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Final Design Report - Senior Design

1. High Side Vo Vb Vc Sto or Side Voltage Sensor Board BipolarT5 V In 1 A va Vb Rotor Side Voltage lt Sensor Boord gt p Measurement Location for Current Sensor 1 Line 1 0 Measurement Location for Current Sensor 2 Line B1 V Measurement Location for Current Sensor 3 Line C1 W BipolarT5 V In e ooo ovco 538 2305 SARO Measurement Locati Current Sensor 2 Line 3 Measurement Locati Current Sensor 3 Line W3 W Measurement Location for Current Sensor 1 Line U3 U on for on for 2 olco 0222 23202 25308 Low Side N Bipolor 15V Out AHH Bipolar 15V Out f Bipolor 15V Out H Bipolar 15V Out Bipolar 15V Out E Bipolar 15V Out Voltage Supply Voltage Divider Board Rotor Crowbar Resistor 3 Rotor Crowbar B Resistor 2 E2 Rotor Crowbar lt G2 Resistor 1 OS CI Resistor 2 55 122 DC
2. PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES D Fl G IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO THIRD ANGLE PROJECTION ME DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION ENGINEERIN OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED marra Aluminum DEFAULT TOLERANCES ASD Power Connection Plate UNIVERSITY OF IDAHO reas 1 DATE ME DEPARIMENT 1 brawser John Feusi 3 28 2013 part m sca 1 1 sue 7 OF 8 Power Input Plate SLDPRT FILE NAME D21 3x 0 25 THRU 3 0313 1 7813 2 7813 0 7813 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES D FIG IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO THIRD ANGLE PROJECTION ME DEPARTMENT ANY REPRODUCTION IN PART EN GI NEERIN G OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF UNIVERSITY OF IDAHO ME DEPARTMENT IS A PROHIBITED materia Zinc Plated Steel UNIVERSITY OF IDAHO ME DEPARTMENT DEFAULT TOLERANCES osscrenon Connecting Plate Style 5 for Castors oe 1 DATE X AY T DRAWN se 11 8 2012 eere B 7 m 4 X XXX 002 huename Connecting Plate Style 5 SLDPRT sca 1 2 sue 8 OF 8
3. lt gt aoe NY 2 25 2 00 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES G 00 IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO THIRD ANGLE PROJECTION E ENGINEERING 2 125 PROHIBITED materia Steel Le 3 00 DEFAULT TOLERANCES Right 2560 Mounting Block UNIVERSITY OF IDAHO BY DATE ME DEPARTMENT brawser John Feusi 1 28 2013 5 m 2 X XXX 1 002 2561 Block R SLDPRT sca 1 2 see 6 OF 12 4 x 52 THRU 10 00 21 375 D8 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO ME DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF UNIVERSITY OF IDAHO ME DEPARTMENT IS DIMENSIONS ARE IN INCHES THIRD ANGLE PROJECTION F MATERIAL ENGINEERNG DFIG PROHIBITED DEFAULT TOLERANCES besceienon NEMA 2560 Motor DATE UNIVERSITY OF IDAHO ME DEPARTMENT oe 1 xxi prawn er John Feusi 5 7 2013 PART 6 m FILE NEMA 256U SLDPRT scare 1 8 sneer 7 OF 12 D9 4X 21 THRU 1 4 28 UNF THRU 8 00 1 1 3125
4. D22 DFIG ENGINEERING UNIVERSITY OF IDAHO ME DEPARTMENT 5 8 2013 DIMENSIONS ARE IN INCHES THIRD ANGLE PROJECTION F 2x 13 Strut 55 228 50262 Qu awney John Feusi 23 50 3 00 5 69 20 402 22 402 26 563 10x 2 0 38 THRU 12x 0 27 H THRU 4 00 28 00 30 00 35 50 D23 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO ME DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED DIMENSIONS ARE IN INCHES THIRD ANGLE PROJECTION Gy 7 materia Hardwood ENGINEERING DFIG DEFAULT TOLERANCES bescernon Doll UNIVERSITY OF IDAHO DATE ME DEPARTMENT 5 7 2013 m NEAS 1 rae prawn sr John Feusi X XXX 002 Dolly SLDPRT scare 1 8 2 OF 10 0 56 9 16 THRU 54 2 50 0 75 Lid 0 18 16 THRU 16 13 15 00 14 38 0 28 THRU 18 75 0 27 H THRU 24 00 3 25 0 8125 2 72 0 75 8 359 8 75 9 875 m 19 75 PROPRIETARY AND
5. brawwer John Feusi 3 28 2013 part C 6 1 Rotor Side Power Plate SLDPRT sca 1 3 sue 7 OF 10 4 00 3 575 1 5 00 6 00 6 x 0 20 0 59 6 1 0 6H 0 47 2x 0 0 21 v 0 61 1 4 28 UNF 0 50 29 ME DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED materia Steel PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES D Fl G IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO THIRD ANGLE PROJECTION ENGINEERING DEFAULT TOLERANCES pescripton 3X4X Block for SCRs UNIVERSITY OF IDAHO ME DEPARTMENT oe 1 DATE 1 brawwer John Feusi Ex 3 6 2013 part C 7 m 3x4x6 Steel Stock SLDPRT FILE sce 1 2 8 OF 10 D30 2 00 2 0 21 y 0 61 1 4 28 UNF 0 50 2x 0 15 0 51 10 24 UNC 0 38 3 00 2 75 1 50 0 425 0 25 4 00 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES D Fl G IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO THIRD ANGLE PROJECTION ME DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISS
6. DESCRIPTION Power Electronics Connection Diagram XX XX XX UNIVERSITY OF IDAHO ECE DEPARTMENT IDRAWN BY Wes Matej DATE 5 8 2013 N A 1 FILENAME Electrical Connections SLDPRT see 1 OF 1 scac 1 1
7. REPRODUCTION IN PART OR AS WHOLE WITHOUT THE WRITTEN PERMISSION E N GI N E E R N G OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED materia Plexiglas DEFAULT TOLERANCES ASD Motor Connection Plate UNIVERSITY OF IDAHO reas 1 DATE ME DEPARIMENT John Feusi Ls 3 28 201 3 part B 4 m X XXX sca 1 1 sue 5 OF 8 Motor Output Plate SLDPRT FILE NAME D19 4x 0 39 THRU 4x 33 64 THRU ALL H9 LO a N 11 i TM BIN 0 34 0 50 1 00 3 50 PROPRIETARY AND CONFIDENTIAL 00 xr p THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES DFIG IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO THIRD ANGLE PROJECTION 6 ME DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION EN G INEERIN G OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED materia Plexiglas UNIVERSITY OF IDAHO ME DEPARTMENT DEFAULT TOLERANCES ASD Ground Connection Plate 1 DATE 1 brawwer John Feusi bs 12 3 2012 part B 5 1 SHEET OF 8 Ground Plate SLDPRT sca 1 2 FILE NAME 4 x 0 39 THRU D20 Volts 208 220 230 240 AC 3 Phase Hz 48 63 1 19 THRU
8. Our ultimate goal for this project was to have the test bed system fully operational with the microcontrollers that govern the power and DFIG rotor side converters programmed with a control scheme Design Report Doubly Fed Induction Generator Test Bed 3 3 Project Plan 3 1 Responsibilities As there were only three members on this team most of the responsibilities were shared However certain members were delegated specific tasks John Feusi s main tasks were mechanical component design and maintaining the project schedule and accounts Wes Matej s specific responsibilities included the electrical component design and assembling team meeting presentations The programming and implementation of the microcontrollers fell under the Carlos Solis s responsibilities Shared responsibilities include research overall system design specifying and procuring parts testing and assembling purchased equipment maintaining records of work accomplished and completing the coursework requirements 3 2 Schedule The main goals for the fall semester were to have all of the main components selected purchased and assembled The original schedule is shown below in Figure 2 Unfortunately we were unable to meet these deadlines By the end of the fall semester we had purchased most of the major components including the AC motor the wound rotor induction machine the adjustable speed drive the IGBT modules and the frame However the assembly of compo
9. Engraving ASD Plates 12 12 2012 414 00 414 00 50 00 Mundy s Welding Frame 1 11 2013 17 99 17 99 0 00 Radioshack HDMI Cable 1 13 2013 357 74 325 42 532 32 McMaster Carr PE Cart Hardware 1 17 2013 545 74 5535 09 510 65 Digi Key Corp Volt Transducers etc 1 17 2013 5135 00 5135 00 50 00 P amp R Sandblasting Painted Frame 1 24 2013 5464 44 5453 00 511 44 Digi Key Corp TVS amp Power Converter 1 24 2013 514 12 5498 41 515 71 Galco Electronics SCR IGBT Gate Drive 1 25 2013 5854 28 5854 28 50 00 UI Facilities Motor Blocks 2 11 2013 513 30 513 30 50 00 UI Facilities Conduit Design Report Doubly Fed Induction Generator Test Bed A2 2 13 2013 5712 13 5691 56 520 57 Digi Key Corp Power Resistors 3 8 2013 5192 02 5181 45 510 57 Digi Key Corp Power Supply Cable 4 5 2013 5695 00 5695 00 50 00 Sunrise Electronics PCBs 4 5 2013 576 52 576 52 50 00 Engraving ASD Plates 4 9 2013 539 52 532 32 57 20 Digi Key Corp Current Sensor 4 25 2013 581 49 581 49 50 00 Center Poster TOTAL 16 645 50 Additional shipping charge from facilities on motors Date Amount 5594 89 10 17 2012 58 078 81 10 30 2012 55 077 07 1 30 2013 53 156 75 4 1 2013 5927 76 Design Report Doubly Fed Induction Generator Test Bed Appendix Calculations DC Link Capacitor Sizing Determining the peak of the worst case AC inverter current 0 612 m Vac Eq
