Energy Systems Research at Oregon State University

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Energy Systems Research at Oregon State
University

• Annette von Jouanne, Ph.D., P.E.
• School of Electrical Engineering and Computer
  Science Oregon State University

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Outline

• Brief Overview of OSUs main Energy Systems Lab
  
• The Motor Systems Resource Facility (MSRF)
• -Capabilities
• -Example Recent Research and Testing Projects
• Current Main Research Thrusts
• -NAVY LCAC (Landing Craft, Air Cushion)
  Hovercraft
• -Ocean Energy Research
• -Hybrid Electric Tank Power Quality

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• Motor Systems Resource Facility (MSRF)
• A Machines, Drives, Power Electronics,
  Renewables and Power Quality Research and
  Testing Laboratory at OSU
• Fully operational since 1996
• Founding Sponsors
• Electric Power Research Institute (EPRI)
• Bonneville Power Administration (BPA)
• US Department of Energy (USDOE)
• Pacific Gas Electric (PGE)
• Co-Directed by Drs. A. Wallace and A. von
  Jouanne

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OBJECTIVES OF THE MSRF

• Create a unique research and testing facility
  where our students can obtain an enhanced,
  hands-on industrial experience, while meeting the
  needs of the Energy Systems Industry.
• Highly flexible capabilities
• converters, drives, power supplies, filters
  and controllers
• motors, generators and renewables (can
  regenerate)
• wide power and speed range
• Highly efficient only system losses
  dissipated.

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MSRF CAPABILITIES
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MSRF Partial Aerial View
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MSRF 300 hp Test Bed (with Hybrid Electric
Vehicle Generator)
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STRENGTHS OF THE MSRF
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Navy STTR Phase I Contract LCAC (Landing Craft
Air Cushion) High Performance Hovercraft (with
Chinook Power)

Objectives Develop improved actuator systems for
steering vanes in thrust engine exhausts, thus
reducing the maintenance, complexity, and failure
modes associated with conventional hydraulic
systems.
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Existing Technology to be Replaced(High
maintenance Hydraulics)
Major Specs 1100lbs oper. thrust 5.1 inches of
travel Speed 5.5 inches/s Wt 12lbs w/out fluid

Solution Replace hydraulic system with a
Switched Reluctance Motor (SRM)/drive, operating
as a linear actuator screw Ave LCAC is
16,000hp, (8,000hp propulsion, 8,000hp lift)
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Mock-up Installation
Drive electronics mounted inside of nacelle
leg (for protection) Note Vibration is a huge
issue
Absolute resolver (as a direct reading sensor,
would give redundancy)
For fail-safe oper., would have home sensor,
and two end-of-travel sensors
SRM/leadscrew actuator
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SRM/leadscrew actuator
Roller Nut
SRM
Roller Screw
Thrust Shaft
See improvements in speed, thrust, maintenance,
wear, lifetime and reliability when compared to
the better known "power screw" and "ball screw"
configurations
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Why Choice of SRM/Drive

• Has ideal characteristics for the combat
  environment
• High power density
• Robust Design (rotor is a simple stack of
  laminations, without any windings or magnets)
• Fault tolerant (limp home capability, e.g. during
  loss of phase)

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MOTOR SYSTEM CLASS CANDIDATES  
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RELUCTANCE MOTOR COMPARISON
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MOTOR POWER ELECTRONICS
Classic Bridge Converter favored (importance of
robustness/fault tolerance)
8/6 SRM - When a stator phase is energized, the
most adjacent rotor pole-pair is attracted
towards the energized stator in order to minimize
the reluctance of the magnetic path. Therefore,
it is possible to develop constant torque in
either direction of rotation by energizing
consecutive phases in succession.
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DESIGN PROCESS FOR SRM
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SRDaS (Switched Reluctance Design and Simulation)
showing size/geometry specs. Dev. by Dr. Peter
Rasmussen, Aalborg University, Denmark
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FEA MAGNETIC FLUX VISUALIZATIONS (using Maxwell
2D)
Aligned position
Unaligned position
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Leadscrew Motor Calculations(115Vp/200V/400Hz)
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SRM SYSTEM PHOTOS
Rotor
Stator
3ph, 120V, ½ hp Position detection by signal
injection
SRM controller
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VERTICAL THRUST PLATFORM (SRM rigged to lift a
load)
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RESULTS OF VERTICAL THRUST PLATFORM
A 140lb weight can be lifted with the setup
(limited by this SRM/contr.), shows trend that
thrust can be further improved (req. operating
thrust is up to 1100lbs)
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Research Thrust Ocean Energy Extraction

• It is estimated that if 0.2 of the oceans
  untapped energy could be harnessed, it could
  provide power sufficient for the entire world.
• OSU is the Prime Location to conduct ocean wave
  energy extraction research
• - Motor Systems Resource Facility (MSRF)
• - Hinsdale Wave Research Lab
• - Wave energy potentials of the Oregon coast.

