The following relates to the field of electrical machines, such as wind turbine generators. The following relates to an assembly for determining the electrical angle of a rotor in an electrical machine, such as a wind turbine generator. The following further relates to a wind turbine generator comprising such an assembly, and to a method of determining the electrical angle of a rotor in an electrical machine, such as a wind turbine generator.
The electrical drive train of a direct-drive wind turbine is required to enable various modes/functions other than power production, the best-known being rotor positioning, which must be able to turn the rotor of a turbine slowly (at a fraction of rpm) and hold it stationary at a target position (0 rpm or as close as possible). Recent developments aim at performing horizontal single blade mounting (HSBM) with the electrical drive train, thus avoiding the installation of a hydraulic tool dedicated to blade installation (also known as HSBM tool). HSBM requires very accurate position and torque control up to the maximum allowable torque. Accordingly, corresponding position feedback and control methods are required.
Typically, torque control of a permanent magnet generator (PMG) is achieved by implementing an inner current controller, which requires accurate and high-resolution electrical rotor position (e.g., for Park transformations). If rotor position information is not available or unreliable, the generated torque is unpredictable. Thus, the turbine's ability to provide the aforementioned functions will be impaired and its structural integrity put at risk. It happens that sensorless (back-emf based) methods employed for position estimation under power production mode (medium/high speed operation) fail at very low speeds. Some machine technologies (e.g., interior permanent magnet (PM) machines) are well suited for alternative sensorless methods, like high-frequency signal injection (HFI) based observers. On the other hand, surface mounted PM and fractional slot concentrated winding machines may not offer a good enough position dependent signature for HFI sensorless methods, forcing the adoption of sensors for position measurement.
High performance motion control often employs shaft-mounted incremental encoders. However, a desirable application for a large outer rotor PMG (permanent magnet generator) presents two major difficulties: (1) the requirement to know absolute rotor position accurately—this is not provided by an incremental encoder; and (2) the lack of a rotor shaft for easy installation of an encoder.
Therefore, there may be a need for simple and cost-efficient ways of determining rotor position with high precision and reliability in an electrical machine, such as a direct-drive wind turbine generator with outer rotor.
An aspect relates to an assembly for determining the electrical angle of a rotor in an electrical machine, such as a wind turbine generator with outer rotor. The assembly comprises: (a) an encoder assembly configured to be mounted on a stator of the electrical machine, the encoder assembly having an encoder wheel configured to contact a surface of the rotor to obtain relative rotor rotation information based on rotation of the encoder wheel, (b) an electrical angle observer configured to provide an absolute electrical angle, and (c) a processing device coupled to communicate with the encoder and the electrical angle observer and configured to determine the electrical angle of the rotor based on the relative rotor rotation information and the absolute electrical angle.
This aspect of embodiments of the invention is based on the idea that an absolute electrical angle provided by an electrical angle observer is combined with relative rotor rotation information obtained by an encoder to determine the electrical angle of the rotor with high precision and high bandwidth. In other words, the encoder is capable of detecting small amounts of rotor rotation and thus corresponding small changes in the electrical angle of the rotor, while the electrical angle observer provides absolute electrical angle information that cannot be obtained by the encoder.
According to an embodiment of the invention, the processing device is configured to utilize the absolute electrical angle as an initial value in the determination of the electrical angle of the rotor.
In other words, the absolute electrical angle from the observer is used as a starting point or reference value in the determination of the electrical angle, while the deviations from the initial value are tracked by the encoder.
According to an embodiment of the invention, the electrical angle observer comprises an HFI (high frequency injection) observer.
In other words, the electrical angle observer is capable of determining the absolute electrical angle by injecting high frequency signals into the generator and detecting corresponding signals in the generator output.
According to an embodiment of the invention, the processing device is further configured to determine the electrical angle of the rotor based on a gear ratio between the encoder wheel and the surface of the rotor.
By considering the gear ratio between the encoder wheel and the surface of the rotor, the actual rotation of the rotor can be derived from the rotation of the encoder wheel.
According to an embodiment of the invention, the processing device is configured to utilize a predetermined fixed gear ratio.
In this embodiment, the gear ratio is fixed and predetermined, e.g., by measuring the respective sizes of the rotor surface and the encoder wheel prior to installation or use.
According to an embodiment of the invention, the processing device is configured to determine and utilize a dynamically corrected gear ratio.
