基于模擬的客戶定制滑環(huán)裝置

By Timo Heinonen (Finland)

作者 | Timo Heinonen（芬蘭）

基于模擬的客戶定制滑環(huán)裝置

By Timo Heinonen (Finland)

作者 | Timo Heinonen（芬蘭）

The slip ring unit (SRU) is one of the key components in doubly-fed (DF) generators. Environmental simulation enables it to be customized for each site.

滑環(huán)單元是雙饋發(fā)電機(jī)的關(guān)鍵組件之一。

環(huán)境模擬使得滑環(huán)單元可以針對(duì)每個(gè)不同的場(chǎng)合來(lái)進(jìn)行定制。

Turbine OEMs install their standard wind turbines in many different environments, ranging from coastal areas to dry, high altitude locations. Environmental conditions affect the operation and service life of the generator SRU. Significant benefits can be achieved for end users if the operation conditions are simulated and the results used to customize the SRU for the specific site where the generator is installed.

風(fēng)電機(jī)組設(shè)備制造商需要在從沿海地區(qū)到高海拔干燥地區(qū)等各種不同的環(huán)境下安裝標(biāo)準(zhǔn)的風(fēng)電機(jī)組。環(huán)境會(huì)影響發(fā)電機(jī)滑環(huán)單元運(yùn)行和使用年限。如果能夠模擬滑環(huán)單元的運(yùn)行情況并根據(jù)模擬運(yùn)行的結(jié)果對(duì)其進(jìn)行定制生產(chǎn)，那么對(duì)最終客戶大有益處。

The demanding SRU要求嚴(yán)苛的滑環(huán)單元

In DF generators reactive and active power is fed to the grid not only from the stator but also from the rotor, which involves high currents and high temperatures. Because the rotor is rotating, reliable slip rings are needed to get the power out from inside the generator.

The SRU comprises a hub with phase slip rings and current rods, a brush rocker with brush holders, phase brushes, and rotor cable connecting studs. Improving the operation of the SRU in different site conditions requires considerable experience. Designing a reliable SRU involves many important factors, including material selection between the slip ring and the brushes, dust removal, efficient cooling and easy servicing. The changing operation condition cycles and need for regular servicing also make this one of the most critical components for the end user.

Many other factors - such as different grid codes and load conditions - affect the size and optimum construction of the SRU. Turbine manufacturers also use the software and hardware configuration of the converter to deliver more reactive power in order to comply with grid support requirements. Different OEM specs involving reactive power, speed range and overspeed affect the performance of the SRU.

Selecting the correct material combinations and setup for the SRU components can therefore be a challenging task.

雙饋發(fā)電機(jī)饋送給電網(wǎng)的無(wú)功功率和有功功率由兩部分組成，一部分來(lái)自定子，另一部分來(lái)自電流大溫度高的轉(zhuǎn)子。因轉(zhuǎn)子是旋轉(zhuǎn)的，所以需要有可靠的滑環(huán)將電能從發(fā)電機(jī)內(nèi)部傳輸出來(lái)?；h(huán)單元包括由三相集電環(huán)和導(dǎo)電桿組成的滑環(huán)、刷架和刷握、三相電刷以及轉(zhuǎn)子電纜連接螺柱等幾部分。不過(guò)針對(duì)不同場(chǎng)合來(lái)改進(jìn)滑環(huán)單元的運(yùn)行需要相當(dāng)豐富的經(jīng)驗(yàn)。設(shè)計(jì)一套可靠的滑環(huán)單元需要多方面的考慮，包括滑環(huán)和電刷的材料選取、除塵、高效冷卻以及方便維護(hù)等等。不斷變化的運(yùn)行情況和定期維護(hù)的需求也使得滑環(huán)單元成為對(duì)最終用戶而言最關(guān)鍵的部件之一。而其他因素諸如不同的電網(wǎng)規(guī)范和負(fù)載條件等也會(huì)影響滑環(huán)單元的大小和最佳結(jié)構(gòu)。此外，風(fēng)電機(jī)組設(shè)備制造商常使用變流器軟件與硬件調(diào)試來(lái)輸出更多的無(wú)功功率以滿足電網(wǎng)的要求，且不同原始設(shè)備制造商的參數(shù)要求包括無(wú)功功率、轉(zhuǎn)速范圍和超速等也會(huì)影響滑環(huán)單元的性能。綜上所述，選擇正確的材料組合和滑環(huán)單元部件的配置是一個(gè)具有挑戰(zhàn)性的任務(wù)。

