Introduction of Double Permanent-magnet High-efficiency Line-frequency. Brushless Synchronous Generator

Transcription

1 Introduction of Double Permanent-magnet High-efficiency Line-frequency Brushless Synchronous Generator 1. Technical Theory DPMG adopts voltage series compensation principle; it joints the main permanent-magnet generator and electric-excited compensation generator stator winding in series under a common stator core. The rotors of the main permanent-magnet generator (PMG) and electric-excited compensation generator are separately independent, and they provide excitation flux respectively. But what the permanent-magnet rotor provides is fixed flux while the compensation generator s rotor provides changeable flux, which is also adjusted automatically according to the needs of motor voltage. The auto adjustment of compensation rotor excitation flux is performed by positive and reverse excitation adjustment through voltage values sensed by rotating AVR based on the voltage signal rotating sensor. When the voltage is higher than the specified value, the permanent-magnet exciter will conduct reverse excitation to the compensation generator rotor through rotating AVR, which will make the voltage emitted by compensation generator go reversely with that of the main permanent-magnet generator, and thus a negative value, and when series add, the compound voltage will descend; on the opposite, when the voltage is lower than the specified value, it will be positive excitation, which will make the voltage emitted by compensation generator go the same as that of the main PMG, and thus a normal value, and series adding will increase the compound voltage. By this way, it can make DPMG voltage constant. Working principle of DPMG is shown in the following figure: 2. Technical Advantages For general PMG, although it realizes brushless, and has advantages of simple structure, small size, light weight, high power density, high efficiency, etc., it also has disadvantages of uncontrollable, unadjusted output voltage, poor stability, and poor ability of loading no-power load because its magnet field is difficult to adjust. And that s why the adjustment of permanent-magnet synchronous generator voltage becomes a bottleneck problem of restricting PMG development.

2 While double permanent-magnet high-efficiency line frequency brushless synchronous generator is a new type of mixed excitation rare-earth permanent-magnet brushless synchronous generator, which has the advantages of small size, light weight, high efficiency of the former PMG on one side, on the other side, it also overpasses the disadvantages of uncontrollable, unadjusted output voltage, poor stability (because its magnet field is difficult to adjust), and poor ability of loading inductive loads (power factor is only cosφ=0.9). The DPMG also has the same electrical performance indexes as those of the electric-excited line frequency brushless synchronous generator. Its main performance advantages are as follows: 1) High efficiency, 4%~10%more than that of electric-excited generator; 2) Small size, light weight, 20%~30% smaller and lighter than the electric-excited generator; 3) Good power supply quality, high precision voltage, with steady-state voltage regulation of±1%; 4) Superior dynamic performance and strong ability of starting asynchronous generator; can start 100%PH no-load asynchronous generator; 5) Excellent load adaptability, be able to drive both inductive loads and capacitive loads; 6) Good electromagnetism compatibility, little radio interference; 3. Main Technical Parameters and Performance Indexes Power Range Rated Speed 10kW~120kW 1500r/min Steady-state Voltage Regulation ±1% Transient Voltage Regulation +20% -15% Voltage Recovery Time 0.5S Voltage Fluctuation Rate 0.5% Efficiency 90% Power Factor (cosφ) ± National Authority Detection Data On July 28 th, 2011, we entrusted the National Mini-to-middle Dynamo Quality Supervision and Detection Center to have full identification test of the two units of ATS.K-12 12KVA DPMG sent by us. The test basis are GB/T phase Synchronous Dynamo Test Methods and Q/ATS Technical Conditions for 12KVA Double Permanent-magnet Line-frequency Brushless 3-phase Synchronous Generator. Test results show that all its performance indexes and function requirements comply with the requirements of Q/ATS Technical Conditions for 12KVA Double Permanent-magnet Line-frequency Brushless 3-phase Synchronous Generator. Find details in Table 5-1. Table 5-1 Achievement Comparison Form of Technical Performance Indexes of 12KVA Double Permanent-magnet Line-frequency Brushless Synchronous Generator

