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Hydraulic transmission for the wind turbine

Design of the system


Identification of the system requirement
System configuration
Selection of the component
Dimensioning
Analysis of the system
Operating scenario
Simulation using Bond Graph
Design of the control system
Design of the feedback PI controller
Stability issue



Design requirement
System configuration
Dimension
Selection and Design of component
Final Dimension
Simulation and Verification
Environmental
model
Control Law
Controller Design
Calculation of Bulk Modulus
K_0@40oC

17.3

kbar

m

5.6

Operating pressure

300

bar

beta

20.49

kbar

2.049E+09

Pa

k_value

1.284E+10

Pa/m3

Pros Cons App
Gear pump
Inexpensive
Less moving part
Medium pressure level(up to 21
Mpa)
Low efficiency (80~90%)
Noise (70~80 dB)
Fixed disp. Unit
Power supply for inexpensive systems
Oil pump for diesel engines, charge
pumps for hydrostatic pilot systems
Gerotor
Pumps
Inexpensive
Less moving part
Low pressure level(~7 Mpa)
Low efficiency (60~80%)
Fixed disp. Unit
Charge pump for hyd. Control system
Makeup flow for hydrostatic transm.
Vane Pump
fairly inexpensive
Less moving part
Self-adjusting for vane wear
Medium pressure level(up to 21
Mpa)
Low efficiency (70~80%)
Fixed disp. Unit
Automotive application for power steerin
g systems
Radial Piston
Pump
High efficiency (85~98%)
High pressure (~42MPa)
Low starting torque
Short and flat
Fairly expensive
Fixed disp. Unit
reverse operation mode as an output mot
or for hydrostatic transm.
Axial-piston
Swash-Plate
pump
High efficiency (85~98%)
High pressure (~42MPa)
Var. diap. Unit
Fairly expensive
Complex construction
Hyd. Transmission, fuel pumps, robotics, h
eavy equip., air-craft flight cont.
Bent-axis
design
High efficiency (85~98%)
High pressure (~42MPa)
Highest degree of var. disp
Low starting torque
Most expensive
Most complex design
More common as motor
Maximum speed ratio (5:1)
PUMP MOTOR
Hydraulic actuator
Type Bent-axis Motor
Grid frequency f 50 Hz
No. of poles n 4
Rotating speed of genarator omega_g 1500 RPM =120f/n
Motor speed omega_m 1500 RPM
157.1 rad/s
Electric power required P_e_out 200 kW
Electrc efficiency eta_e 95%
Power output of the motor P_m_out 210.5 kW =P_e_out/eta_e
Motor torque T_m 1340.3 Nm =P_m_out/omega_m
Differential pressure p_max 285.3 bar
Found by the pump
calculation. (Iteration)
Calculated flow Q_id 442.7 l/min =P_m_out/p_max*600/1000
disp_ideal disp_m_id 0.0470 l/rad =Q/omega_m/60
295.1 cm3/rev
Selected Motor Parker Gold Cup P24
disp_actual_max disp_m_id 403.2 cm3/rev
6.42E-05 m3/rad
Flow_max Q_max 604.8 l/min
Efficiency eta_m 87%
Hydraulic pump
Type

Radial piston type
Power output of the motor P_m_out 210.5 kW =P_e_out/eta_e
Efficiency of the motor eta_m 87%
Efficiency of the fluid transm. eta_tran 99%
Power output P_p_out 244.43 kW =P_m_out/eta_m/eta_tran
Differential Pressure p_p_max 285.33 bar
rotational speed omega_p 8.57 rad/s
Found by wind turbine
calculation (Iteration)
Flow Q_max 513.98 l/min =P_p_out/p_p_max/1000*600
Displacement disp_p 0.999 l/rad =Q_max/omega_w/60
6280.0 cm^3/rev
Efficiency 95%
Selected pump
Hagglund CA140 100
displacement disp_p' 6280 cm^3/rev
1.00 l/rad
Flow Q_max' 513.98 l/min =disp_p'*omega_p*60
Differential pressure p_p_max' 285.33 bar =P_p_out/Q_max'
Charge pressure p_p_c 5 bar
System pressure p_s 290.33 bar =p_p_max+p_p_c
Torque_eff100 T_p_100 28518.95 Nm =P_p_out*1000/omega_p
Efficiency eta_p 95%
Required Torque T_p 30020 Nm =T_p_100/eff_p
Wind turbine
Power output P_p_out 244.43 kW =P_m_out/eta_m/eta_tran
Efficiency of the pump eta_p 95%
Power output P_w_out 257.30 kW =P_p_out / eta_p
Density of air rho_air 1.23 kg/m^3
Design wind velocity U 12.5 m/s
Turbine efficiency Cp 0.5021
Number of blades Z 3
Tip speed ratio TSR 8
Airfoil NACA 23015
angle of attack alpha 8 deg
0.1396 rad
Lift coefficient Cl 0.8
Radius R 11.6676 m
rotational speed omega_w 8.571 rad/s =U*TSR/R
81.84 rpm
Torque T_w 30019.9 Nm =P_w_out/omega_w
Calculated using the blade element method (MATLAB Code)