New innovations in SRU design滑環(huán)單元設(shè)計(jì)亮點(diǎn)

To help turbine OEMs meet the often unknown environmental conditions at installation sites, ABB has worked with leading SRU manufacturer to create an innovative modular slip ring design which enables load optimization and effective cooling based on exact load conditions.

為了幫助風(fēng)電機(jī)組設(shè)備制造商在安裝現(xiàn)場(chǎng)應(yīng)對(duì)常常未知的環(huán)境條件，ABB和行業(yè)領(lǐng)先的滑環(huán)單元制造商密切合作以便開(kāi)發(fā)一種創(chuàng)新的模塊化滑環(huán)設(shè)計(jì)。該設(shè)計(jì)旨在實(shí)現(xiàn)基于準(zhǔn)確負(fù)載條件的負(fù)載優(yōu)化和高效冷卻。

A development initiative was launched with the aim of achieving a flexible standardized design which would enable perfect optimization for each individual case. The focus was on reliable, troublefree operation with long service intervals and low maintenance needs in order to maximize availability and kWh production.

為了實(shí)現(xiàn)靈活的滑環(huán)單元標(biāo)準(zhǔn)化設(shè)計(jì)以便能為每個(gè)獨(dú)立案例提供完美的優(yōu)化，ABB開(kāi)始了滑環(huán)單元的進(jìn)一步開(kāi)發(fā)設(shè)計(jì)。開(kāi)發(fā)設(shè)計(jì)的重點(diǎn)是使滑環(huán)單元長(zhǎng)期可靠地?zé)o故障運(yùn)行并減少維護(hù)需求，從而實(shí)現(xiàn)利用率和發(fā)電量的最大化。

The design was based on a new modular construction which can be easily optimized for each load case. This also contributed to efficient cooling and dust removal. At the same time an advanced brush set up was also developed which enables easy brush installation and maintenance. To standardize the construction for different load cases, the same brush size is used and the number of brushes needed for each phase is optimized, resulting in a cost effective solution. A widely known brush grade, proven in most environmental conditions, was selected as the standard option.

該設(shè)計(jì)以一種全新的模塊化結(jié)構(gòu)為基礎(chǔ)，該結(jié)構(gòu)便于針對(duì)不同的負(fù)載條件進(jìn)行優(yōu)化，也有助于高效冷卻和除塵。同時(shí)還包括一種先進(jìn)的電刷結(jié)構(gòu)設(shè)計(jì)，使電刷便于安裝和維護(hù)。為了使不同負(fù)載條件下的結(jié)構(gòu)標(biāo)準(zhǔn)化，對(duì)電刷規(guī)格進(jìn)行了統(tǒng)一，對(duì)每相電刷數(shù)量也進(jìn)行了優(yōu)化，這是一個(gè)非常有成本效益的方案。此外，一個(gè)在大多數(shù)環(huán)境條件下都得到驗(yàn)證的知名電刷品牌被選定為標(biāo)準(zhǔn)選項(xiàng)。

The unit is straightforward and robust, and it features efficient cooling, easy maintenance and a rigid structure for high overspeed endurance. All the main components, including the brushes, are made by one of the biggest global turn-key slip ring manufacturers.