3 Test value/standard value Actually measured Q/ATS 0101 JB/T10747 No. values in Technical Technical Remark Items Identification Test Conditions Conditions 1 Hi-pot Test 1800V 1800V 1800V 2 Measurement of Thermal Insulation Resistance (MΩ) Examination of Voltage Regulation Range (%) Meet requirements of 95, ~105 95~105 Measurement of Sinusoidal 4 Distortion Rate of No-load Line Voltage Waveform (%) is cold 5 Measurement of Steady-state Voltage Regulation (%) 0.838, ±2.5or ±1.5 ±2.5or ±1.0 state, is thermal state 6 Measurement of Transient Voltage Regulation and Recovery Time (%) (S) +13.9, or or or Measurement of voltage 7 deviation when generator runs with asymmetrical loads (%) Temperature Rise Test (K) 61 (F) 105 (F) 105 (F) Test of no-load direct starting of 9 mouse cage 3-phase asynchronous generator (kw-4p)

4 10 Efficiency Measurement (%) (10kW/0.85) 86.1 (10kW/0.85) 79.8 (12kW/0.8) Efficiency is 89.2 when COSφ= Comparisons among Domestic and International Similar Products The PMG researched at present is one of line-frequency generators. Now we compare it with domestic and international electric-excited line generators and permanent-magnet line-frequency generators. Find details in Table 5-2. Table 5-2 Comparisons of PMG and domestic, international similar products: Standard or company Technical Index Actual measured values of DPMG Q/ATS 0101 Technical Conditions JB/T10747 Technical Conditions STAMFORD Electric-excited Generator HATZ PMG PMG of one company in Shanghai Items Rated Power (kw) Power Factor (COSφ) ±0.85/0.8 ± Base Size (H) (mm) Weight (kg) 83 / / 106 / 109 Efficiency (%) Sinusoidal Distortion (COSφ=1.0) (COSφ=0.85) 89.2 (COSφ=0.8) 86.1 (COSφ=0.85) 79.8 (COSφ=0.8) 80.7 (COSφ=0.8) 90 (COSφ=0.9) / Rate of No-load Line Voltage Waveform / 3 (%) Steady-state Voltage Regulation (%) ±1.138 ±2.5 or ±1.5 ±2.5 or ±1.0 ±2.5 or ±1.0 ±10 ±5

5 Transient Regulation (%) Voltage or or or +20 / ± Measurement Recovery Time (S) of or / 0.5 From table 5-2 we can see that PMG performance indexes are advanced among similar products in the world. For example, the generator efficiency is up to 90%, its transient voltage index is much higher than G3 Level (highest level) of ISO8528, which is at a level of 13.91%,-10.87%, and recovery time reaches a highly 0.298S. 6. New Product Identification On February 25th, 2012, our DPM line frequency brushless synchronous generator passed the new product identification which was organized by the National Mechanical and Industrial League (See details in the attached Identification Certificate). The identification Committee regarded: the research and development of this product is successful; it meets requirements of product technical conditions, performance reaches an advanced level of international similar products; engine efficiency, transient voltage regulation, recovery time, and other performance indexes have achieved leading level of domestic and international similar products. Agree the product identification to pass. 7. Energy Saving Analysis of PMG Take 16kW high-efficiency permanent-magnet line-frequency generator for example, analysis as follows: 1) Reduced prime engine work power due to efficiency improvement: 16/80.4%-16/89.3%=1.9834kW 2) According to relevant data, the fuel consumption of prime engine is about 238/kW.h 3) If it works 8h per day, 300 days per year, then one 16kW unit can save fuel oil per year by: =1132kg=1.132 tons 4) At present, diesel price is 9.4 Yuan/kg (7.83Yuan/L), so one user can save cost operation per year by: =10640 Yuan 5) If there are 100,000 sets of such high-efficiency double permanent-magnet line-frequency generator under use in society, then Saved diesel per year is: = 113,200 tons Users can save operation cost per year by: =1,064,000,000 Yuan 8. Discharge Reduction Analysis of DPMG Calculate based on relevant data introduction, as follows: 1) Diesel combustion value is 1.3 times of that of standard coal 2) CO2 produced by 1 ton of standard coal is 3 times of that of diesel 3) 100,000 units of 16kW high-efficiency DPMG can reduce CO2 discharge per year by: 113,200tons 1.3 3=441480tons To sum up, high-efficiency double permanent-magnet generator is a type of high-efficiency, energy-saving,

