Reserch & Development – The new wind turbine

Following the experience accumulated in the first phase we concluded that: offering a complete solution without running the entire chain of production, protection, primary conversion, storage and final conversion a client will be unsatisfied. In conclusion, I decided to find the best variant of the energy chain.

(In urma experientei acumulate in prima parte a proiectului am ajuns la concluzia ca fara oferirea unei solutii complete de functionare a intregului lant de productie, protectie, conversie primara, stocare si conversie finala un client va fi nemultumit. In concluzie am luat decizia de a gasi cea mai buna varianta a acestui lant energetic.)

Flowchart functioning energy chain:

(Schema logica de functionare lant energeticJ

Generator

I have also modified the design of the generator. I chose a more compact version of the same power cut.

(Totodata am modificat si desig-ul generatorului. Am ales o varianta mult mai compacta la aceeasi putere debitata.)

Disc coreless PMG have advantage in low Rated speed, Low starting wind speed, Small volume, Energy Small, Light weight, Compact structure, High efficiency etc.

1) Coreless, anhysteresis, slotless, have low starting torque.

2) No iron loss, have high efficiency

3) Adopt unique coreless precision winding technology design precision coil

4) Adopt the rare earth permanent magnet, which is multipole, mean gap, high power density and high output power.

5) Low speed direct driving, no torque fluctuations

6) Compact structure, high ratio of power to volume

7) No iron loss, low calorific value, small temperature rise

8) Simple structure, easy to install

9) The brushless structure, free maintenance

Disc PMG are avantajul de viteză nominală redusă, viteza redusă a vântului de pornire, volum mic, greutate redusa, structura compacta, cu randament ridicat, etc.

1) Fara miez, anhysteresis, necanelat, cu un cuplu de pornire redus.

2) Nici o pierdere de fier, au o eficiență ridicată

3) Adoptarea de precizie unic de lichidare coreless tehnologie bobina de design de precizie

4) Magnet permanent, multipolar, înseamnă decalaj, densitate mare de putere.

5) Viteză redusă de conducere directă, fără fluctuații de cuplu

6) Structura compactă, raport mare de putere la volum

7) Nici o pierdere de fier, valoare calorică scăzută, temperaturii mici

8) Structura simplă, ușor de instalat

9) Structura fără perii, care nu necesită întreținere

Parametrii initiali (fisier PDF)

GENERATOR PERFORMANCE PARAMETER

1 Rated power KW 5

2 Rated speed RPM 500

3 Rated voltage V 110VAC

4 Rated Current 26.24A

6 Efficiency >85%

7 Resistance (Line-Line) -

8 Winding type Y

9 Insulation Resistance 100Mohm Min(500V DC)

10 Leakage level <5 ma

11 Start torque N/M <0.3

12 Phase Three phase

13 Structure outer rotor

14 Stator coreless

15 Rotor - Permanent magnet type (outer rotor)

16 Gen. Diameter mm 386

17 Gen. Length mm 199

18 Gen. Weight kg 32

19 Shaft. Diameter mm 50

20 Housing Material Aluminum ( Alloy )

21 Shaft Material Steel

22 Gross Weight KG 39

WIND CONTROLLER

- Design for off-grid wind/solar hybrid power system.

- Integrated design of wind controller and solar controller. Optional temperature compensation function.

- Optional Boost function.

- Optional Buck Function.

- Optional Buck & Boost Function.

- Optional RS232/RS485 to communicate with computer or USB data logging automatically.

- Optional Temperature Compensation Function

- Applicable to different kinds of batteries.

- PWM step-less unload mode, which burn the excess power into dump load, making the battery charging in best status.

- Digital intelligent control, With powerful imported MCU control as the core device .To ensure Simple peripheral circuit Structure, and more flexible and powerful control method and control strategy.

- Modular design with simple structure and easy maintenance.

- LCD display function, visually display wind power, wind voltage, wind current, wind turbine speed, PV power, PV voltage, PV current, battery voltage, battery power, charge current .

- Perfect protection function: Solar reverse charge protection, Solar reverse connection protection, Battery overcharge protection, Battery over current protection, Battery reverse connection protection, Open battery protection, Wind turbine automatic brake and manual brake, thus the system has higher reliability.

- Optional temperature compensation function.