In other words, the processing device is capable of correcting the gear ratio in a dynamic manner, i.e., continuously during operation. Thereby, by utilizing the thus dynamically updated gear ratio, the precision of the determined electrical angle is further improved.
According to an embodiment of the invention, the processing device is configured to determine a gear ratio correction factor based on the relative rotor rotation information and the absolute electrical angle.
In other words, the gear ratio correction factor is determined on the basis of the output (relative rotor rotation information) from the encoder and the output (absolute electrical angle) from the electrical angle observer.
According to an embodiment of the invention, the processing device is configured to determine the gear ratio correction factor by performing a closed-loop control algorithm that receives a difference between the determined electrical angle of the rotor and the absolute electrical angle.
In other words, a closed-loop control algorithm is used to determine the gear ratio correction factor in such a way that the difference between the determined electrical angle and the absolute electrical angle (provided by the electrical angle observer) is minimized.
According to an embodiment of the invention, the processing device is configured to determine the gear ratio correction factor by performing a closed-loop control algorithm that receives a difference between an integrated first rotor speed signal and an integrated second rotor speed signal. The first rotor speed signal is calculated based on the determined electrical angle of the rotor. The second rotor speed signal is calculated based on the absolute electrical angle.
In other words, in this embodiment the closed-loop control algorithm minimizes a difference between rotor angles obtained by integrating first and second rotor speed signals, respectively, where the first rotor speed signal is derived from the determined electrical angle of the rotor and the second rotor speed signal is derived from the absolute electrical angle (provided by the electrical angle observer).
This embodiment may be particularly advantageous in cases where the rotor speed is used for other purposes and thus already available.
According to an embodiment of the invention, the processing device is configured to determine the dynamically corrected gear ratio based on a predetermined fixed gear ratio and the gear ratio correction factor.
For example, the gear ratio GR may be determined as GR=GR0·(1−GRcf), where GR0 denotes the predetermined fixed gear ratio and GRcf denotes the gear ratio correction factor.
According to a further aspect of embodiments of the invention, there is provided a wind turbine generator comprising: (a) a stator, (b) a rotor arranged to rotate around the stator, (c) a wind turbine controller, and (d) an assembly, wherein the encoder is mounted on the stator, wherein the encoder wheel contacts a surface of the rotor, and wherein the wind turbine controller is configured to perform rotor position control utilizing the determined electrical angle as a control signal.
This aspect of embodiments of the invention is essentially based on the same idea as the first aspect discussed above and benefits from the precise and rapid determination of the electrical angle while performing rotor position control.
The rotor may in particular be an outer rotor. Furthermore, the encoder wheel may in particular contact an inner surface of the rotor.
According to a further aspect of embodiments of the invention, there is provided a method of determining the electrical angle of a rotor in an electrical machine, such as a wind turbine generator with outer rotor. In embodiments, the method comprises: (a) arranging an encoder having an encoder wheel such that the encoder wheel contacts a surface of the rotor to obtain relative rotor rotation information based on rotation of the encoder wheel, (b) providing an absolute electrical angle by an electrical angle observer, and (c) determining the electrical angle of the rotor based on the relative rotor rotation information and the absolute electrical angle.
This aspect of embodiments of the invention is essentially based on the same idea as the first aspect discussed above and relies on a corresponding method.
According to an embodiment of the invention, the absolute electrical angle is utilized as an initial value in the determination of the electrical angle of the rotor.
In other words, the absolute electrical angle from the observer is used as a starting point or reference value in the determination of the electrical angle, while the deviations from the initial value are tracked by the encoder.
According to an embodiment of the invention, determining the electrical angle of the rotor is based on a gear ratio between the encoder wheel and the surface of the rotor.
By considering the gear ratio between the encoder wheel and the surface of the rotor, the actual rotation of the rotor can be derived from the rotation of the encoder wheel.
According to an embodiment of the invention, the method further comprises determining a gear ratio correction factor based on the relative rotor rotation information and the absolute electrical angle.
In other words, the gear ratio correction factor is determined on the basis of the output (relative rotor rotation information) from the encoder and the output (absolute electrical angle) from the electrical angle observer.
It is noted that embodiments of the invention have been described with reference to different subject matters. Some embodiments have been described with reference to method type claims whereas other embodiments have been described with reference to apparatus type claims. However, a person skilled in the conventional art will gather from the above and the following description that, unless otherwise indicated, in addition to any combination of features belonging to one type of subject matter also any combination of features relating to different subject matters, in particular to combinations of features of the method type claims and features of the apparatus type claims, is part of the disclosure of this document.