6 low-carbon, green mechanical and electrical products, and it can bring huge economical and social benefits to users and society. 9. Patents 5 invention patents, 12 practical new type patents, 6 appearance design patents, i.e, applied patents of the double permanent-magnet line-frequency brushless synchronous generator were totally 23, and we are applying for patents of European and American areas. 10. Application The strategic orientation of Javac is to be inland advanced, world-famous, competitive leading and excellent supplier of domestic high-efficiency DPMG manufacturing industry. DPMG technique can be used in all generators, including single phase, 3-phase and line frequency, middle-frequency, DC, high-speed, low-speed, and other brushless generators; from power range, it can be put forward to entire mini and middle power. The double permanent-magnet line-frequency brushless high-efficiency synchronous generator has compact structure, high efficiency, small size, light weight, good power supply quality, and other advantages. It is an excellent product with low operation cost and green, energy-saving, environment-friendly dynamo; main application: military power supply, vehicle power supply, communication base station power supply, marine power supply, and other fields. Details are as follows: 1. Military market: thanks to the compact structure, high efficiency, small size, light weight, good power supply quality of DPMG, it can minimize military power supply, reduce fuel consumption and pollutant discharge. For it is a new product of high-efficiency, low operation cost, green, energy-saving, environment-friendly dynamo, it is fairly suitable for vehicle power supply, military mobile and fixed power supplies to improve power supply efficiency and power density so as to enhance its flexibility. 2. Vehicle power supply market: DPMG which can minimize car power supplies also has quite a strong competition in the vehicle power supply market, such as refrigerated trucks, mobile power vehicles, engineering vehicles, etc. We are carrying out project cooperation of 9KW vehicle PMG with Taiwan businessmen; meanwhile, we are talking over with several domestic special vehicle enterprises. 3. Communication base station market: according to a statistics, there are over one million points of mobile communication base stations nationwide. Among them, 10% need to be equipped with small size emergency or standby diesel genset. Thanks to the compact structure, high efficiency, small size, light weight, good power supply quality, and its features of being able to reduce fuel consumption and pollutant discharge, DPMG is a new product of high-efficiency, low operation cost, green, energy-saving, environment-friendly dynamo, and it is superbly suitable for the communication base station to produce electricity, to improve product efficiency and reliability, as well as lower operation cost and maintenance cost. 4. Marine power supply market: with continuous increase of ships and ports in our country, the demand for marine generators in the future will enhance steadily. As known, fishing-boats in Guigang, Guangxi province are over 20,000, with a generator demand power range of 20~120KW. What they use right now are traditionally low-efficiency, oil-consumed, electric-excited generators. The administrative authorities of Guigang are actively taking account of adopting our high-efficiency marine DPMG to reduce boat s comprehensive operation cost and discharge. Thus the DPMG has a wide market future.

7 5. Overseas market: our country has been in WTO for more than 10 years. To implement the strategy of Going outward, quite a number of high-tech enterprises which have actual strength extend overseas market actively and build up their own brands. According to a survey, the generator equipment demand in Europe per year is about one million units, and they have higher requirements for discharge. Such demand in the Middle East, Africa, Southeast Asia, and other areas is about two million. In Europe, people pay highly attention to energy saving and environmental protection, and they have full interest in low-carbon, green industrial new products. At present, a Belgian trader has reached preliminary cooperation intension of being our primary agency of the double permanent-magnet line-frequency brushless high-efficiency synchronous generators in Europe, who will push forward the DPMG in Europe through its formerly owned tunnels. Thus we can say that overseas market for DPMG is optimistic to some extent. ATS.K Series of DPMG Product Introduction: ATS.K series of double permanent-magnet line-frequency brushless 3-phase synchronous generator is a kind of open structure DPMG, with various defensive structures, such as IP21/IP22/IP23, etc. Performance Advantages: 1) High efficiency, 4%~10% higher than that of electric-excited generator; 2) Small size, light weight, 20%~30% smaller and lighter than electric-excited generator; 3) Excellent power supply quality, high voltage precision, with steady-state voltage regulation of ±1%; 4) Superb dynamic performance and strong ability of starting asynchronous generators; can start 100%PH no-load asynchronous generator; 5) Adapt loads well, can load both inductive and capacitive loads; 6) Good magnetic compatibility, little radio interference. Application: Double permanent-magnet line-frequency brushless synchronous generator has compact structure, small size, light weight, high efficiency, and good power supply quality, which can minimize military power supplies. It is a new type of green, energy-saving, environment-friendly dynamo product with high efficiency, low operation cost, quite suitable for vehicle and military power supplies. Among them, IP23 is the protecting structure for marine generator, such series of DPMG has single bearing and double bearings: double bearing structure is universal generator structure, while single bearing is the one specially equipped to diesel engine to assembly of diesel genset. Main Technical Parameters Model ATS.K Rated Power (kw) Rated Voltage (V) 400V Phase Number 3