Torque
Calculation =
f(V_wind, _WT)
Inertia Force
(Rotor)
Friction Loss
(Rotor)
First design the blade using BEM








Torque calculated for given wind velocity and
angular velocity using BEM
I
n
p
u
t

Power : 260 kW
Wind Velocity : 12.5 m/s
Wing profile : NACA 23015
Angle of attack : 8 deg
Initial Cp : 0.5

O
u
t
p
u
t

Radius : 11.67 m
Angular velocity : 8.57 rad/s
Torque : 30336 Nm
Cp : 0.5061
Chord length and induction
factor for segment
-0.1
0
0.1
0.2
0.3
0.4
0.5
0.6
0 5 10 15 20 25
C
p

Wind Speed (m/s)
Wind Turbine Cp Curve
VESTAS V25
y = 3.507E-04x
4
- 1.122E-02x
3
+ 1.026E-01x
2

- 2.052E-01x + 3.695E-01
0
0.2
0.4
0.6
0.8
1
1.2
0 5 10 15
E
f
f
i
c
i
e
n
c
y

TSR
Efficiency vs. TSR
Wind speed _WT
TSR U Wind WT
P U P q q e = ) , (
3 2
2
U R P
air Wind

t
=
http://www.dansk-vindenergi.dk/print.asp?id=2370
Volumetric
Loss

Q = f(p)
Friction Loss

p = f(_p)
Mech -> Hyd

disp_m x p = T
disp_m x _m = Q

disp_m is fixed
Friction Loss (bar)
= f(_p)
= 0.022 _p^2 + 0.0340
_p^2
Volumetric Loss (l/min)
= f(p(kbar))
= 141.38 p^3 - 18.037p^2 +
17.863p
Friction Loss

Input - Pressure(HP),
displacement,
_m
Output Pressure
loss
Hyd -> Mech

disp_m x p = T
disp_m x _m = Q

disp_m is variable
Volumetric Loss

Input Flow(HP),
displacement,
_m
Output Leakage
flow
y = -0.3618613702 x
2
+
0.1550623874 x + 0.9757857143
y = -0.0795774715 x +
0.8275000000
y = -1.1579563845 x
2
+
0.5420362633 x + 0.9115142857
y = -0.0318309886 x +
0.9180000000
y = -1.7369345767 x
2
+
0.8703501745 x + 0.8453714286
y = -0.0238732415 x +
0.9392500000
75.0%
80.0%
85.0%
90.0%
95.0%
100.0%
0 0.1 0.2 0.3
Angular Velocity (x1000 rad/s)
eta_V@69
eta_m@69
eta_t@69
eta_V@207
eta_m@207
eta_t@207
eta_V@345
eta_m@345
eta_t@345
(eta_V@69)
(eta_m@69)
(eta_m@69)
(eta_V@207)
Full Stroke
Similar performance curve available for , . Stroke
Pressur
e
eta_m & eta_v =
f(_m) @ full
stroke
f(_m) @ stroke
f(_m) @ stroke
f(_m) @ stroke
Interpolate for
given stroke
eta_m & eta_v =
f(_m) @ given stroke
_m
eta_m &
eta_v
Volumetric
Loss