10. FILE 6 25x6 25 Deep Drawn 5 1 2 SHEET 11 OF 12 26 THRU 90 D13 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO ME DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF UNIVERSITY OF IDAHO ME DEPARTMENT IS DIMENSIONS ARE IN INCHES THIRD ANGLE PROJECTION F MATERIAL Plexiglas ENGINEERNG DFIG PROHIBITED DEFAULT TOLERANCES pescripton Connection Plate DATE UNIVERSITY OF IDAHO ME DEPARTMENT CHECKED prawn sr John Feusi bae 2 13 2013 PART 1 1 1 FILE SCIM Cover Plate SLDPRT sce 1 2 SHEET 12 OF 12 D14 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES D Fl G IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO THIRD ANGLE PROJECTION ME DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION ENGINEERIN OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED UNIVERSITY OF IDAHO ME DEPARTMENT DEFAULT TOLERANCES besceienon ASD Cart M 1 ev DATE 1 brawwer John Feusi n 5 8 2013 parra 1 sca 1 10 OF 8 ASD Cart SLD
11. Since the jaw type couplings were eliminated quickly as previously mentioned our two options were disc and bushed type sleeve couplings The disc couplings were designed to handle both axial and angular misalignment However they require much more space The other advantage that the bushed type sleeve coupling has is that it is much less expensive 5 2 Portable Components We decided to use the Unistrut to fabricate a cart for the ASD and purchase a dolly onto which we can mount a platform for the power electronics This way we were able to easily and quickly manufacture the cart while taking advantage of surplus goods For the power electronics cart we decided Design Report Doubly Fed Induction Generator Test Bed 12 to purchase a wooden dolly on which we could build a Unistrut frame We decided to go with the dolly because it would provide additional mounting space which was not an issue for the ASD cart Steel panels would be mounted onto the frame which would create a place to attach electronics to as well as provide electromagnetic shielding Plexiglas panels were mounted on either side to create panels for which the SUPERCON receptacles could be attached By using Plexiglas instead of steel like the rest of the cart we were able to tap holes directly into it which was useful for mounting printed circuit boards When deciding upon our connection scheme cables and connectors we decided to use taperfit connections for the input and 25A
12. THIRD ANGLE PROJECTION F materia Aluminum DFIG ENGINEERING DEFAULT TOLERANCES loescrenon 8X6X3 Cover Plate for ASD I O UNIVERSITY OF IDAHO ME DEPARTMENT FILE NAME oe 1 DATE CO John Feusi 12 9 2012 parte 2 m X XXX 002 Project Enclosure Plate 8x6x3 SLDPRT _ cue 1 2 sneer OF 8 D17 RO 16 3 81 1 06 075 99 0 75 5 81 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES D Fl G IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO THIRD ANGLE PROJECTION ME DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION ENGINEERIN OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED materia Aluminum UNIVERSITY OF IDAHO ME DEPARTMENT 1 SHEET 4 OF 8 CHECKED BY brawny John Feusi Es 12 9 2012 parte Project Enclosure Plate 6x4x2 SLDPRT scue 1 2 FILE NAME D18 4x 0 39 THRU 8 Phase Induction Volts 208 240 Amps 4 84 48 4 0 52 THRU 0 50 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES DFIG IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO THIRD ANGLE PROJECTION DEPARTMENT
13. CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES DFIG IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO THIRD ANGLE PROJECTION ME DEPARTMENT ANY REPRODUCTION IN PART OR AS WHOLE WITHOUT THE WRITTEN PERMISSION ENGINEERING OF UNIVERSITY OF IDAHO ME DEPARTMENTIS PROHIBITED materia 0 072 Steel UNIVERSITY OF IDAHO DATE ME DEPARTMENT DEFAULT TOLERANCES pescripon Back Plate 1 brawwer John Feusi bie 3 7 20 3 parre 2 l XXXX 002 frenan Back Plote SLDPRT sae 1 6 2x 0 19 THRU 2x 0 14 THRU 8x 0 25 THRU 4x 0 56 THRU 15 36 8 56 14 61 6 00 0 81 71250 4 25 5 00 5 75 8 75 10 92 14 00 14 75 15 50 17 25 0 50 0 99 1 25 D25 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO ME DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF UNIVERSITY OF IDAHO ME DEPARTMENT IS T PROHIBITED 18 94 EN VN DIMENSIONS ARE IN INCHES THIRD ANGLE PROJECTION materia 0 075 Steel DFIG ENGINEERING 19 75 2 gt lt gt 2 lt 2 lt 1 CHECKED DEFAULT TOLERANCES Jpescripon Front Plate DATE UNIVE
14. Ch opper ig C2EI Resistor 1 14 1 J4 2 A GATE gt J4 3 d J4 4 rmn 4 14 5 56 B 5 14 6 14 7 7 148 2 C GATES J3 1 _ 1 332 gt 7 J3 3 1 13 4 135 5 B GATE 5 J3 6 T 7 J3 7 _ 338 a C GATE 8 Enerpro Firing Board FCOAUX60 D32 I 2 3 4 T z 5 1 9 2 zi 3 08 LI I Ies 58 x 58 7 2 2 3 sad 7 Rotor Side Driver Board Connection to MicrocontrollerPicTail Prototype Board 21 ajja a 20 wa 2218 Ha PRR Es Qllm 2 9 5 5 LS Stator Side IGBT Driver Board 7 5 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO Rotor Side Driver Board Connection to MicrocontrollerPicTail Prototype Board Q 70 21 gt zxmiv 21 SIS e lt ells 12119 ds SIS Rotor Side IGBT Driver Board 7 15 PROHIBITED ECE DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF UNIVERSITY OF IDAHO ECE DEPARTMENT IS MATERIAL DFIG Engineering
15. SUPERCON connections for the output of the ASD drive This gives the ASD good compatibility with other university machines and also compatibility with the AMPS power lab Safety is always a concern when working with electrical equipment To prevent injury to a person and or damage to the equipment we decided to use different connections for the input and output of the ASD drive This will make it difficult for a user to accidentally switch the input and output connections For the power electronics cart all the connections are SUPERCON because they are more convenient to work with Connecting the DFIG is a more involved process and so it is less likely that someone will interchange the grid and rotor side without thinking 5 3 Sensors When making our final decision for the torque transducer we chose the Himmelstein MCRT 48202V 1 3 Our rationale was that it was the cheapest while providing both analog and digital outputs Furthermore it comes with a software package to support its operation We were limited in our selection of the position encoder Originally we had wanted to use a shafted encoder due to their relatively cheap cost However after we selected the doubly fed induction generator we contacted the vendor to determine whether or not the DFIG had an opposite drive end shaft We were informed that it did not and were supplied with photographs From our inspection of the photographs we concluded that using a shafted encoder would not b
16. V 42 8 32 UNC v 33 4 25 4 25 r 2 90 6x D PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES D Fl G IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO THIRD ANGLE PROJECTION ME DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION ENGINEERIN OF UNIVERSITY OF IDAHO ME DEPARTMENT I PROHIBITED UNIVERSITY OF IDAHO ME DEPARTMENT NEMA 215T Motor SCIM DEFAULT TOLERANCES bEsCRIPTION oe ae ICHECKED BY DATE 1 John Feusi Es 1 1 6 201 3 PART 9 1 sca 1 7 sue 10 OF 12 NEMA 215T SLDPRT FILE NAME 1 1 4X 22 THRU 1 50 THRU D12 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO ME DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED DIMENSIONS ARE IN INCHES THIRD ANGLE PROJECTION F materia Aluminum ENGINEERNG DFIG DEFAULT TOLERANCES pescripton Connection Box DATE UNIVERSITY OF IDAHO ME DEPARTMENT oe 1 prawney John Feusi bae 2 11 2013 PART 1 0 im 1
17. nominal operating conditions determined by the DFIG which are 10 HP and 1800 RPM we were able to calculate the resulting shaft torque which was 350 1 in Ibf This and other calculations can be found in Appendix B Using a safety factor of 3 meant that we needed a torque transducer with an operating torque of roughly 1000 in Ibf Using this criteria we narrowed our options down to three different models These models were the Himmelstein MCRT 48202V 1 3 NA the Interface 5 15 and the Futek TRS605 5 02058 We began our process of choosing a position encoder by first looking at the encoders used on the machines in the university s power lab in the Gauss Johnson building All of the encoders on the lab s machines were purchased from BEI and had position measurement resolutions of 2160 cycles turn Different rotary incremental encoders offered by BEI were compared Our options for choosing an encoder were divided into two categories shafted encoders and hollow shaft encoders Shafted encoders use a design that allows them to be placed on the end of a shaft These were preferable due to more Design Report Doubly Fed Induction Generator Test Bed 8 reasonable pricing Hollow shaft encoders have a design that enables it to be slid onto the shaft of which it is measuring the position For the current transducers we first needed to determine where we would be measuring current and what the ratings of the transducers would need to be The curr