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Power from WavesAverage of 5 buoys off the
Oregon coast over past 10 years
(From National Data Buoy Center)
Power from a wave is kW/m of crest
length (distance along an individual crest) ?
the density of sea water 1025 kg/m3 g
acceleration due to gravity 9.8 m/s/s T
period of wave (s) (averages 8s in the winter to
6s in the summer) H wave height (m) (averages
3.5m in the winter to 1.5m in the summer)
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Our Planned Devices and Goals
Must be Survivable, Reliable, and
Maintainablewith efficient and high quality
power take-off systems

• Direct Drive Buoy
• (Current Focus)
• Simplify the current buoy technology
• Avoid hydraulic based units, looking at direct
  drive rollerscrew and linear PM gen. systems
• Increase lifespan and decrease maintenance

• Oscillating Water Column
• (Will also be fully investigated)
• Create novel approach
• Simplify the units, introduce modularity with
  flexibility
• Investigate Advanced Composite Materials
• Bring overall costs down

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Oscillating Water Column Concept
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Hydraulic AquaBuoy Prototype System (Well be
developing the Power Take-off (PTO) system for
this unit)
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OSU is Currently Investigating Two Novel Direct
Drive Buoy Approaches
Exploring Roller Screw Concept (allows increased
Gen speeds)
Permanent Magnet Linear Generator
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OSUs air gap wound, permanent magnet, linear
generator buoy
Uses the vertical motion of the waves to power a
linear generator (shaft anchored to sea floor,
floater moves armature coils relative to PM
translator to induce voltages)
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OSUs air gap wound, permanent magnet, linear
generator
Translator, air gap, plastic tube
(aqua), Armature coils (yellow), steel lamination

The translator shaft has an alternating assembly
of high permeability steel pole tip pieces
(needed for the transfer and direction of flux)
and high density Neodymium-iron-boron
magnets The armature coils are spirally encased
with electrical lamination steel (outer grey) to
provide for flux coupling through the generator.
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Armature Coils of the air gap wound, PM, linear
generator
Showing One Phase
Constructional Section
Translator, air gap, plastic tube
(aqua), Armature coils (yellow), steel lamination

The armature consists of a thin walled plastic
tube (aqua) wrapped with copper magnet wire
(yellow) forming eight individual coil sections
spaced such that they are 90 degrees out of phase
with each adjacent section (for two phase
application).
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Actual Armature (top) and Translator Shaft
(below)
Armature coils wrapped on plastic tube, using Al
shaft for support
Translator shaft (total 32cm long), alternating
pole pieces and magnets (magnet poles opposed to
double the available flux). The steel pole tip
pieces are threaded for ease of assembly on
nonmagnetic shaft. Magnets N-35, Ni coating,
outer dia. 45mm, inner dia. 20mm, thickness10mm
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Actual Translator Shaft in Armature
Armature shown with Aluminum casing around steel
laminations
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Direct Drive Buoy Based on a Novel Roller Screw
Concept
A float/spring will be attached to the nut,
moving the nut up and down approximately 0.45m
above and 0.45m below the equilibrium position as
the water moves up and down. It is envisioned
that a generator will be coupled to the end of
the screw to be rotated by it. The up and down
motion will make the screw rotate in a clockwise
and counter clockwise direction, moving the rotor
of the generator to generate electricity.
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PM Synchronous Generator in Dynamic Reciprocating
Mode
Sine driven Speed/Wave Profile Enabled by
Programmable Dyno -max speed avail. in given
time (T 3.5s) is 262rpm clockwise to 262 counter
cw
Output line voltage and three-phase currents
modulated by the speed of rotation, Showing
correlation between min. and max. speeds and
generator output power
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Our Planned RD Process

• Currently Funded Work
• Initial research and development into the
  prototypes and power take-off (PTO) systems
• Following the RD we will experimentally simulate
  the electrical characteristics in the MSRF
  (generators, controllers and converters, PTO
  etc.), with regeneration back onto the utility
  grid
• Next Stage Plans with Future Funding
• Build larger scale prototype models to test in
  the Hinsdale Wave Research Lab
• Testing/demonstration of working devices off the
  Oregon Coast

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United Defense Contracts

• Research on the Power Quality issues involved
  with Hybrid Electric Tanks (has highly
  sensitive status, thus detailed discussion must
  be avoided)
• Analyzing the harmonics on the main bus while
  considering multiple (proprietary) converter
  loads. (includes analytical open-form
  derivations, closed-form solutions, simulation
  and experimental verification, as well as
  investigation mitigation techniques)