Patent Application
20150042293
The invention relates to a drive train of an energy production plant and a method for controlling the operation of a drive train of an energy production plant.
The technical development in the area of wind turbines is leading to, i.a., larger and larger rotor diameters and tower heights. Thus, large power fluctuations due to, for example, grid faults or strong wind gusts cause a correspondingly large deflection on the tower; this in turn leads to high loads on the plant. For this reason, for example, wind turbines that for implementing a variable rotor speed generally use three-phase generators in combination with full-scale power converters are connected with large resistors via so-called choppers to the DC link of the full-scale power converter so that with a spontaneous loss of the load (for example, grid faults), the load on the rotor can be maintained and thus rapid adjustment of the rotor blades can be avoided. Rapid adjustment of the rotor blades would be necessary in a rapid load loss in order to avoid overspeed of the rotor, but it would lead to a correspondingly large change of the rotor thrust and would thus dramatically load the tower. This problem becomes greater, the higher the tower.
Similar problems can also occur in, for example, hydroelectric plants by, for example, in the case of longer-lasting grid faults, the turbine going into overspeed due to the absence of a load that under certain circumstances would cause damage to it Likewise, for drives for industrial applications, there are also operating states in which in the case of, for example, a power failure for a short interval, a drive-side or output-side braking moment is necessary in order to bring the system into a safe state.
The time interval for recognizing the fault up to shutdown of the plant or up to the end of the grid fault can last up to several seconds, with which a correspondingly large dimensioning of the aforementioned resistors is necessary.
The method described for plants with full-scale power converters cannot be implemented, however, with classic differential systems (electromechanical, hydrostatic and hydrodynamic), since in these cases, the generator is connected directly to the grid. The same also applies, i.a., to so-called double-fed three-phase AC machines.
The object of the invention is therefore to solve this problem.
This object is achieved with a drive train with the features of claim 1.
This object is furthermore achieved with a method with the features of claim 20.
By a service brake being mounted downstream from the rotor of the energy production plant or the industrial machine, which brake can deliver a braking torque to the drive train, in the case of, for example, wind turbines, the pitch system can react in a delayed manner; this leads to a correspondingly slow change in the thrust of the plant, and thus the load especially on the tower and on the supporting framework structure is kept as small as possible.
By a service brake being mounted between the rotor of the energy production plant or the industrial machine and the generator, which brake can deliver a braking torque to the drive train for a limited time, in the case of, for example, wind turbines, the pitch system can react in a delayed manner; this leads to a correspondingly slow change in the thrust of the plant, and thus the load especially on the tower and on the supporting framework structure is kept as small as possible.
Preferred embodiments of the invention are the subject matter of the dependent claims. Preferred embodiments of the invention are explained below with reference to the attached drawings. Here:
The output of the rotor of a wind turbine is computed according to the following formula
Rotor output=rotor area*power factor*air density/2*wind speed3
with the power factor being a function of the high speed number (=ratio of the blade tip speed to the wind speed) of the rotor of the wind turbine. The rotor of a wind turbine is designed for an optimum power factor based on a high speed number that can be established in the course of development (generally a value of between 7 and 9). For this reason, in the operation of the wind turbine in the partial load range, a correspondingly low speed should be set in order to ensure an optimum aerodynamic efficiency.
The power input of the plant according to the aforementioned formula is proportional to the cube of the wind speed. The thrust acting on the plant is proportional to the square of the wind speed. Both, however, i.a., depend also on the set rotor blade angle. Accordingly, thrust and power approach zero as soon as the rotor blades are adjusted in the direction of the feathering position.
Subsequently, the rotor 1 drives the main gear 3. This main gear 3 generally consists of two planetary gear stages and one spur gear stage. With reference to the number and type of gear stages, however, there are a host of variants here. The fast-running side of the main gear is generally connected by means of a clutch 5 to the generator 6, for example a permanent-magnet-activated low-voltage synchronous machine. For safety reasons, in addition or alternatively to rotor blade adjustment, there is an emergency brake 4 that in most cases is located between the main gear 3 and the generator 6 and that can also be made only as a restraining brake (for example for maintenance purposes). The emergency brake 4 is generally a non-positive device, for example a disc brake, but can also be made as a positive device, for example as a rotor-arresting device. Moreover, the emergency brake 4 can also be positioned between the rotor 1 and the main gear 3 or upstream or downstream from the generator 6. The main function of this emergency brake 4 is to reliably shut down the plant when a fault occurs or for protection of personnel, preferably in combination with the aforementioned rotor blade adjustment. Thus, the emergency brake 4 is a self-contained protective apparatus that (based on the valid standards) generally may not assume further operating functions. The rotor blade adjustment that is not shown in the drawings can theoretically also perform solely the function of the emergency brake 4 that in this case would not be necessary. The generator 6 is connected via a frequency converter to a rectifier 7 and an inverter 8 and a transformer 9 to the medium-voltage grid 10. A so-called chopper 12 with a resistor 11 is connected to the DC link that connects the rectifier 7 and the inverter 8.
