Designing a Halbach Rotor Magnetic Gear for a Marine Hydrokinetic Generator
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Engineering↗
Engineering topics
Williams, Wesley
Publications and source records attributed to Williams, Wesley.
Uncertainty Quantification in High-Low Dynamic System Coupling using RAVEN and TRANSFORM
This work demonstrates new functionality and applications stemming from the development of high-fidelity to low-fidelity (high-low) coupling for system simulations and to further explore the capabilities of the Risk Analysis Virtual Environment (RAVEN) in the performance of uncertainty quantification in this kind of high-low coupled system models. The work builds from previous work on high-low coupling that utilized COBRA-TF (CTF), the high-fidelity subchannel analysis code, with a low fidelity model built in ORNL’s TRANSFORM, the system analysis code, utilizing the Functional Mock-Up Interface (FMI). Steady-state and transient analysis examples using the high/low coupled models generated from CTF and TRANSFORM/FMI are investigated. The workflows for both steady-state and transient coupled simulations are described. A steady-state parameter sweep and uncertainty analysis of the primary flow rates and reactor power are demonstrated. Likewise, a transient pump trip and power ramp sensitivity studies are also demonstrated. This work elucidates some of the potential benefits and future needs of using RAVEN for high/low system coupling analysis of energy systems. It also shows some of the difficulties that can be encountered in coupling system simulations.
Williams, Wesley↗
Electromagnetic analysis of a wind turbine magnetic gearbox
The design of the second stage of a 59:1 multi‐stage magnetic gearbox for a wind turbine demonstrator is presented. The multi‐stage series‐connected magnetic gearbox is composed of a 6.45 first stage and 9.14 second stage. A flux‐focusing spoke‐type rotor typology is used with a unique segmented fully laminated design. The impact of structural design changes is considered with respect to torque density. A new rotor typology is presented that enables the magnetic gearbox to be mechanically assembled first without magnets.
Li, Kang↗
Electromagnetic analysis and experimental testing of a flux focusing wind turbine magnetic gearbox
The electromagnetic design of the second stage of a 59:1 multistage magnetic gearbox for a wind turbine demonstrator is presented here. The multistage series connected magnetic gearbox is composed of a 6.45:1 first stage and 9.14:1 second stage magnetic gear. The magnetic gears utilize a flux focusing spoke type rotor typology with a unique segmented fully laminated design. The electromagnetic impact of structural design changes on the second stage gearbox is considered with respect to torque density. Severe 3-D edge effects were encountered that greatly reduced the expect torque density of the stage 2 magnetic gear. Experimental testing of the multistage magnetic gear highlight unexpected problems associated with eddy current loss and torque ripple.
17 WIND ENERGY↗
Vibration Analysis of the First Stage of a Multi-stage Coaxial Magnetic Gearbox
This paper describes an analytical model of a single stage of a series- connected multi- stage coaxial magnetic gear (MSMG). This model is a system of spring-mass-dampers which is then used to investigate the vibrational modes and natural frequencies of the system at the rotational speeds observed during operation. This approach includes the bending and shear forces created in the magnetically active area of the gearbox which are generated due to the relative motion of the magnets that in turn produce fluctuating magnetic fields. Understanding these vibrational modes is important for magnetic gearboxes to realize their potential for long duration, low maintenance operation.
17 WIND ENERGY↗
Designing and Experimentally Testing a Magnetic Gearbox for a Wind Turbine Demonstrator
Here, the design of the first stage of a 59:1 multistage magnetic gearbox for a wind turbine demonstrator is presented here. The multistage magnetic gearbox (MSMG) is composed of a two stage magnetic gearbox (MG). The first stage of the MSMG has a gear ratio of 6.45. A spoke type MG rotor typology is used with a unique segmented fully laminated rotor structure. Axial-ly segmented magnets and a unique set of radial deflection rotor support rings are utilized. Design issues with respect to losses and torque ripple are highlighted.
17 WIND ENERGY↗
Electromagnetic and Mechanical Design of a Hermetically Sealed Magnetic Gear for a Marine Hydrokinetic Generator
This article presents a new type of hermetically sealed magnetically geared generator typology for a marine hydrokinetic application. The proposed magnetically geared generator is composed of two series connected magnetic gearbox stages with the second stage having an integrated stator. This paper focuses only on presenting the electromagnetic design for the first stage magnetic gearbox with a 5kW (at 40RPM) rating. A volumetric and mass torque density tradeoff analysis is utilized in order to arrive at a high torque density design. The designed magnetic gearbox uses a unique laminated flux concentration inner rotor and Halbach array outer rotor typology with a 6.67:1 gear ratio. Furthermore, a mechanical deflection analysis is performed to verify that the proposed magnetic gearbox is mechanically robust.
16 TIDAL AND WAVE POWER↗
Advanced High Torque Density Magnetically Geared Generator
The objective of this research project was to investigate the fundamental torque density limitations of multistage flux focusing magnetic gears and magnetically geared direct-drive generators for wind turbines. Magnetic gears create non-contact speed amplification by modulating the air-gap magnetic field harmonics created by magnetic rotors. By integrating a stator into the magnetic gear structure a very high torque density direct-drive generator can be created. Magnetic geared systems offer unique capabilities that are currently not available using existing mechanically geared systems, such as overload protection. Magnetic gears also offer the potential for higher reliability, higher efficiency and quieter operation than is currently achievable using a mechanically geared generator. By increasing reliability and design life magnetic gears could decrease the overall life-cycle costs when compared with equivalent mechanical or direct-drive drivetrains. This research project investigated and experimentally testing two sub-scale magnetic gearboxes (0.12 m diameter) and two large diameter magnetic gearboxes (0.56m and 0.63m diameter). The goal of the project was to demonstrate a torque density >300Nm/L for a multistage magnetic gearbox with integrated stator. A nested multistage magnetic gear structure was first proposed and studied. However, it was shown that the nested design greatly increased mechanical complexity and therefore a two-stage series typology was utilized. A multi-stage magnetic gear with a 59:1 gear ratio was successfully experimentally tested. A peak torque of 4.25 kN·m was measured and this resulted in an overall active region torque density of 141 N·m/L (when including support rings). The torque density was significantly reduced from what was computed using 2-D electromagnetic analysis. This reduction was due to the 3-D edge effects, increased power losses and the inclusion of additional mechanical support rings as well as other mechanical assembly design changes. At large diameters contiguous lamination parts could not be fabricated and so a segmented laminated rotor design had to be used. This reduced the mechanical strength of the design when compared to small diameter magnetic gears and resulted in the need for the addition of mechanical support rings to prevent deflection. The final experimentally tested design also had a high torque ripple and the power loss within the magnetic gear did not change significantly with load. This therefore resulted in the efficiency being high only at peak loads. Despite not experimentally achieving the 2-D calculated high torque density the analysis has shown that the problems encountered with the scaling can be overcome with careful design changes. For example, understanding the unique mechanical deflection requirements during the electromagnetic design of the large diameter magnetic gears is key to achieving both a high torque density based on the electromagnetic analysis and a high torque density based on the mechanical support needs. Furthermore, ensuring that end plates are made of non-conductive material and minimizing other conductive support elements within the magnetic structure is a key requirement for reducing eddy current losses. In summary, if the mechanical design can be made more robust and eddy current loss mitigation strategies are used in the mechanical design phase then the magnetic gear is capable of being scaled up whilst operating at a very high torque density. This will then enable it to be potentially performance and cost competitive with alternative direct-drive and mechanically geared wind turbine drivetrains.
17 WIND ENERGY↗