Innovative Axial Flux Air Cored Permanent Magnet Generator suitable for Slow, Medium Speed and Direct Drive Wind Turbines Dr Makhlouf Benatmane CEO NGenTec Ltd 1
Starting from a blank sheet, we created the foundation of the technology with only one objective in mind: To design a generator that specifically meets the requirements for wind turbines 2
Focused Characteristics High contribution to lowering Cost of Energy Highly modular in manufacturing, assembly and transport both rotor and stator Easily stacked for higher power ratings Flexibility in operation - High availability, redundancy Easy integration into any wind turbine mechanical structure Simpler bearing arrangement Standard materials allowing multiple sourcing - wide supply chain price competitiveness 3
Focused Characteristics Lightweight rotor and stator modules Can be handled using turbine internal crane Repeatable process - Progressive high quality checks Safe method of magnets insertion and assembly Magnetic forces are neutralised within the rotor Zero Cogging Torque The rotor can literally be turned by a single hand around the stator 4
Flexible Generators / converters systems configurations Each stage can be operated independently A number of stages can be operated to suit wind conditions and availability G1 G2 G3 G4 C1 Converters Higher Redundancy, Efficiency, Availability Tx 5
Independent study confirmed significant cost savings and Internal Rate of Return IRR improvement by using axial flux air cored generator in a typical offshore wind farm: LCOE reduced by up to 6% over the life of the wind farm; NGenTec fault tolerant design reduces O&M and increases availability compared to baseline Lower the turbine cost by approx. 1.3% Reduced wind farm CapEx by 0.8% O&M costs down 12% to 20% for the whole wind park Availability: up 0.7% Internal Rate of Return: up to 20% increase 6
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Successfully designed, manufactured Full-scale 1MW prototype that rotates at the speed and diameter of a 6MW machine The prototype represents a single stage of a 6MW direct drive generator, it consists of four 250kW stacks that can operate independently, in pairs or in full with a voltage output of 690V Prototype has been built by NGenTec and David Brown Gear Systems and the diameter is similar to the diameter of a full 6MW rated machine The machine has been tested for over seven months and achieved over 200 hours of load testing Conducted tests: Open circuit No Load Performance Temperature Rise Partial Load Full Load Waveform Analysis Efficiency Single Stage Load Tests Multiple Stage Load Tests November 2011 and tested 1MW prototype 8 8
Design and Operation Factory to Installation Operation and Maintenance Increased reliability and availability High efficiency across full operating range Scalability by simple common components Flexible system design, high capacity factor Flexibility to suit wind conditions/wind turbine output Zero cogging torque - minimal vibration and generator noise Easy adaption to any wind turbine design and requirements No risk of ovalisation during magnets insertion or generator UMP Designs suitable for direct, slow and medium speed Increased accessible market Avoids needs for large manufacturing investments Easy module manufacturing, assembly and installation High advantage in transport and overall logistics. Minimum part count and use of standard parts - rewarding impact on supply chain and costs Assembly possible by reasonably skilled operators (vs highly skilled workforce for traditional PMG) Progressive testing prior to full machine assembly enhanced quality and reliability Reduced weight and size, with positive impact on required nacelle size, tower structure and foundations for new installations. flexibility of assembly at the wind turbine maker facility if required Higher energy yield Low or medium generator voltage designs Inter-changeability, redundancy Higher flexibility and availability Reduced maintenance: easy replacement of single module resulting in reduced downtime, resulting in reduced O&M costs Low spare parts holdings Flexibility to locate generator assembly facilities with wind turbine manufacturing facility at quayside location Cost competitive initial and through life Simplification Across All Stages 9
Thank you for your attention Should you require any further information, please contact Dr Makhlouf Benatmane - CEO Office Tel: +44 (0)131 524 9444 Mobile: +44 (0) 741 512 4641 Email: makhlouf.benatmane@ngentec.com Web: www.ngentec.com 10