滑環(huán)單元結(jié)構(gòu)簡(jiǎn)單且堅(jiān)固，主要特點(diǎn)包括冷卻效率高、易于維護(hù)且擁有耐受超速的剛性結(jié)構(gòu)。包括電刷在內(nèi)的所有主要部件都是由一家全球最大的成套滑環(huán)制造商制造的。

High quality, partial discharge resistant insulation materials are used so that the SRU can withstand the voltage stresses encountered in converter duty. Every SRU will undergo a 5 kV HV test. A partial discharge test is also performed in order to verify the high quality of the insulation.

滑環(huán)單元使用優(yōu)質(zhì)且抗局部放電的絕緣材料，可以耐受變流器工作時(shí)的電應(yīng)力。每個(gè)滑環(huán)單元都會(huì)進(jìn)行5kV的高壓測(cè)試，還會(huì)進(jìn)行局部放電試驗(yàn)以確保優(yōu)異的絕緣性能。

Tailor made testing in simulated site conditions模擬現(xiàn)場(chǎng)條件來(lái)定制測(cè)試

A new slip ring testing laboratory was built to enable R&D to support customers by performing comprehensive testing with the exact installation site conditions. The results are used to customize the setup of the new SRU components according to the load and environmental conditions.

建立一個(gè)新的滑環(huán)單元測(cè)試實(shí)驗(yàn)室可以使研發(fā)部門在與實(shí)際安裝現(xiàn)場(chǎng)一致的條件下進(jìn)行全面的測(cè)試從而為客戶提供支持。測(cè)試結(jié)果可用來(lái)根據(jù)負(fù)載和環(huán)境條件定制新的滑環(huán)單元組件。

The new SRU testing laboratory follows the conditions of IEC standard 60068-1 7th edition on environmental testing procedures. Wind turbine load conditions can be emulated based on IEC 61400. The requirements of these two standards can be combined to create tailored test programs, which can also incorporate the customer's other requirements and site conditions.

新的滑環(huán)單元測(cè)試實(shí)驗(yàn)室遵循《IEC 60068-1》標(biāo)準(zhǔn)（第七版）中有關(guān)環(huán)境測(cè)試過(guò)程的要求，同時(shí)根據(jù)《IEC 61400》標(biāo)準(zhǔn)模擬風(fēng)電機(jī)組的負(fù)載條件。測(cè)試程序的制訂則參考了以上這兩個(gè)標(biāo)準(zhǔn)的要求，測(cè)試程序同樣也可以包括客戶的其他要求和現(xiàn)場(chǎng)情況。

“We work with turbine OEMs throughout the generator development process to find the best solutions for each case. And now with our new R&D lab we can customize the SRU for the exact site conditions and help wind park operators to maximize their production time,” says Raimo Sakki, product manager for wind power generators at ABB.

ABB風(fēng)力發(fā)電機(jī)產(chǎn)品經(jīng)理Raimo Sakki先生說(shuō)：“在發(fā)電機(jī)設(shè)計(jì)過(guò)程中，我們始終和風(fēng)電機(jī)組設(shè)備制造商密切合作，針對(duì)每個(gè)案例來(lái)尋找最佳方案?，F(xiàn)在通過(guò)新成立的實(shí)驗(yàn)室，我們可以模擬真實(shí)的現(xiàn)場(chǎng)條件來(lái)定制滑環(huán)單元并可以幫助風(fēng)電場(chǎng)管理人員實(shí)現(xiàn)運(yùn)行時(shí)間最大化?！?/p>

Different environmental and load parameters can be simulated based on ABB's broad experience in generators, research studies, environmental conditions and customer specifications. Using separate converters in both the rotating and feeding system sides it is possible to test all major turbine operation points while the climate chamber controls the humidity and ambient temperature.