18. starting the motor If the motor is driving another induction machine make sure that the leads for the driven machine are NOT shorted together 5 Connect the motor to the ASD using the 3 taper fit jumpers Be sure to match the labels e g U2 to U2 etc DO NOT connect the motor ground to the ASD ground The motor ground terminal is for measuring voltages only 6 Connect the ASD to the power supply using the SUPERCON jumpers Be sure to connect the neutral line of the power supply to the ASD ground terminal using the SUPERCON to taper fit jumper 7 Use the banana plug shorting bar to connect GND to DCOM on the ASD digital I O panel 8 Turnthe power supply on 9 Follow the start up instructions that begin on page 33 This model has the Assistant Control Panel so you will have the option to perform the assisted startup on page 38 For parameter values refer to the table below Parameter 1103 will have to be changed manually To turn on a digital signal connect a banana plug jumper between 24V and the desired digital signal 10 Once you have completed the setup be sure to familiarize yourself with the Assistant Control Panel p 44 63 Parameter Value Notes 9902 1 ABB Standard Mode 9904 1 Vector speed control 9905 9909 See motor nameplate 9910 0 No ID run 2001 Min Speed 2002 Max Speed 2202 5 Acceleration time 2203 5 Deceleration time 1103 0 Control panel is reference Calculated using t IxRPM 307 2xT where i
19. which can be used to help engineers and students learn more about the operation of wind turbines The specifications that we received from our client were that the system is to use a 7 5 to 10 HP and 1200 to 1800 RPM doubly fed induction generator and be run using the Analog Model Power System AMPS infrastructure provided by the University of Idaho Wind conditions are to be simulated with a Design Report Doubly Fed Induction Generator Test Bed 2 squirrel cage induction motor SCIM controlled with an adjustable speed drive ASD and connected to the shaft of the DFIG Furthermore the system is to be designed such that the control of the DFIG can be determined by the user In addition to this the system is to have all of the sensors necessary to control and evaluate the behavior of the DFIG From what our client told us we were able to develop a block diagram of the system that we wanted to create which is shown below in Figure 1 The process for designing and selecting components for this system are discussed in sections 4 and 5 More information on the protective circuits crowbar and DC chopper can be found in section 4 5 Discussion of the power and information flows in this diagram follows in section 6 Rotor Side Converter Simulate Wind Turbine IGBT Module _ L IGBT Module Power Electronics oo Grid Side Converter Figure 1 Block diagram of test bed setup for DFIG
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21. 3 e 3125 5 69 6 00 PROPRIETARY AND CONFIDENTIAL DIMENSIONS ARE IN INCHES DFIG THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO THIRD ANGLE PROJECTION DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION EN IN EER N OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED marra Sheet Metal DEFAULT TOLERANCES bescernon DFIG Connection Box UNIVERSITY OF IDAHO 1 checkeo DATE ME DEPARTMENT y John Feusi bs 2 7 2013 part 7 n sca 1 2 8 OF 12 DFIG Box SLDPRT FILE NAME D10 STATOR 1 19 THRU JL ae PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES D Fl G IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO THIRD ANGLE PROJECTION ME DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION ENGINEERN OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED materia Plexiglos UNIVERSITY OF IDAHO pesceirnon Connection Plate DEFAULT TOLERANCES LINEAR DEPARTMENT brawwer John Feusi bx 5 7 201 3 parte A 8 m sca 1 2 9 OF 12 menam Cover Plate2 SLDPRT D11 4X
22. 8 57 Mohan m 0 8 amplitude modulation ratio upper bounds Vr r 170V H on rotor side Determining the DC bus voltage V Vac Cm Using Mohan 0 612 m equation Determining the max AC power letting pf 1 The peak of worst case AC inverter current E c Vac What value of voltage ripple do we want Beginning with a capacitance value what is the resulting calculated voltage Av 06 ripple G 1 Cactink 47004F At m lt Av2 TAL Cactink2 At The resulting capacitance Av2 057V Design Report Doubly Fed Induction Generator Test Bed B2 Capacitor Discharge Resistor Sizing Plan 1 Decide how fast to discharge the capacitor t_discharge Longer times will waste less power 2 Calculate a value for the resistor so that the RC time constant is 2 3 oft discharge 3 V 2 R will tell how much power am wasting and let me size the resistor discharge 10min Cactink 4700uF V ctink 350V V clinkhigh 450V T T i T R ischarge C clink 3 discharge G esete Rdischarge gt R discharge S5 106 k 2 Vas dclink 7 Pid c n 1 439 W discharge v dclinkhigh 7 Phighvoltage Phighvoltage 2379 W Rehoose 1000 For chosen resistor V clinkhigh Rchoose Pioss 2 025 W Design Report Doubly Fed Induction Generator Test Bed B3 Heat Sink Sizing Using nominal horsepower and vol
23. Design Report for Doubly Fed Induction Generator Test Bed Prepared for Normann Fischer Principal Engineer Schweitzer Engineering Laboratories Inc Prepared by Wes Matej Undergraduate Electrical and Computer Engineering University of Idaho and Carlos Solis Undergraduate Electrical and Computer Engineering University of Idaho and John Feusi Undergraduate Mechanical Engineering University of Idaho 10 May 2012 Abstract This report documents the design process used to develop a test bed for a doubly fed induction generator to fulfill the requirements of the client Normann Fischer of Schweitzer Engineering Laboratories Inc The intent is to convey the work that has been accomplished and justify the design choices that were made This project was conducted to fulfill in part the requirements of the University of Idaho senior design capstone curriculum University of Idaho College of Engineering Moscow ID 83844 May 10 2013 Schweitzer Engineering Laboratories Inc 2350 NE Hopkins Court Pullman WA 99163 ATTN Normann Fischer Subject Doubly Fed Induction Generator Test Bed Enclosed is our final design report for the doubly fed induction generator test bed At the conclusion of our time working on this project we have designed and fully assembled the test bed system as well as completed some of the programming required to control the DFIG Our deliverables consist of a motor and generator setup mounted to a stee
24. IDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES DFIG RE OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION ENGINEERING OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED Plexiglas DEFAULT TOLERANCES Grid Side Connection Plate UNIVERSITY OF IDAHO DATE ME DEPARTMENT 1 X AY T brawwer John Feusi ze 3 28 2013 parta C 5 X XXX 002 huename Grid Side Power Plate SLDPRT sca 1 3 sueer_ 6 OF 10 8x 0 09 THRU 4 40 UNC THRU 21 19 THRU 4x 0 39 W THRU 4x 0 11 THRU 6 32 UNC THRU 0 719 028 loo 9 9 Sua i S eo S e qu xO x o LO 42 qe p oO OY a 1 587 2 375 2500 5 250 657 PROPRIETARY AND CONFIDENTIAL 9 250 THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES DFIG IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO THIRD ANGLE PROJECTION DEPARTMENT ANY REPRODUCTION IN PART EN GI G 9 375 PROHIBITED marra Plexiglas 10 281 DEFAULT TOLERANCES bescernon Rotor Side Connection Plate UNIVERSITY OF IDAHO 000 X 2s BY DATE ME DEPARTMENT
25. ION ENGINEERIN OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED materia Steel DEFAULT TOLERANCES 3 4 2 Block for IGBT UNIVERSITY OF IDAHO ME DEPARTMENT oe 1 DATE 1 brawwer John Feusi bie 4 1 201 3 parte 8 m sca 1 2 sue 9 OF 10 3x4x2 Steel Stock SLDPRT FILE NAME D31 2x 2 0 15 V 0 51 10 24 UNC 0 38 x 00 280 THRU oj 1 ES 2x 0 13 THRU These two holes are ommitted for grid side heat sink O O O N 2 515 4 7453 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES D FI G IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO THIRD ANGLE PROJECTION ME DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION EN G INEERIN G OF UNIVERSITY OF IDAHO ME DEPARTMENT IS l PROHIBITED Extruded Aluminum DEFAULT TOLERANCES pesceemow Rotor Side Heat Sink UNIVERSITY OF IDAHO ME M 1 SHEET 10 OF 10 CHECKED BY DATE prawner John Feusi b 5 7 2013 part C 9 Heat Sink CH5116 SLDPRT scate _ 1 3 FILE NAME Stator Side Connection Box Rotor Side Connection Box Rotor Side IGBT Module PM100CLAO60 Stator Side IGBT Module PM100CLAO60 DC Bus Capacitor
