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TRANSCRIPT
Center for Wind Power Drives
Full Size Nacelle Ground Testing
Advanced testing at the
1 MW Test Bench Demonstrator
4 MW System Test Bench
5 MW High Speed Test Bench
Winergy HybridDrive
Direct Drive
Load Application System
HybridDrive
Rubber Bushings
Geared Coupling
Specifications
Source: MTS
Wind Load Simulator
5 DOF load application system
Force capacity: ~ 3 MN
Bending moment capacity: ~ 7 MNm
Backlash-free cylinders
pre-loaded in pairs
Static support for load compensation
Full sensoring for torque,
bending and forces
PMSG Direct Drive
Nom. Power Pn = 4000 kW
Nom. Speed nn = 14 rpm
Max. Speed nmax = 30 rpm
Const. Torque nTn = 4-14 rpm
Nom. Torque Tn = 2,7 MNm
Max. Torque Tmax = 3,4 MNm
Source: GE
Grid
17 MVA converter power
High dynamic by three
interleaved converters
Galvanic isolation through four-
winding transformer
Minimum series inductance
through filter connection to an
additional tertiary winding
DC-Bus
MV7308
MV7308
MV7308Filter
PCC
Trafo
Hardware in the Loop
User
Interface
Wind Field
Generator
Pitch System
Model
RTDS
DC-Link 20 kV
1 DOF 5 DOF
=
10kV Grid
__
_
Prime Mover
Load Unit
Controller HILWind
HIL Grid
PCC
Original WTG Controller
-
-Control
Units
Wind Load
Calculator
Drivetrain
Model
nrotor
set
point
Recuperation
Loop=
Emulated
Sensors
HIL Validation
0
5
10
15
20
25
30
35
0
50
100
150
200
250
300
350Rotorspeed rpmTorque kNm
-5
0
5
10
15
20
25
30
-200
0
200
400
600
800
1000
1200Windspeed m/sPitchangle degElectric Power kW
140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440
-200
-150
-100
-50
0
50
100
150
200
-200
-150
-100
-50
0
50
100
150
200
Thrust kNRadial Force kNTilt Bending Moment kNmYaw Bending Moment kNm
Grid
Connection
Generator Mode
Switching
Fast
Shutdown
Test campaign with
original WTG
controller on the
1MW test bench
demonstrator in HIL
operating mode
realistic behaviour of
drivetrain and WTG
controller
original intended
control strategy
5 MW high speed test rig
Schematic of the test bench for medium-voltage high-
speed drives. Energy flow with DUT in motoring mode
• Tests of
(high-speed) drives
generators
dc-dc converters
converters for doubly-fed generators
grid-connected converters
• Specification
power: 5 MW
rotational speed: 15,000 min-1
ac voltage: 3.3 kV
Future Projects
• Torque measurement in the MNm range
Develop traceable measurement methods in the MNm range
Investigate effects of multi-comp- loading
Develop a calibration procedure for nacelle test benches
• FVA-Nacelle
Reduction on local stresses in WTG-drivetrains
Validation
Local models (e.g. gears, bearings)
Global MBS-model
Thank you for your attention
Dennis Bosse
Center for Wind Power Drives
RWTH Aachen