In the examples of
Due to a fault in the drive train or in the case of an operation-induced fast or emergency stop of the plant or in the case of a grid fault or power failure, the generator 6 can no longer accept power and a power dip occurs. With it, the torque driving the rotor 1 would bring the drive train of the plant into overspeed. In order to prevent speeds that damage the plant, theoretically the emergency brake 4, which in most cases is made as a disk brake, could be activated. In the case of a weak grid 10, however, the latter often fails; in any case, this also leads to a power dip. For reasons of safety technology, therefore for this recurring operating state, the use of an emergency brake 4 is not acceptable. Therefore, in plants according to the state of the art, the overspeed is prevented by prompt adjustment of the rotor blades, as a result of which activation of the emergency brake 4 can be avoided. One major disadvantage of this method is that in this way, the thrust acting on the plant is also accordingly promptly reduced; this leads mainly to a high load on the tower of the plant. Another disadvantage would be that in the case of a short-term power failure, that is a power failure with a briefly recurring rated voltage, abbreviated LVRT, it can last for a relatively long time until the plant returns to the power level that was produced before the occurrence of this grid fault since the rotor blade adjustment must again return to the original working position; this sometimes lasts longer than is required by the current grid-feed regulations.
For this reason, in the meantime in plants according to the state of the art, the chopper 12 and the resistor 11 are dimensioned such that they can accept the rated output of the plant for several seconds and can convert it into heat. The resulting advantage is that the torque on the drive train can be maintained for the time being and thus rapid rotor blade adjustment is not necessary, as a result of which the thrust acting on the plant also does not change suddenly. Moreover, when the grid returns, the power delivered into the grid can be again promptly adjusted upward since then instantaneously the inverter 8 can again deliver power into the grid while the chopper at the same time sets back the energy delivered into the resistors. In the ideal case, the torque on the drive train thus remains constant during a brief line voltage dip.
The torque equation for the differential drive is as follows:
Torquedifferential drive=Torquerotor*y/x,
with the size factor y/x being a measure of the transmission ratios in the main gear 3 and in the differential gear 14. The torque in the differential drive 16 is always proportional to the torque in the entire drive train.
One disadvantage of this concept in contrast to the plant concept according to
The same also applies to so-called double-fed three-phase AC machines in which the rotor of the generator is connected via a frequency converter to the grid, but the stator of the generator is connected directly or by means of a transformer. Thus, also in this case when a fault occurs, the output cannot be maintained, with which according to the state of the art, there remains only the option with the prompt adjustment of the rotor blades, which under certain circumstances acts unfavorably, as a means for avoiding overspeed.
In the case of start-up, the plant control first detects whether it is a power failure or a brief grid fault (a so-called LVRT fault) in which the plant is to remain or must remain on the grid. Depending on the technical grid feed conditions, this takes an interval from roughly 0.5 to 3 seconds during which ideally the rotor blades are not essentially reset. Thus, in a sudden return of the grid, the power to be delivered to the grid can be very quickly adjusted up by the power that has been “destroyed” by the service brake 20 being reduced correspondingly promptly. Ideally, the service brake 20 should be regulated such that the torque acting on the rotor 1 from the drive train remains essentially constant over this time interval or is at least so high that an overspeed of the rotor 1 is prevented. This works much more quickly than what could be accomplished by adjusting the rotor blades. If this is not the case and there is another fault, the plant can slowly shut down. Such a shutdown process can last, for example, up to 15 seconds, during which correspondingly large amounts of energy must be removed, for example converted into heat. In doing so, the torque acting on the rotor 1 from the drive train is adjusted accordingly toward zero, after preferably at most 7 seconds, but ideally, in order to limit the thermal load, after roughly 3 to 5 seconds.
In summary, it can be maintained that the main function of the service brake 20 is to limit the rotor speed and/or the generator speed, since thus rapid adjustment of the rotor blades is for the most part no longer necessary. In contrast to this, the emergency brake 4 is intended to shut down (rotor speed roughly 0 min−1) the plant.
The service brake 20 can assume different embodiments. Here, for starters, the group of hydrodynamic retarders should be mentioned. Hydrodynamic retarders generally work with oil that if necessary is routed into a converter housing. The converter housing consists of two rotationally symmetrical and opposite blade wheels, a rotor that is connected to the drive train of the plant, and a stationary stator. The rotor accelerates the supplied oil, and the centrifugal force forces it to the outside. The shape of the rotor blades routes the oil into the stator that in this way brakes a braking torque in the rotor and subsequently then also brakes the entire drive train.