26. PRT FILE NAME 8 x 0 17 THRU 4 x 0 20 THRU 2 x 1 00 THRU 12x 0 39 THRU 4 x 0 39 THRU 23 00 23 25 24 00 19 00 12 75 1 1 1 015 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO NY REPROI DIMENSIONS ARE IN INCHES THIRD ANGLE PROJECTION EPRODUCTION PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED materia 0 072 Steel ENGINEERING DFIG DEFAULT TOLERANCES pescription Back Plate UNIVERSITY OF IDAHO ME DEPARTMENT ICHECKED BY DATE x zm brawwer John Feusi 5 7 201 3 1 m X XXX x 002 Funan ASD Back Plate SLDPRT sca 1 6 2 OF 8 0 5 7 81 2 O AO1 AO2 O DI2 O O 014 DIS 016 1 00 24V GND 5 81 D16 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO ME DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED DIMENSIONS ARE IN INCHES
27. RD ANGLE PROJECTION ME DEPARTMENT ANY REPRODUCTION IN OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION ENGINEERIN OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED materia Mild Steel UNIVERSITY OF IDAHO ME DEPARTMENT LINEAR X 25 Xo m 1 28 2013 parte 1 m X XXX 002 sca 1 16 3x 33 88 3 8 24 UNF Y 75 D4 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO ME DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED DIMENSIONS ARE IN INCHES THIRD ANGLE PROJECTION materia Mild Steel ENGINEERING DFIG DEFAULT TOLERANCES DEsCRIPTION Left 215T Mounting Block DATE UNIVERSITY OF IDAHO ME DEPARTMENT 1 28 2013 PART A 2 lox 2 i HON 1 LO brawwer John Feusi X XXX 002 FILE NAME 2151 Block L SLDPRT sce 1 2 OF 12 D5 3x 33 88 3 8 24 UNF Y 75 3 735 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES D Fl G IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO THIRD ANGLE PROJECTION ME DEPARTMENT ANY REPRODUCTION IN PART EN G
28. RSITY OF IDAHO ME DEPARTMENT _ John Feusi 5 8 2013 PART C 3 1 FILE Front Plate SLDPRT sca 1 5 sneer 4 OF 10 D26 4x 0 56 9 16 THRU 12 50 e 8 00 6 50 0 8125 0 902 25 9 75 18 94 19 75 _ PROPRIETARY AND CONFIDENTIAL DIMENSIONS ARE IN INCHES DFIG THE INFORMATION CONTAINED IN THIS DRAWING THIRD ANGLE PROJECTION ENGINEERING IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO ME DEPARTMENT ANY REPRODUCTION IN PART UNIVERSITY OF IDAHO ME DEPARTMENT OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF UNIVERSITY OF IDAHO ME DEPARTMENT IS 7 PROHIBITED marar 0 075 Steel DEFAULT TOLERANCES Bottom Plate 1 DATE 1 brawwer John Feusi m 5 7 2013 parte 4 m 5 OF 10 sca 1 5 Bottom Plate SLDPRT FILE NAME D27 1 19 THRU 8x 0 09 THRU 4 40 UNC THRU 1 ES 4x 0 39 W THRU e gt o lt 1 O o F noS M IS Q a e b O 88 Y Y 1 1 b 0 25 _ 4 34 _ 5 750 8 820 9 688 10 281 pa 11 000 PROPRIETARY AND CONF
29. Sincerely DFIG Engineering Table of Contents Executive Summa u z epe RR IE d rete eet tien i in eh aia ee d tende 111 Back Ground MENU CDL e 1 2 Problem ine spa e puas 1 3 Project Plan yn P eee fie uet eec t ease pa a Aaa 3 3 1 Responsibilities ace ete He I EU NC ER De 3 32 Schedule beet rte et ep P ertet ege c 3 4 Concepts Considered 2 ene na aa ieee a A A es R Se lees 5 41 Induction Machines u inttr tecto eee tete eei better ete lee 3 4 2 Mechanical work a tenente teret ete are 6 4 3 Sensors i duro ctae esame tetas dis 7 44 Power laudos iba 8 45 Self Protection Circuits rette aii 9 S Concept Selection ene ie Re et ee lose ee ae E saq p ete a eoe get 10 5 1 Critical Components a Sua e Ue LER idet den ittis 10 2 2 Portable Components reinen eruere aate iere reete 11 tute Ete ee e acte Pa eL 12 54 Power Electronics a E de Ee et a e Hte o ete b d Et d 13 5 self Protection p ert ette lees tr tee rte AS Ai 14 6 System Architecture e E e s e ae 14 sott eret ie e ter B 17 G EUtULS X E 18 9 Summary D pP ORE OO CE EE Res 18 Appendix A ze una eee dd ett e eee mn Al A
30. ction of the equipment and the fact that the Powerex would require more assembly and component selection Taking all of this into consideration we decided to go with the PM 100CLAO60 With the IGBT module selected we could then select a heat sink Using information from the IGBT module datasheet we were able to calculate the maximum allowable thermal resistance for the heat sink See appendix B for more details Based off of our calculations we determined that we needed a heat sink with a thermal resistance of no more than 0 09 C W The recommended heat sink for our module was the CH5116 from C amp H Technology This recommendation was corroborated by our calculations When making a decision on the selection of a DC link capacitor several capacitors were compared from Cornell Dubilier and United Chemi Con With voltage ripple calculations it was decided that a capacitance value around 3000uF or higher would be suitable The options available at Cornell Dubilier were very expensive and it was found that United Chemi Con was willing to give us samples for Design Report Doubly Fed Induction Generator Test Bed 14 free so our team decided to choose a United Chemi Con capacitor We were able to obtain two 4700uF sample capacitors rated for 400V 5 5 Self Protection Circuits After review and research of the four considered concepts for power electronics protection circuits a decision was made to implement both the DC bus chopper and the passive
31. design would be implemented with bidirectional switches and damping resistors connected in series with the stator Activation of the crowbar would increase stator resistance and provide passive damping The DC chopper circuit design requires a bypass resistor and controllable switch placed in parallel with the DC bus capacitor During activation the switch is closed and the DC bus voltage and current is limited accordingly to the resistor dimensioning 5 Concept Selection 5 1 Critical Components Our decision for which doubly fed induction generator to choose was based mostly on price as all of our narrowed down options would have fit our criteria and there was little difference in terms of expected performance The used Louis Allis was available for 750 Although we were still required to get an overhaul for 500 a significant amount of money was saved when compared with the other choices We chose to go with the Baldor EM3714T motor and ABB ACS 550 U1 031A 2 because they met all of our specifications and were available at a lesser price than the Toshiba motor and Toshiba ASD Cost was also a factor in choosing the ACS 550 U1 031A 2 over the ACS 800 U1 0011 2 P901 The 550 model provided all the features that we needed independent torque and speed control at a much lower cost In selecting the frame we quickly ruled out using a design that was roll formed A roll formed solution would have been weaker and more difficult to manufacture From
32. e viable From there we chose the HS45 because it was the only hollow shaft encoder model available that was compatible with the larger Design Report Doubly Fed Induction Generator Test Bed 13 1 375 in shaft diameter of the DFIG We also decided to go with 8192 counts per revolution because it was inexpensive 25 to upgrade to this resolution 5 4 Power Electronics The IGBT modules are the most sensitive parts in our design Should there be an error or a miscalculation it is likely that it would cause irreparable damage to the IGBT modules This played a large role in influencing our decision for which part to choose The quote we received for the IAP100T120 from Applied Power Systems was for 5 250 Furthermore they were unwilling to supply us with pricing information for the individual components that makeup the IAP100T120 Using the Powerex PM100CLA060 on the other hand we were able to purchase all of the required parts including spares for under 2 400 Another distinct advantage of using the Powerex IGBT modules is that should we damage them and then decide that we need a higher current rating it will be cheap to purchase the higher rated modules because all of the other components can still be used Some considerations other than price that we took into account were the fact that the APS module had over current protection and over voltage protection disadvantage because it limits what we can investigate but good because it adds prote