ABB憑借在發(fā)電機(jī)、技術(shù)研究、環(huán)境條件和客戶要求上的豐富經(jīng)驗(yàn)?zāi)軌蚰M不同的環(huán)境和負(fù)載條件。在轉(zhuǎn)子側(cè)和電網(wǎng)側(cè)使用獨(dú)立的變流器，這樣就可以測(cè)試所有風(fēng)機(jī)的主要運(yùn)行點(diǎn)同時(shí)可用氣候模擬箱控制濕度和環(huán)境溫度。

The tests are performed with a real SRU housing and fans, in a configuration similar to a complete generator in wind turbine nacelle conditions. In addition to overspeed and high voltage tests, the comprehensive test program also includes verification of partial discharge, brush wear and air flow measurement for easy dust removal.

測(cè)試會(huì)在一個(gè)真正的滑環(huán)室內(nèi)并且在有風(fēng)扇的條件下進(jìn)行，這些測(cè)試條件模擬了一個(gè)在風(fēng)機(jī)機(jī)艙內(nèi)的完整的發(fā)電機(jī)。除超速試驗(yàn)和高電壓試驗(yàn)外，這套完整的測(cè)試程序還包括局部放電認(rèn)證、電刷磨損試驗(yàn)和為方便除塵而進(jìn)行的氣流測(cè)量。

Benefits for turbine OEMs and end users給風(fēng)電機(jī)組設(shè)備制造商和最終用戶帶來(lái)好處

The test results are used to select the correct combination of SRU components by optimizing parameters such as the slip ring size and number of brushes, as well as the brush and ring material. Load optimization ensures safe operation temperatures and effective cooling.

根據(jù)測(cè)試的結(jié)果并通過(guò)優(yōu)化相關(guān)參數(shù)如滑環(huán)尺寸、電刷數(shù)量、電刷與滑環(huán)的材料等等，可以確定配置合理的滑環(huán)單元組件。而負(fù)載優(yōu)化則保證了安全的運(yùn)行溫度和有效的冷卻。

For turbine OEMs and end users the main benefit of using pretested components is that it eliminates the need for design changes and avoids unnecessary turbine shut downs. Using site specific optimization also minimizes maintenance and enables long service intervals. This results in continuous operation and maximized kWh production.

對(duì)于風(fēng)電機(jī)組設(shè)備制造商和最終用戶而言，如果使用經(jīng)過(guò)預(yù)測(cè)試的組件，則不需要進(jìn)行后期的設(shè)計(jì)變更，也可避免不必要的風(fēng)電機(jī)組停機(jī)。針對(duì)特定場(chǎng)合的優(yōu)化設(shè)計(jì)會(huì)大大減少相應(yīng)的維護(hù)并能保證長(zhǎng)期地運(yùn)行，這樣有利于連續(xù)地運(yùn)行和最大化地產(chǎn)生電能。

The English version of this article was written by Timo Heinonen (MSc. Mech. Eng.), who has over 15 years of experience in wind power generators at ABB Oy, Finland. The Chinese version was translated by Xingchen Xia and Ranran Lin, who work at Technology Center (Asia), ABB Business Unit Motors and Generators.

本文英文版由芬蘭ABB公司Timo Heinonen先生（機(jī)械工程專業(yè)碩士）撰寫(xiě)，他在風(fēng)力發(fā)電機(jī)領(lǐng)域擁有超過(guò)十五年的經(jīng)驗(yàn)。中文版由ABB電機(jī)與發(fā)電機(jī)業(yè)務(wù)單元亞洲技術(shù)中心夏星晨先生和林然然先生負(fù)責(zé)翻譯。

A slip ring unit laboratory will come into use soon at Technology Center (Asia), ABB Business Unit Motors and Generators. Please feel free to contact us.

ABB電機(jī)與發(fā)電機(jī)業(yè)務(wù)單元亞洲技術(shù)中心的滑環(huán)單元實(shí)驗(yàn)室即將投入使用。敬請(qǐng)聯(lián)系我們。

Visiting address: No.59, Tianning Rd., Minhang District, Shanghai, China. Phone: 0086 21 3478 2835 / 3478 2505.

地址：上海市閔行區(qū)天寧路59號(hào)。 電話：021-34782835 / 34782505。