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Ultra-Compact Electrical Machines for Wind EnergyDE-FOA-0000978: Demo Machine

C. L. Goodzeit and M. J. BallMay 1, 2014

General List of Tasks by Performance Period (stage) and Institution

5/1/2014 V1

Project is 18 months total, with 3 stages of 6 months each. Participating Institutions are

Fermilab (FNAL) as principal, for ~60% of effortBrookhaven (BNL) for ~32% of effort

Florida Institute of Technology (FIT) for ~8% of effort

FNAL Stage 1: • Order SC / cable and parts for the field coils.• Prepare engineering drawings for the field coil assembly and demo device.• Start the winding and vacuum impregnation of the field coils.• Prepare progress report. BNL Stage 1: • Order SC / cable for the inner and outer armature coils.• Order temperature sensors and required instrumentation for data acquisition.• Prepare engineering drawings for winding the inner & outer armature coils (to

include temperature sensors. )• Program the direct wire machine for winding the armature coils.• Prepare progress report. FIT Stage 1: studies and planning listed on next slide

5/1/2014 V1 2

Performance Period 1 = months 1 to 6 Stage 1 will be preparation and perhaps start of coil winding.

FIT Stage 1: (months 1-6)• a. Create finite element models of demonstration machine for electromagnetic , mechanical

and thermal analysis. • b. Electromagnetic study: magnetic field, coil inductances, Lorentz forces on coils, flux

linkages, generated power.• c. Initial thermal model study: Using empirical values of the expected energy deposition due

to AC losses in the specified armature conductor at various frequencies, compute temperature profiles in armature coils.

• d. Test plan: Develop the portion of the test plan required to obtain the temperature gradient data from the testing at the FNAL VMTF and processing the data.

• d. Test equipment: Establish requirements and specify equipment for mechanical drive required for testing the generator at various rotational speeds. Develop circuitry to measure and absorb output power from generator test. Include requirements for mounting the test equipment on the top plate of the VMTF at FNAL.

• e. Coordinate efforts with Goodzeit and Ball as required for demonstration machine design, temperature dependent materials properties, initial energy deposition estimates and documentation.

• f. Prepare Progress Report.

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Performance Period 1 = months 1 to 6 Stage 1 will be preparation and perhaps start of coil winding.

FNAL Stage 2: (months 7-12)• Complete the winding and vacuum impregnation of the field coils.• Assemble field coils onto strong back fixture.• Test field coil assembly for quench properties, transfer function, inductance.• Fabricate components for demo device.• Design and fabricate components for test stand.• Start assembly of the demo device.• Liaison with FIT re device test equipment.• Prepare progress report. BNL Stage 2: (months 7-12)• Wind the inner and outer armature coils.• Test armature coils for quench properties, transfer function, inductance.• Test armature coils for performance of temperature sensors.• Ship completed armatures to FNAL.• Prepare progress report.

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Performance Period 2 = months 7 to 12Stage 2 will be coil winding and testing and perhaps start of the demo device assembly.

FIT Stage 2: (months 7-12)• a. Thermal model study: Complete temperature profile studies. Prepare

analytical models to compute the energy deposition in a unit volume of the armature coils from temperature sensor data at the specific locations in the armature coils. This will be used to compare the predicted and measured results.

• b. Participate in testing the armature coils at BNL for involvement in data acquisition and processing data of the temperature sensors.

• c. Complete the fabricating and in house testing of the generator test equipment and deliver to FNAL.

• d. Coordinate efforts with Goodzeit and Ball for technical support and documentation services.

• e. Prepare progress report.

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Performance Period 2 = months 7 to 12 Stage 2 will be coil winding and testing and perhaps start of the demo device assembly.

FNAL Stage 3: (months 13-18)• Complete assembly of the demo

device.• Set up demo device in vertical test

facility dewar.• Perform designated test plan, with

FIT assistance.• Implement

market/commercialization plan• Prepare progress report.• Prepare final project report.

• BNL Stage 3: (months 13-18)• Participate in demo device tests at

FNAL.• Prepare progress report.

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Performance Period 3 = months 13 to 18Stage 3 will be demo device testing and analysis of results.

FIT Stage 3: (months 13-18)• a. Generator testing:

Participate in the testing program at FNAL for the acquisition and processing of the temperature sensor data using the supplied equipment according to the developed test plan.

• b. Data processing and analysis: Combine analytical and measured test results in a final report form with conclusions relating to the results of this research.

• c. Coordinate efforts with Goodzeit and Ball for technical support and documentation services.