33. ent ratings of the DFIG 28A on the primary side and 32A on the rotor side We decided LEM was a good company to purchase current transducers from and we decided to go with a current transducer with a 100A rating to be safe 4 4 Power Electronics To control the DFIG we must take 3 phase alternating current convert it to direct current and then convert it back to alternating current of a different frequency which is then supplied to the rotor windings This is accomplished through the use of an AC DC AC converter which employs insulated gate bipolar transistors IGBTs For a single phase two IGBTs are required to convert from AC to DC or vice versa This means that for the rotor side voltage converter two sets of six IGBTs are required Because we wanted our system to be off the shelf as much as possible we decided to use six pack IGBT modules one AC DC that came with gate driver circuits and were optically isolated to reduce noise Finding products that matched this description was difficult As a result we only found two viable options One was the IAP100T120 from Applied Power Systems which included two six pack IGBT modules with a DC link between them mounted on a heat sink with blowers The other option we found was the PM100CL1A060 from Powerex Inc The PM100CL1A060 did not have the optical isolation itself but was sold in conjunction with the BP7B LS which provides the optical isolation A heat sink is also required for the IGBTs N
34. er electronics on the rotor side of the DFIG Two Microchip Explorer 16 development boards with dsPIC33FJ256MC710A microcontroller plug in modules are used to control the power electronics on the rotor side of the DFIG as well as record data taken during experimentation The microcontrollers interface with the IGBT modules current and voltage transducers and the position encoder during normal operation Powerex BP7B LS boards provide optical isolation between the microcontrollers and the IGBT modules A third Explorer 16 development board is used to control the two self protection circuits The power electronics on the rotor side of the DFIG consist of Powerex PM100CLA060 IGBT modules with built in gate driver circuits and a 4700 uF United Chemi Con capacitor for the DC link between converters The circuits that provide protection for the power electronics are the rotor crowbar and DC chopper The rotor crowbar consists of three TE Connectivity 100 Q 2 kW wire wound resistors Design Report Doubly Fed Induction Generator Test Bed 17 that can be connected across the lines of the rotor through the use of 162 16101 IXYS SCR modules The SCR modules switching is performed by an ENERPRO FCOAUX60 firing board 7 Testing At the conclusion of our time on this project the system has been assembled and testing has been performed on the ASD both induction machines the position encoder the torque transducer and a space vector modulation algo
35. erator Test Bed Appendix Datasheets and User s Manuals The following list details all relevant datasheets and user s manuals associated with components purchased for this project Hardcopies have been collected and brought together in a black three ring binder for reference use while in the lab The binder is stored in the Gauss Johnson Junior Power Electronics Lab room GJ 102B along with the ASD and power electronics carts When the project is transferred to the basement of the Buchanan Engineering Lab the binder will be moved as well The URL s included with these datasheets were accessed on 5 9 2013 Copies of these reference materials can also be found on the U of I engineering senior design website in the project archive section http seniordesign engr uidaho edu archive html or our individual team website http seniordesign engr uidaho edu 2012 2013 sel index html e ABB Adjustable Speed Drive ACS 550 01 Drives 1 200 hp User s Manual http www05 abb com global scot scot201 nsf veritydisplay 87d2 1c000e17fc33c12575ef004f3 107 f ile EN_ACS550_01_UM_G_A4 ScreenRes pdf Himmelstein Digital Torque Transducer MCRT 48202V 1 3 NA http himmelstein com images manuals 6dfda10183edMCRT 48200V Digital Torquemeter Manua l pdf and http www himmelstein com images product datasheets 25ad174381b0B7410 pdf BEI HS45 Position Encoder HS45F 137 R2 SS 8192 ABZC 28V 5 SM18 http www beiied com PDFs
36. for their generous support especially Normann Fischer Without the backing of these people this proJect would not have been possible Design Report Appendices Doubly Fed Induction Generator Test Bed Appendix Budget Al Date Amount Price Shipping Vendor Description 10 18 2012 51 750 00 51 350 00 5400 00 Power Equipment Louis Allis Motor 10 18 2012 5135 30 5127 90 57 40 Digi Key Corp Current Sensors 10 18 2012 1 291 03 1 255 80 35 23 State Motor amp Control ASD 10 18 2012 961 81 876 81 585 00 Priest Electric Baldor Motor 10 22 2012 517 04 510 34 56 70 Digi Key Corp BP7B Parts 10 22 2012 5196 67 5186 13 510 54 McGuire Bearing Couplers 10 24 2012 2 892 75 2 892 75 50 00 S Himmelstein amp Co Torque Transducer 10 30 2012 1 560 72 1 498 28 562 44 Powerex Inc IGBT Modules 10 31 2012 394 15 380 08 514 07 Galco Electronics Gate Driver Board 11 2 2012 172 50 148 50 24 00 McMaster Carr ASD Cart Hardware 11 5 2012 392 16 5374 98 517 18 Microcontrollers 11 14 2012 41 34 31 70 9 64 Arcade Electronics Fans 11 14 2012 331 70 311 50 20 20 C amp H Technology Heat Sink 11 16 2012 1 101 00 1 101 00 50 00 Industrial Encoders Position Encoders 11 16 2012 582 69 564 60 518 09 C amp H Distributors Dolly 11 28 2012 91 35 584 04 57 31 Zero Manufacturing Connector Box 12 5 2012 5120 00 5120 00 50 00
37. ith their existing power labs modular and adaptable for future applications The solution that we have developed employs components purchased from manufacturers alongside components that were designed to provide the physical framework for the test apparatus These parts will be installed in the University of Idaho s Analog Model Power System AMPS lab which will provide the conditions under which the DFIG can be tested Through our selection of the purchased components we were able to create a system that will supply our client with torque current and voltage measurements from the DFIG that occurred during operation According to our design the power electronics on the rotor side of the DFIG will makes it possible for different control algorithms to be implemented These two features will enable our client to develop their understanding of DFIGs through experimentation under different fault conditions as well as with different control algorithms At this point the components have been purchased and assembled Some testing of the machines sensors and IGBTs has been conducted 1 Background Increases in the cost of energy and paradigm shifts in societal priorities have led to a higher demand for energies produced without the use of fossil fuels One such technology that fills this niche is the wind turbine Due to the stochastic nature of wind speeds doubly fed induction generators DFIGs are often used to convert the mechanical power of the
38. l NEERIN G OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED materia Mild Steel 2 25 DEFAULT TOLERANCES Right 215T Mounting Block UNIVERSITY OF IDAHO LINEAR BY DATE ME DEPARTMENT lx 2 SHEET 4 OF 12 John Feusi 1 28 2013 bars 2151 Block R SLDPRT 1 2 3 00 DRAWN BY FILE NAME D6 39 y 1 03 7 16 20 UNF 88 2x 33 88 3 8 24 UNF Y 75 PROPRIETARY AND CONFIDENTIAL 00 THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES DFIG IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO THIRD ANGLE PROJECTION DEPARTMENT ANY REPRODUCTION IN PART OR AS WHOLE WITHOUT THE WRITTEN PERMISSION E N G N R N G 8 5 rn OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED materia Mild Steel 3 00 DEFAULT TOLERANCES psceewow Left 2560 Mounting Block UNIVERSITY OF IDAHO PONES BY DATE ME DEPARIMENT X AS 2 01 John Feusi Es 1 28 201 3 part A 4 2 X XXX 1 002 2561 Block L SLDPRT scate 1 2 D7 E o 39 1 03 7116 20 UNF 88 2 D 33 88 3 3 8 24 UNF Y 75 CN n 2 2 735