- Optional Boost function.

- Optional Buck Function.

- Optional Buck & Boost Function.

- Optional RS232/RS485 to communicate with computer or USB data logging automatically.

- Optional Temperature Compensation Function

-

Rated Battery Voltage	96v
Rated Wind Turbine Power	5Kw
Maximum Wind Turbine Input Power	6Kw
Rated Solar Charge Current	10A
Over-discharge Voltage	102V (adjustable)
Over-discharge Recovery Voltage	115V (adjustable)
Over-charge Voltage	144V (adjustable)
Over-charge Recovery Voltage:	130V (adjustable)
Floating Voltage:	135V (adjustable)
Dump-load Start Voltage:	200V
Dump-load Start Rotate Speed:	500RPM(adjustable)
Wind Turbine Charging Voltage:	50V
Wind Turbine Charging Mode:	MPPT and PWM
Solar Charging Mode:	PWM
Control Dump-load Mode:	Over rotate speed limiting, Over voltage limiting,Over current limiting ,PWM
Display Mode:	LCD
Display Parameters:	wind power , wind voltage , wind current , wind turbine rotate speed, PV power, PV voltage, PV current, battery voltage, battery power, charge current, over voltage, under voltage, system state ,etc
Working Temperature	-20~+55°C
Humidity:	35~85%RH (Without Condensation)
Quiescent Power Drain:	<3W
Protection Function:	Solar reverse-charging protection , solar reverse-connection, battery over charge protection, battery over-discharge battery reverse-connection protection, wind turbine automatic brake, wind turbine manual brake
Communication (Optional):	RS232 or RS485
Storage (Optional ):	USB data logging
Controller Size (L*W*H):	510*250*395MM
Package Size:	(L*W*H) 750*450*260MM
Controller Gross Weight:	10KG
Dumpload Gross Weight:	22KG

INVERTOR:

- Design for off-grid wind power system, off-grid solar power system, off-grid wind/solar hybrid power system.

- Applicable to different kinds of batteries.

- Digital intelligent control: With powerful MCU control as the core device .To ensure Simple peripheral circuit structure, and more flexible and powerful control method and control strategy.

- Modular design with simple structure and easy maintenance.

- Pure sine wave output, compared with square wave or modified wave, has higher efficiency and higher capability of driving load.

- Cooling fan is intellectual controlled, and its working status is controlled by CPU, which mostly increased its service life and helps to save the power consumption, improve work efficiency.

- Low working noise. High working efficiency.

- Perfect protection function: Battery reverse connection protection, Battery over discharge protection, Output overload protection, Output short circuit protection, overheating protection. Thus the system has higher reliability.

- Normal Output Power 5kW

- Normal DC Input Voltage 96VDC

- Over Voltage Shutdown 136VDC

- Over Voltage Recovery 132VDC

- Under Voltage Shutdown 84VDC

- Under Voltage Recovery 96VDC

- Output Wave Pure Sine Wave

- Rated Output Voltage 220VAC

- Total Harmonic Distortion ≤5％

- Output Frequency 50Hz±0.05Hz

- Dynamic Response 5%

- Inverter Efficiency 90%

- Noise Level（1m） ≤40dB

- Isolate Level 1500VAC, 1min

- Overload Protection Battery reverse connection protection,

- Battery over discharge protection, Output overload protection, Output short circuit protection, overheating protection

- Operation Altitude ≤4000m

- Operation Ambient Temperature -20～50℃ (no condensing)

- Operation Ambient Humidity 0~90%, （no condensing）

- Machine Size Dimension (L*W*H) 460*260*470mm

- Package Size Dimension (L*W*H) 555*345*530mm

- Net Weight (KG) 33

- Gross Weight (KG) 35

Testing equipment:

(Testare echipamente:)

Parametrii testati pentru generator:

- tensiune in functie de turatie la diverse sarcini

- putere in functie de turatie la diverse sarcini

- rezistenta linie la linie

- temperatura in regim de functionare

- defazaj intre linii (*)

- distorsiuni (*)

- inductanta linie la linie (*)

Parametrii testati pentru charger:

- functiile Buck, Boost

- putere

- randament

Parametrii testati pentru invertor:

- putere

- power surge

- curent de stand-by

- randament

- stabilitate tensiune

- distorsiuni (*)