Q = f(p)
Constant Flow
Pump

Q = 0.002
Reservoir

P = 0 bar g
Safety Valve

Q = k * (p)^0.5
K = 0.0632
Pressure in kbar
Compressibility
Effect

p = -/V_pipe x V
V = Q
V_pipe = D^2/4 x L
Addition of head
due to gravity

p = g H
(H = 30m)
Pressure drop due to pipe
friction

p = f V^2 D / L
f = f(Re) = -0.0114 ln(Re) + 0.1348
Re = V D /
V = Q / (D^2/4)
Addition of head
due to gravity

p = - g H
(H = 30m)
Safety Valve

Q = k * (p_hp p_set)^0.5
K = 0.0340
Pressure in kbar
Power consumed by the generator
All power generated by the motor will be
consumed by the generator
Generator load

P_gen = P_motor
T_gen = P_motor / omega_m
Inertial Force (incl. flow
inertance)

I_total = J_rotor + I_flow*disp_m^2
Omega_m = T_m / I_total
Wind Simulation
U(t) = Ug(t) + Um(t)
Constant mean velocity assumed




NORSOK Standard Spectrum
for Wind Gust
U(t)
4
6
8
10
12
14
16
18
20
0 100 200 300 400 500 600 700 800 900 1000
W
i
n
d

V
e
l
o
c
i
t
y

(
m
/
s
)

Time (sec)
Wind Simulation
V_w V_w_avg(10sec)
Control Objective
Adjust the _turbine so that optimum efficiency of the turbine is
achieved.


Displacement of the motor works as accelerator or brake to the
turbine

Reference Model
Constant TSR for the best efficiency of the wind turbine



Use mean wind velocity for 10 sec in order to stabilize the
controller
0 ) ( lim
_
=

D WT WT
t
e e
R
t U
TSR t
d WT
) (
) (
_
= e
Block diagram PI Controller
|
|
.
|

\
|
+ = +
} }
dt V P f Q
V
Vol
dt
V
V
Vol
V
T c J
p pv lp cv
av
a a
lp
lp
av
a a
p pv
hp
hp
pt
p
WT
u q q
q
e
|
q
e
u q
|
q
u u

) (
Initialization
Initial wind turbine rotor velocity
_wt_0 = 8.57 rad/s for U(0) = 12.5 m/s
Set by initial angular momentum of the wind turbine

Initial circuit pressure
p_hp = 300 bar, p_lp = 5 bar
Set but initial compressed fluid volume

Initial motor rotor speed
_m_0 = 157.1 rad/s
Set by initial angular momentum of the motor &
generator and equivalent flow inertance


Total efficiency


Wind Turbine


Hydraulic pump



Hydraulic motor


}
}
=
dt t U A
dt t t T
air
WT WT
WT
3
) (
2
1
) ( ) (

e
q
}
}
A
=
dt t t T
dt t Q t P
WT WT
pump
) ( ) (
) ( ) (
e
q
}
}
A
=
dt t Q t P
dt t t T
WT WT
motor
) ( ) (
) ( ) ( e
q
}
}

=
dt t U A
dt t P t P
air
e ch out
3
arg
) (
2
1
) ( ) (

q

Circuit
}
} }
A
+ + A
=
dt t Q t P
dt t P t P t P dt t Q t P
SR comp friction
circuit
) ( ) (
) ( ) ( ) ( ) ( ) (
q
Simulation compared for different mean wind
speed (8->12.5 vs. 8 vs. 12.5 m/s) for 1000 sec

Tuning of Control Gains
Tuning by parameter sweeping
Ki : 0.0001 ~ 0.1
Kp : 0.0001 ~ 0.1
The control objective was best achieved at
Ki = 0.002
Kp = 0.03

Efficiency Comparison

Speed 8 -> 12.5 m/s 8 m/s 12.5 m/s
Type Variable Fixed Variable Fixed Variable Fixed
Total 32.3% 32.2% 21.1% 18.5% 35.6% 34.8%
Charge 90.6% 90.7% 75.9% 73.7% 95.0% 95.0%
Wind Turbine 45.1% 44.7% 37.3% 34.0% 46.7% 46.6%
Pump 98.6% 98.8% 99.0% 99.5% 98.4% 98.3%
Motor 88.9% 89.1% 81.9% 82.9% 91.9% 91.8%
Circuit 97.8% 96.7% 97.9% 94.6% 95.8% 94.6%
Miscellaneous 92.3% 93.5% 93.7% 94.7% 92.5% 92.2%

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