39. l frame a power electronics cart and an adjustable speed drive cart The sensor array that comes with this setup includes a torque transducer position encoder and current and voltage transducers The power electronics cart includes two IGBT modules a DC chopper three SCR modules the driver boards for the previous items and a bank of power resistors Testing has been performed on the adjustable speed drive the DFIG and the space vector modulation algorithm In the ASD test the adjustable speed drive successfully ran the SCIM and the alignment of the machines shafts was verified The DFIG s ability to generate power was tested and verified by applying a variable frequency voltage and current to the rotor using a synchronous generator with speed controlled by a DC machine The field oriented control algorithm required to control the DFIG is not fully implemented at this time though we have most of the code required for this An algorithm for open loop space vector modulation has been tested but still requires adjustment in order to successfully control the switches The remaining work required to implement the full algorithm consists of coding to read sensors as well verifying correct implementation of the space vector modulation We would like to thank you for your support and sponsorship Without a sponsor it would not have been possible to realize this project Your investment of time and money into this project is deeply appreciated
40. nents had not been initiated by the end of the fall semester Design Report Doubly Fed Induction Generator Test Bed 4 GANTT Ordering DFIG SCIM and TT Assoc Parts Frame Design Find Vendor Order Prepare for Snapshot 1 Prepare for Snapshot 1 Snapshot Day 1 Snapshot Day 1 Prepare for Design Review Design Review Presentations Prepare for Design Review Design Review Presentations Assembly Assembly T gt Mounting Mounting Ass Part Assembly Ass Part Assembly Testing amp Troubleshooting Testing amp Troubleshooting Thanksgiving Thanksgiving LI Prepare for Snapshot 2 Prepare for Snapshot 2 Esa Snapshot Day 2 4 18 Due Snapshot Day 2 Logbooks Due Figure 2 Project schedule created at the beginning semester For the spring semester we picked up where we had left off at the end of the fall starting with the mounting of the motor generator pair We had still hoped to meet our ultimate goals for this project We set out another schedule for the spring semester with which we would be able to achieve this end The schedule can be seen below in Figure 3 While we were able to accomplish much of the work we were unable to meet all of our goals The objectives that we were unable to hit included wiring for the DC power sup
41. oducts Devices aspx dDocNamezen546066ftdocumentation e Baldor AC Motor EM3714T http www baldor com support Literature Load ashx MN408 ManNumber MN408 Louis Allis wound rotor induction machine 10hp 220V 28A secondary 170V 32 A No documentation was found e BlackStar Split Taper Bushing used with CSH coupling http www mcguirebearing com wp content uploads 2009 01 blackstar bushings web pdf e Abbreviated startup procedure specific to use in our lab See next page February 20 2013 ASD Setup Procedure 1 1 Objective The objective of this handout is to safely walk through the procedure for connecting the ACS550 U1 031A 2 to an induction motor This handout is intended to be a supplement to the User s Manual Equipment ACS550 U1 031A 2 and corresponding User s Manual 3 taper fit to taper fit jumpers 3 SUPERCON to SUPERCON jumpers 1 SUPERCON to taper fit jumper 2 Banana plug to banana plug jumpers 1 Banana plug shorting bar e Multimeter e Watch Procedure 1 Verify the motor s compatibility with the ASD Refer to the table near the top of page 14 in the User s Manual For the value see page 272 If the motor is compatible continue with the procedure otherwise stop 2 Readthrough the start up instructions in the User s Manual p 33 40 3 Make sure that the power supply is turned off 4 Make sure that driven equipment will not be damaged by
42. options Design of the cart for the power electronics followed a similar path One important consideration that had to be taken into account that was less of an issue for the ASD is that the microcontrollers needed to be shielded from electromagnetic radiation emanating from the IGBT modules Also much more space Design Report Doubly Fed Induction Generator Test Bed 7 was needed for all of the power electronic equipment We had the same construction options available to make the power electronics cart as we did for the ASD cart In order to make our system flexible we had to make sure our electrical connections would be compatible with both the power lab tables in the university s Gauss Johnson Power Lab and also with the Analog Model Power System AMPS Lab in the Buchanan Engineering Lab when considering the choices for our connection scheme cables and connectors The power lab tables use specially manufactured taperfit connectors and the AMPS lab uses 25A SUPERCON connections The engineering department has available taperfit to 25A SUPERCON adapters It is desired for the ASD to be compatible with other machines in the power labs that use taperfit connections 4 3 Sensors The first sensor that we set about selecting was the torque transducer because they are commonly more expensive and have longer lead times In order to search for torque meters that would be feasible we first had to determine the minimum torque rating Using our
43. ose one that provided a sufficient number of inputs and outputs Initially we wanted to make sure the microcontroller had 6 PWM channels to control the IGBTs but later decided this was not an important requirement since we could use a different method involving interrupts instead of the built in signals Our choice was also governed by the idea that we should choose a microcontroller that has a sufficient amount of library material written for it already We compared microcontrollers from both Atmel and PIC 4 5 Self Protection Circuits Due to the possibility of voltages and currents in the DFIG system exceeding system ratings and response to external disturbances it was desired to implement into the system a method of system self protection Four different concepts commonly applied in the field were researched and considered for protection circuits These were the passive rotor crowbar active rotor crowbar stator crowbar and DC chopper The passive rotor crowbar design consists of a bank of bypass resistors connected to the rotor windings by controllable switches During activation the generator rotor windings are short circuited through the crowbar circuit and the rotor currents are limited accordingly to the crowbar resistor dimensioning Design Report Doubly Fed Induction Generator Test Bed 10 The stator crowbar design is somewhat similar to the rotor crowbar except that it would be located on the stator side of the machine This
44. plies and microcontrollers as well as implementing field oriented control However even without these items we were still able to give SEL the deliverables they desired These items will provide opportunity for future work Design Report Doubly Fed Induction Generator Test Bed 5 gt gt Gan Tat gt gt 2013 February 2013 March 2013 2013 2013 project Week 2 Week 3 4 Week 5 6 Week 7 Week 8 Week 9 10 11 12 13 14 15 16 17 18 19 ood Develop Control Algorithms _ Develop Control Algorithms Mount Machines Mount Machines Construct ASD Cart Construct ASD Cart onstri Cart Design Design Frame Frame Wiring pU Snapsot Day 3 ae Day 3 Spring Break j El b Uu Testing R m m m m eS I ASD Testing ASD Position Encoder Torque Transducer Torque Transducer Cur and Volt Transducers Cur and Volt Transducers IGBTs and SCRs IGBTs and SCRs Prepare for Expo Prepare for Expo Expo Expo Logbooks Due Due Figure 3 Project schedule created for the second semester 4 Concepts Considered 4 1 Induction Machines The item in our system design that was most difficult to obtain was the doubly fed induction generator Knowing this our conceptual design process started with this part In consideration for the DFIG our choice wa
45. ppendix B Calculations ada sisi eed tee opto aaa B Capacitor Discharge Resistor 5121 6 1 0 000 nennen rennen B2 Heat Giese ss eter aee et ettet eo B3 Appendix C Datasheets and User s 18 2 1 1 00 00 enne rennen eren Appendix D Drawing rie oec REGERE a s e PRSE D1 iii Executive Summary Schweitzer Engineering Laboratories Inc is interested in the construction of a test bed for a doubly fed induction generator DFIG or wound rotor induction machine Our team has been tasked with designing and constructing such a setup Their current understanding of how a DFIG acts during faults does not explain the behavior that they have observed during actual faults in the power distribution networks that they monitor The test bed that we develop needs to be able provide a way to investigate how doubly fed induction generators affect power and protection systems as well as verify software models currently being used by our client With this knowledge in hand Schweitzer Engineering Laboratories will be better able to design and produce relays and other protective equipment for power distribution networks that include DFIGs Our secondary client the University of Idaho U of I also needs the device to be compatible w