8 Power Factor ±0.85/±0.8 Rated Speed (r/min) Rated Frequency (H Z ) Excitation double permanent-magnet excitation Insulation Class F Base Size (H) Weight (kg) Efficiency (%) Main Performance Indexes No-load Voltage Regulating Range (%) Steady-state Voltage Regulation (%) Transient Voltage Regulation (%) 95~105 ±1/± /-15 Voltage Stabilization Time (S) 0.5 Voltage Fluctuation Rate (%) 0.5 Line Voltage Waveform Distortion Rate (%) 3 Compared with traditional generators (Sample Data) Rated Power of Siemens (kw) Siemens Base Size H / / 280 Siemens Efficiency (%) / / 91 Rated Power of Stamford (kw) Stamford Base Size H Stamford Efficiency (%)

9 ATS.B Series of DPMG Product Introduction: ATS.B series of fully closed double permanent-magnet line-frequency brushless 3-phase synchronous generator is a kind of double permanent-magnet line-frequency brushless 3-phase synchronous with full closed structure, with IP55 and IP57 defensive structures. Performance Advantages: 1) High efficiency, 4%~10% higher than that of electric-excited generator; 2) Small size, light weight, 20%~30%smaller and lighter than the electric-excited generator; 3) Excellent power supply quality, high voltage precision, with steady-state voltage regulation of ±1%; 4) Superb dynamic performance and strong ability of starting asynchronous generators; can start 100%PH no-load asynchronous generator; 5) Adapt loads well, can load both inductive and capacitive loads; 6) Good magnetic compatibility, little radio interference. Application: Double permanent-magnet line-frequency brushless synchronous generator has compact structure, small size, light weight, high efficiency, and good power supply quality, which can minimize military power supplies. It is a new type of green, energy-saving, environment-friendly dynamo product with high efficiency, low operation cost, quite suitable for vehicle and military power supplies. Among them, IP55 is the dust-proof, water spray-proof generator, can be used for marine or other generators which have special protecting requirements, such as axle belt generator for civil use and workshop emergency standby power supplies in textile factories. IP57 is dust-proof, immersion-proof generator and can be used as axle belt generators for military equipment. Main Technical Parameters Model ATS.B Rated Power (kw) Rated Voltage (V) Phase Number 3 400V Power Factor ±0.85/±0.8 Rated Speed (r/min) 1500 Rated Frequency (H Z ) 50 Excitation Insulation Class double permanent-magnet excitation Base Size (H) Weight (kg) Main Performance Indexes No-load Voltage Regulating Range (%) F 95~105 Steady-state Voltage Regulation (%) ±1/2.5 Transient Voltage Regulation (%) +20/-15 Voltage Stabilization Time (S) 0.5 Voltage Fluctuation Rate (%) 0.5 Line Voltage Waveform Distortion Rate (%) 3

10 Technical Features of ATS Double Permanent-magnet Genset: 1. Matching the high-efficiency DPMG with advanced diesel engine perfectly, it can make genset run more economically, more environment-friendly. 2. The combination of DPMG ensures perfect output of voltage waveform, as well as outstanding transient response and superb dynamo starting ability. 3. Wholly compact design, reliable operation, small size, large power; 4. Secondary vibration-reduction chassis, more reliable and stable running; 5. Secondary muffler, quieter operation