Rezultate:

Generator
Turatie (rpm)	42	83	125	166	208	250	291	333	374	416
U gol	31	45	60	74	90	105	122	135	150	175
U1(R1=5.8)	14	28	42	56	67	85	98	112	126	138
U2(R2=3.4)	13	26	40	51	64	77	92	102	117	126
U3(R3=2.2)	12	26	38	50	65	75	87	100	111	121
Indicatie VFD	4	8	12	16	20	24	28	32	36	40

Invertor
R(ohmi)	Inf	50	35	29	22	21, 3	13, 1	10, 8	10, 63
Uo(V)	223	227	227	226	225	227	220	217	220
Uin(V)	101	99, 7	98, 5	98	96, 8	96, 8	94, 9	93, 2	91, 4
Iin(A)	0, 7	11, 5	16, 5	19	25, 5	26, 3	43	55	64

Concluzii:

Generator (Alternator):

Rezistenta linie la linie: Rll = 0.6ohmi.

Din graficul tensiune in functie de turatie, observam ca intr-adevar alternatorul este capabil sa dea 110V la o turatie pana in 500rpm.

Din graficul putere in functie de turatie, observam ca alternatorul este capabil sa furnizeze puterea de 5kW.

Sarcina de 3.4ohmi genereaza 5kW fara a depasi limita de curent linie la linie de 26.24A.

In timpul testarii, carcasa alternatorului s-a incalzit pe la aproximativ 30 de grade. Nu au fost semne ca s-ar supraincalzi.

Invertor:

Din graficul putere in functie de rezistenta, observam ca invertorul poate da o putere de 5kW. Noi am tras maxim continuu 4500W, deoarece se incingeau cablurile ce legau invertorul de baterii.

In timpul testarii in regim continuu, invertorul nu a generat alarme.

Curentul tras din baterii in lipsa unei sarcini este de 0.7A, la 101V, ceea ce inseamna putere consumata in regim "idle" de 70W (adica invertorul descarca complet bateriile in 6 zile in lipsa oricarei sarcini si daca ele nu sunt incarcate). Acest curent ar fi OK daca invertorul s-ar alimenta din baterii de 12V, dar la baterii de 96V, este destul de mare.

Dupa cum se vede si din tabel, tensiunea pe iesire este stabilizata destul de bine. Nu au fost spikeuri vizibile pe multimetru la schimbarea de sarcina.

Graficul randamentului in functie de putere arata faptul ca randamentul scade odata cu cresterea puterii consumate, ceea ce este de asteptat deoarece aparatul are transformator cu fier. Acest lucru ar putea fi cauzat de faptul ca cablurile de legatura cu bateriile erau prea subtiri si tensiunea la bornele aparatului era mai mica. Totusi, masurarea tensiunii a fost facuta exact pe bornele aparatului, deci randamentul indicat in grafic este aproape de cel real.

Puterea de surge: Am conectat la iesire sarcini astfel incat la 220V sa traga 6750W. Puterea masurata pe intrarea invertorului a fost de 9900W, timp de 2s.

In regim continuu de functionare la putere maxima (la aproape de 5kW) invertorul nu genereaza alarme.

Project Manager

Eng Dragos Preda

Derulare proiect Cercetare&Dezvoltare – Reserch&Development Project

Testarea nolui model de generator de 5kw, 110V, 28A	Testing the new model 5kW generator (110V, 28A)
Testare echipamente electronice si de conversie (controller baterii, protectia dump-load, invertor, baterii)	Testing the electronic devices (battery controller, load dump protection, inverter, batteries)
Realizare corp turbina eoliana	Achievement body wind turbine
Bancul de baterii 12V, 100A (TOTAL 96V, 800A) Dock batteries 12V, 100A (TOTAL 96V, 800A)	Conexiuni controller baterii Connections controller batteries
Protectia de rezistente in caz de vant prea puternic (supraturatii) Dump load protection
Afisaj invertor 5kW	Afisaj controller 5kW eolian + 2kW solar
Asamblare finala (corpul turbinei a fost intai zincat apoi vopsit electrostatic)	The final assembly (turbine body was first galvanized and then powder coated)
	Turbina in miscare (CLIP VIDEO)