46. pplies to sensors 2 Connecting microcontrollers to gate drivers the SCR firing board and sensors 3 Verification of current and voltage sensors readings 4 Calibrations of sensors a Current b Voltage c Torque 5 Coding a Invert PWM signals b Field Oriented Control c Read outputs from current voltage torque and position sensors 6 Verification of gate driver board and IGBT module switching 7 Verification of self protection circuit performance 9 Summary This report discussed the development of a test bed system for a doubly fed induction generator It was designed as part of the curriculum for the engineering senior design capstone project at the University of Idaho The system consists of an adjustable speed drive squirrel cage induction machine torque transducer position encoder wound rotor induction machine back to back IGBT modules a DC chopper and a rotor crowbar The system was designed for power transmission protection engineers at Schweitzer Engineering Laboratories and can be used to test effects on power transmission protection systems due to interactions between external grid faults and a DFIG The DFIG Engineering team would like to thank their advisors Drs Joe Law and Brian Johnson as well as the support from U of I faculty Design Report Doubly Fed Induction Generator Test Bed 19 and staff including Drs Herb Hess and Richard Wall Greg Klemesrud and Russ Porter The team would also like to thank SEL
47. rithm Testing the ASD and induction machines consisted of using the ASD to drive the SCIM at a range of speeds from 0 to 1770 RPM While running the SCIM we were also able to test the wound rotor machine and the position encoder The wound rotor s ability to generate power was tested and verified by applying a variable frequency voltage and current to the rotor using a synchronous generator with speed controlled by a DC machine For the position encoder we verified that we were getting pulses on each of the six outputs A static test was also performed to verify that the torque transducer would output analog measurements which was successful However tests were only performed to approximately 20 in Ibf With the space vector modulation algorithm we were able to successfully generates PWM signals but the signals as they are now still need to be inverted in order for them to successfully control the IGBTs The signals that we were able to generate can be seen below in Figure 6 15 J F 1 t I I WFreq 2 20 1kHz Freq 1 20 0kHz Freq No signal Figure 6 PWM signals generated for high and low gate of one leg Design Report Doubly Fed Induction Generator Test Bed 18 8 Future Work There are still additional items that need to be completed These items are left as work for future teams They include 1 Connecting DC power su
48. roll formed solutions The latter two of these possibilities were found in the existing power lab at the University of Idaho The options considered for mounting were a bolt driven system welded blocks bolted on blocks or mounting directly onto the structure The bolt driven system came as a suggestion from our client We also found examples of adjustable motor mounting bases from distributors Since we were not designing the couplers the options that we had were limited but straight forward The three types of couplings that we considered purchasing were curved jaw disc and bushed type sleeve couplings The jaw type couplings had been used previously at the University of Idaho with a great deal of success However they have a large amount of backlash which was unacceptable so they could be immediately disregarded For our considerations in choosing wheeled carts for the ASD and power electronics we wanted to minimize time spent constructing the carts We also wanted the adjustable speed drive mounted on its own cart so that it could later be used separately from this project for other machines Different options in construction methods and materials were considered We observed electronics carts from previous projects that were located in the Gauss Johnson power lab for ideas The engineering department had available spare Unistrut strut channels which provide a versatile medium We also browsed catalogs of equipment distributors to garner other
49. rotor crowbar Although only one form of protection circuit is needed the two circuits were included for the purpose of comparing their operation The protection circuits we chose were two of the more common designs used by industry because the ultimate purpose of this project is to investigate the effects on power transmission protection systems due to external faults interacting with a DFIG This way we will be able to see how the DFIG would respond to the disturbances with the different self protection schemes 6 System Architecture The system that we developed consists of three main components the adjustable speed drive cart the motor generator pair mounted on the frame and the power electronics cart These components are displayed below in Figure 5 These components are he deliverables that we will be able give SEL The frame of the test bed provides a platform to which the DFIG SCIM and torque transducer can be mounted This makes it possible to align the shafts and keep the motors rigid during operation It is constructed out of two 5 ft W 6x12 beams with C 6x8 2 channels welded on both ends On the top in the middle is a in roll formed piece of steel that provides a platform on which to mount the torque transducer Most of the design of the frame was drawn from previous work done at the University of Idaho However one feature that sets it apart from the rest is the mounting blocks The mounting blocks are steel blocks with bolt holes
50. s governed by our rating specifications and by price Our specifications were that the generator needed to be rated between 7 5 10 HP and 1200 1800 RPM The goal was to procure a generator in this range for the best price After sorting through many different used and new generators our choices were narrowed down to a used 10 HP Louis Allis as well as machines made by Reuland and Doug Beat The SCIM was considered next after the selection of the DFIG It was to be chosen with ratings compatible with the DFIG and purchased new off the shelf Also we wanted to try to purchase the SCIM and the adjustable speed drive ASD together as a package to ensure that they were compatible An important requirement for the ASD was that it allowed for control of speed and torque independently We explored several options and narrowed it down to two that met our requirements which were an ABB ACS550 drive matched with a Baldor SCIM and a Toshiba ASD and SCIM Design Report Doubly Fed Induction Generator Test Bed 6 4 2 Mechanical Framework Once the generator and motor were chosen it was time to design the frame onto which they would be mounted The concepts that were considered for the design of the frame can be broken down into two main groups structure and mounting The structure is the pieces that are welded together in rectangle and provide the skeleton For the structure the main options that were investigated were wide flange I beams C channels or
51. s the angular inertia Ibm ft 2 RPM is the angular speed rot min and T is the average torque Ibf in Design Report Doubly Fed Induction Generator Test Bed Appendix D Drawing Package Table of Contents Frame Assembly wu a aS Adjustable ates eee bau QS a S Wiring DEEP DI PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES D Fl G IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO THIRD ANGLE PROJECTION ME DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION ENGINEERIN OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED MATERIAL UNIVERSITY OF IDAHO ME DEPARTMENT DEFAULT TOLERANCES besceienon Frame Assembl DATE H ea ICHECKED BY busy John Feusi m 5 8 2013 002 huename Frame Assembly CSH SLDPRT sca 1 10 sue 1 OF 12 D3 38 50 4 15 32 469 THRU 16x X 397 THRU 0 25 W 6x12 6x8 2 0 25 Inick PROPRIETARY AND CONFIDENTIAL 11 00 THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES DFIG S THE SOLE PROPERTY OF UNIVERSITY OF THI
