometry specs.Dev. by Dr. Peter Rasmussen, Aalborg University, Denmark


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FEA MAGNETIC FLUX VISUALIZATIONS(using Maxwell 2D)

Aligned position Unaligned position


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Leadscrew & Motor

Calculations(115Vp/200V/400Hz)

Parameter Formula Value Unit

Stroke 5.6 inch

Operating thrust 1,100 Lb

Speed 5.5 in / sec

Thread lead 0.08 in / rev

Rotational speed of screw 69.85 rev / sec

Rotational speed of screw in RPM 4,191 RPM

Assumed screw efficiency 80% %

Screw outer diameter in inches 0.79 inches

Mechanical advantage of the screw 25.1

Force applied to the screw 44 lbf

Motor output torque 17 in*lbf

Output torque in Newton meters 1.95 N*m

Angular speed of screw 438.9 Rad/sec

Min. output power of the motor,W 854.4 Watts

sF

v

l

lvn r /

d

ldMA s

sscrew MAFF /

2/* dFT screw

rn 2

TPOutMin

T

rn


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SRM SYSTEM PHOTOS

SRM controller

Stator

Rotor

3ph, 120V, ½ hpPosition detection by signal injection


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VERTICAL THRUST

PLATFORM(SRM rigged to lift a load)


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RESULTS OF VERTICAL THRUST PLATFORM

0

20

40

60

80

100

120

140

160

0 1 2 3 4 5 6 7 8

Phase Current (A)

Load

Wei

ght (

lbs)

A 140lb weight can be lifted with the setup (limited by this SRM/contr.), shows trend that thrust can be further improved (req. operating thrust is up to 1100lbs)


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Research Thrust: Ocean Energy Extraction

• It is estimated that if 0.2% of the ocean’s untapped energy could be harnessed, it could provide power sufficient for the entire world.

• OSU is the Prime Location to conduct ocean wave energy extraction research: - Motor Systems Resource Facility (MSRF)- Hinsdale Wave Research Lab- Wave energy potentials of the Oregon coast.


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Power from WavesAverage of 5 buoys off the Oregon coast over past 10 years

Average Seasonal Wave Power

0

20

40

60

80

100

120

J F M A M J J A S O N Dmonths

Av.

Pow

er, k

W/m

Power from a wave is kW/m of crest length (distance along an individual crest) = the density of sea water = 1025 kg/m3g = acceleration due to gravity = 9.8 m/s/sT = period of wave (s) (averages 8s in the winter to 6s in the summer)H = wave height (m) (averages 3.5m in the winter to 1.5m in the summer)

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22THgP

(From National Data Buoy Center)


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Our Planned Devices and Goals

Direct Drive Buoy(Current Focus)

• Simplify the current buoy technology

• Avoid hydraulic based units, looking at direct drive rollerscrew and linear PM gen. systems

• Increase lifespan and decrease maintenance

Oscillating Water Column(Will also be fully investigated)

• Create novel approach • Simplify the units, introduce

modularity with flexibility• Investigate Advanced

Composite Materials• Bring overall costs down

Must be Survivable, Reliable, and Maintainablewith efficient and high quality power take-off systems


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Oscillating Water Column Concept


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Hydraulic AquaBuoy Prototype System(We’ll be developing the Power Take-off (PTO) system for this unit)


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OSU is Currently Investigating Two Novel Direct Drive Buoy Approaches:

Exploring Roller Screw Concept(allows increased Gen speeds)Permanent Magnet Linear

Generator


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OSU’s air gap wound, permanent magnet, linear generator buoy

Uses the vertical motion of the waves to power a linear generator (shaft anchored to sea floor, floater moves armature coils relative to PM

translator to induce voltages)


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OSU’s air gap wound, permanent magnet, linear generator

The translator shaft has an alternating assembly of high permeability steel pole tip pieces (needed for the transfer and direction of flux) and high density Neodymium-iron-boron magnets

The armature coils are spirally encased with electrical lamination steel (outer grey) to provide for flux coupling through the generator.

Translator, air gap, plastic tube (aqua),Armature coils (yellow), steel lamination


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Armature Coils of the air gap wound, PM, linear generator

The armature consists of a thin walled plastic tube (aqua) wrapped with copper magnet wire (yellow) forming eight individual coil sections spaced such that they are 90 degrees out of phase with each adjacent section (for two phase application).

Showing One PhaseConstructional Section

Translator, air gap, plastic tube (aqua),Armature coils (yellow), steel lamination


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Actual Armature (top) and Translator Shaft (below)

Translator shaft (total 32cm long), alternating pole pieces and magnets (magnet poles opposed to double the available flux). The steel pole tip pieces are threaded for ease of assembly on nonmagnetic shaft.

Magnets: N-35, Ni coating, outer dia. 45mm, inner dia. 20mm, thickness10mm

Armature coils wrapped on plastic tube, using Al shaft for support


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Actual Translator Shaft in Armature

Armature shown with Aluminum casing around steel laminations


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Direct Drive Buoy Based on a Novel Roller Screw Concept

A float/spring will be attached to the nut, moving the nut up and down approximately 0.45m above and 0.45m below the equilibrium position as the water moves up and down.

It is envisioned that a generator will be coupled to the end of the screw to be rotated by it. The up and down motion will make the screw rotate in a clockwise and counter clockwise direction, moving the rotor of the generator to generate electricity.


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PM Synchronous Generator in Dynamic Reciprocating ModeSine driven Speed/Wave Profile Enabled by Programmable Dyno-max speed avail. in given time (T =3.5s)is 262rpm clockwise to 262 counter cw

Output line voltageand three-phase currents modulated by the speed of rotation,Showing correlation between min. and max. speedsand generator output power


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Our Planned R&D ProcessCurrently Funded Work

• Initial research and development into the prototypes and power take-off (PTO) systems

• Following the R&D we will experimentally simulate the electrical characteristics in the MSRF (generators, controllers and converters, PTO etc.), with regeneration back onto the utility grid

Next Stage Plans with Future Funding • Build larger scale prototype models to test in the

Hinsdale Wave Research Lab• Testing/demonstration of working devices off the

Oregon Coast


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United Defense Contracts

• Research on the Power Quality issues involved with Hybrid Electric Tanks (has “highly sensitive” status, thus detailed discussion must be avoided)

• Analyzing the harmonics on the main bus while considering multiple (proprietary) converter loads. (includes analytical open-form derivations, closed-form solutions, simulation and experimental verification, as well as investigation mitigation techniques)

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