Friction converts the energy of motion into heat that must be removed again by a heat exchanger; this can take place, for example, using a cooling water circuit of the plant. For activation, the retarder is preferably flooded with oil from a storage tank, which oil is automatically pumped back again by the blade wheels.
Another execution option is a water retarder that likewise works according to the hydrodynamic principle, but uses water instead of oil as the brake fluid. The braking moment is built up according to the fill factor and the speed difference between the rotor and stator. The energy that arises in doing so is converted solely into heat energy in the hydrodynamic working space of the retarder and is absorbed directly by the cooling water. The heated cooling water is cooled directly via the cooling water circuit of the plant in this case. This cooling water circuit is generally present anyway in order to be able to cool, for example, the generator 13, the differential drive 16, and the frequency converter 17, etc.
In the case of an electrodynamic retarder as the service brake, for example an eddy-current brake, for example two steel disks (rotors) that are not magnetized are connected to the drive train. In between is the stator with electric coils. When current is applied by activating the retarder, magnetic fields are generated that are closed by the rotors. The magnetic fields with opposite directions then generate the braking action. The heat that has formed is, for example, dissipated again by internally ventilated rotor disks.
One important advantage of a retarder as a service brake is its absence of wear and ease of regulation. Thus, the braking moment can be adjusted or optimized depending on the operating state of the plant, or over the course of a braking operation.
Alternatively, a disk brake is also conceivable as the service brake 20. Here, so-called pole friction brakes are especially suitable due to the activation that sometimes recurs frequently. A pole friction brake has fundamentally the same structure as a disk brake, but has friction linings made of steel that are almost free of wear. The braking moment can also be adjusted here.
The braking moment acting on the drive train is distributed to the rotor shaft of the generator 13 and the differential drive 16 according to the transmission ratio of the differential gear 14. For a transmission ratio of, for example, 5, the braking moment acting on the drive train rises by roughly 20%, compared to a retarder that has been positioned as in
Moreover, the system that is shown in
The task of regulation is thus to prevent an overspeed of the drive train; at the same time, for example in the LVRT case, the speed or the phase angle of the generator 13 can be kept constant. I.e., the differential drive 16 and the frequency converter 17 that is connected to it in this embodiment according to the invention must perform two functions: first, the supply of the service brake 20 with exciting current from the DC link of the frequency converter 17, and second, the regulation of the speed of the generator 13 in order to be essentially in phase with the grid 19 when the latter returns.
For example, the characteristic for the service brake 20 is fixed such that it approaches the speed/torque characteristic of the plant as closely as possible, as a result of which, for example, in a power failure, the behavior of the plant is hardly changed compared to normal operation. In this connection, a hydrodynamic retarder when used on a flow machine is an especially good choice since a retarder fundamentally likewise has a cubic characteristic and thus, for example, a somewhat necessary regulation effort can be kept low.
At a speed equal to zero, the retarder does not generate a braking moment. Since in the case of energy production plants at low plant speed only a low torque also prevails, in this way, however, an application-specific disadvantage does not arise.
This is shown by
The broken line is the characteristic of the retarder, which preferably describes a cubic line. At the middle operating point in nominal operation of the plant that is, for example, at roughly 105% of the speed, the torque line of the wind turbine intersects the characteristic of the retarder.
In one especially simple embodiment variant, the variation of the fill factor is omitted, and the characteristic is laid out such that at the intersection point of the two characteristics, a braking moment at the level of the nominal torque of the plant is reached. Since the rotor of the wind turbine, when the rotor blade adjustment is not active, likewise follows a cubic characteristic, the plant in the case of a brief power failure is kept adequately in balance by the service brake 20. Admittedly, the effect is not perfect for all operating ranges, but since a power dip in operation of the plant with high output has an especially harmful effect, this simplification is a good compromise between, on the one hand, the behavior of the plant in the case of a fault and, on the other hand, the complexity of a service brake 20. The torque characteristic of the service brake 20 shown in
In the described embodiment, the drive machine is the rotor of a wind turbine. Instead of this, however, rotors can also be used to extract energy from ocean currents, hydroelectric turbines and pumps. Moreover, the embodiment according to the invention can also be used for industrial applications in order to, for example, be able to brake in a system disruption in the operating mode to prevent an overspeed in the case of a fault.
According to the invention, the service brake (20) can also be used for energy production plants according to
| Number | Date | Country | Kind |
|---|---|---|---|
| A 558/2012 | May 2012 | AT | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/AT2013/000052 | 3/28/2013 | WO | 00 |