52. tage calculate the nominal current 745 7 RMS HP Determine the peak current for the collector and emitter len V2 IGBT and Diode losses are made up of two components steady state and switching IGBT 1 cos 0 Pos IcoVce sat 5 Few Esw on Esw off A A pl Diode 1 Dcos Pac lenVec gt 37 Pry 0 125 ler pk fsw The temperature of the case is then dictated by one of the two following equations T T j IGBT c Pss T Poy E vo jc IGBT T j FWD jc FWD Then you can calculate the allowable thermal resistance for the heat sink T m Ta N Pss Pew Pac Ppr Design Report Doubly Fed Induction Generator Test Bed B4 Using the following values HP 10hp sat 2 35V D 0 75 0 0rad 10kHz Esw on 5 5mJ pulse Esw off 5mJ pulse Ve 3 3V 35A Try 0 25us Vee pk 550V Rjc iggr 0 35 C W 9 56 C W cer Tj ger 125 C Tg 25 C We calculated that the maximum allowable thermal resistance of the heat sink was R 4 0 09 C W For additional information on these calculations see Powerex s application note General Considerations IGBT amp IPM modules section 3 4 As of 5 19 2013 this information could be found at http www pwrx com pwrx app IGBT Intelligent PwrMods pdf Design Report Doubly Fed Induction Gen
53. tapped into the bottom and top These blocks are bolted onto the wide flange beams and then the motor is mounted onto the blocks Previous designs had welded the mounting blocks onto the base Our design has two main advantages One it makes the task of alignment easier because without the welding there is less deformation Second it allows for more flexibility Should Design Report Doubly Fed Induction Generator Test Bed 15 there be an issue with the manufacture of the frame or mounting blocks our design makes it possible to remove the mounting blocks and re machine them It also makes using different motors a feasible option Figure 5 Test bed system for DFIG 1 ASD Cart 2 Frame 3 Power Electronics Cart The machine on the left is the SCIM and on the right is the wound rotor induction machine The ABB ACS 550 U1 031A 02 adjustable speed drive provides a way to power and control the SCIM One feature of the ASD that we chose is that it allows for the control of speed and torque independently It comes with several pre programmed and customizable application macros for different operation schemes to minimize setup time The motor generator set consist of a Baldor EM3714T SCIM as the prime mover and a Louis Allis wound rotor induction machine The DFIG is rated for 10 HP and 1750 RPM The SCIM is rated for 10 HP and 1770 RPM Design Report Doubly Fed Induction Generator Test Bed 16 The shaft to shaft torque transducer is a Himmels
54. tein MCRT 48202V 1 3 NA It is the piece that physically transmits the mechanical input from the SCIM into the DFIG The purpose that it serves is to enable our client to take measurements of the torque that is being input to the DFIG The measurement of torque is an important part because the mechanical torque being put on the generator is used in both the control and modeling of the DFIG Without this measurement there is not enough information for our client to verify the models that they have in place The torque transducer also has a speed pickup which could possibly be used by the ASD or other testing purposes On either shaft of the torque transducer is one of the bushed type sleeve couplings These couplings provide the mechanical link between the shafts of the torque transducer and the shafts of the induction machines The BEI HS45 rotary incremental encoder is a hollow shaft encoder that mounts directly to the shaft and is held in place by an arm that mounts to the frame of the test bed It has the purpose of taking a mechanical reading from the shaft encoding it and outputting a digital quadrature output that conveys the speed and position of the shaft It also allows for the option of sending the signal differentially to reject more signal noise and obtain a more accurate cleaner signal and better performance It has a very high resolution of 8192 cycles per turn The signal from this device is fed into the microcontroller that controls the pow
55. there we decided to use the I beams over the C channels Since the frame will only be moved a few times in its lifespan the additional weight of the I beam is an irrelevant point Also this additional weight adds more strength to the structure The other reason that we went with I beams rather than C channels is that the I beams are flat on both sides whereas the C channels are not The fact that the C channel is not flat on both sides creates Design Report Doubly Fed Induction Generator Test Bed 11 additional problems when bolting the mounting mechanism onto the C channels The mounting option that we decided to go with was bolt on blocks Welded blocks would not have given the adaptability that we want to provide Purchasing a bolt driven system would have made integrating with the structure of the frame difficult because the generator and motor are different frame sizes and fabricating our own bolt driven system would have been complicated and costly in terms of time Mounting directly to the structure would have been the cheapest and simplest but would not have had enough clearance to allow for our shaft alignment tool A drawing of the frame and mounting system can be seen directly below Figure 4 Frame with mounting blocks attached I beams run the length of the frame and the ends are capped with C channels Square cutouts in I beams allow for the use of straps in hoisting the frame assembly Selection of the couplings was simple
56. umerous different types including extruded bonded fin and forced convection heat sinks were available The selection of the heat sink was dependent on the allowable thermal resistance for the IGBT module The DC link capacitor needed to be chosen at a voltage rating compatible with the DC link voltage The DC link voltage was calculated to be approximately 350 V The capacitance needed to be high enough to give us an acceptable value for voltage ripple Calculations were made and different Design Report Doubly Fed Induction Generator Test Bed 9 capacitance values were compared with their resulting calculated voltage ripple Deciding upon the capacitor involved weighing tradeoffs between voltage ripple cost and space The capacitance be increased to lower the voltage ripple but the size of the capacitor as well as the price increases with the capacitance rating Too large of a capacitor could make the power electronics too bulky Also if too much energy can be stored in the capacitor problems can arise Another factor that influenced our decision was availability The capacitors were offered in their standard values and some capacitors had very high and prohibitive lead times up to 6 weeks Price was a significant contributor to our choice as well since these capacitors can reach upwards of 400 Different capacitors from Cornell Dubilier and United Chemi Con were compared For the microcontrollers that control the IGBTS we needed to cho
57. wind to electrical power The reasoning behind this is that these types of generators can handle a wider range of shaft speeds while outputting a fixed power system frequency Furthermore the size of the power electronics used to control the DFIG can be reduced because the power electronics do not need to handle the full armature power However less is known about the behavior of DFIGs during abnormal conditions compared to conventional induction machines The motivation for this project comes from our client Normann Fischer who needs to know more about how DFIGs operate during fault conditions in order to design protective equipment and systems for wind turbine farms The benefits of this system are that it will allow engineers to work in a laboratory setting to investigate how DFIGs react during faults affect power and protection systems investigate different load flow conditions and verify software models currently in use Engineers will be able to run simulations to see how different operating and power system conditions affect fault response The knowledge gained from tests performed with this system can lead to improvements in wind turbine technology 2 Problem Definition The stakeholders of this project are interested in learning how to better protect these types of systems against power system instabilities such as faults Therefore it is the goal of this project is to design and construct a doubly fed induction generator test bed system

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