The aspects defined above and further aspects of embodiments of the present invention are apparent from the examples of embodiments to be described hereinafter and are explained with reference to the examples of embodiments.
Some of the embodiments will be described in detail, with reference to the following figures, wherein like designations denote like members, wherein:
The illustration in the drawing is schematic. It is noted that in different figures, similar or identical elements are provided with the same reference numerals or with reference numerals which differ only within the first digit.
The scaling unit 332 receives a signal 327 representative of a count from the encoder 202 and scales the count value to obtain a raw angle value, for example by multiplying the count value by 360° and dividing it by the corresponding maximum count value, e.g., 40000.
The raw angle value is supplied to the angle increment unit 334 which calculates an angle increment value corresponding to one processing cycle, i.e., a predetermined period of time.
The resulting angle increment value is supplied to multiplier 335 where it is multiplied with the number of generator pole pairs pp and divided by the gear ratio GR between the encoder wheel and the opposing surface of the rotor, i.e., the ratio between the number of encoder wheel turns and corresponding rotor turns which is equal to the ratio between the rotor diameter and the encoder wheel diameter. The gear ratio GR may be a fixed value or a dynamically corrected value (as described further below in conjunction with
The resulting electrical angle increment value is supplied to both electrical angle calculation unit 336 and speed calculation unit 338. The electrical angle calculation unit 336 also receives an initial electrical angle value θ0 and calculates the electrical angle value θ by adding the received electrical angle increment value to the previous electrical angle value (or the initial electrical angle value θ0 as appropriate). The speed calculation unit 338 calculates the electrical angle speed ω by dividing the received electrical angle increment value by the corresponding period of time.
The gear ratio correction block 550 comprises angle wrap unit 551, subtraction unit 552, low pass filter 553, gain adjustment unit 554, multiplier 555, enabling unit 556, and PI control unit 557. The angle wrap unit 551 receives the electrical angle from the processing device 530 and supplies the processed electrical angle to the subtraction unit 552. The subtraction unit 552 also receives the absolute electrical angle from the electrical angle observer 540 and subtracts it from the electrical angle supplied by angle wrap unit to generate an error signal which is then low pass filtered by low pass filter 553 and supplied to the gain adjustment unit 554 which applies a factor 1/pp to obtain an error value corresponding to the mechanical angle of the rotor. The resulting signal is multiplied with a value s by multiplier 555 and supplied to the PI control unit 557. The value s is indicative of the speed direction of the rotor (e.g., s=1 indicates clockwise rotation, s=−1 indicates counterclockwise rotation). If asserted by a corresponding signal from enabling unit 556, the PI control unit 557 outputs a gear ratio correction factor GRcf which is supplied to the processing device to allow dynamic correction of the gear ratio GR, e.g., by calculating GR=GR0·(1−GRcf), where GR0 denotes a predetermined fixed gear ratio.
The gear ratio correction block 560 comprises angle wrap unit 561, a first speed calculation unit 562 with low pass filter, a first integration unit 563 with angle wrap, a second speed calculation unit 564 with low pass filter, a second integration unit 565 with angle wrap, an enabling unit 566, subtraction unit 567, multiplier 568, and PI control unit 569. The angle wrap unit 561 receives the electrical angle from the processing device 530 and supplies the processed electrical angle to the first speed calculation unit 562 with low pass filter. The corresponding calculated first speed is supplied to the first integration unit 563 with angle wrap, which outputs a first mechanical angle as a result. The second speed calculation unit 564 with low pass filter receives the absolute electrical angle from the electrical angle observer 540 and the corresponding calculated second speed is supplied to the second integration unit 565 with angle wrap, which outputs a second mechanical angle as a result. The subtracting unit 567 receives the first and second mechanical angles and outputs a corresponding error signal to multiplier 568 which multiplies the error signal with a value s before supplying it to the PI control unit 569. The value s is indicative of the speed direction of the rotor (e.g., s=1 indicates clockwise rotation, s=−1 indicates counterclockwise rotation). If asserted by a corresponding signal from enabling unit 566, the PI control unit 569 outputs a gear ratio correction factor GRcf which is supplied to the processing device to allow dynamic correction of the gear ratio GR, e.g., by calculating GR=GR0·(1−GRcf), where GR0 denotes a predetermined fixed gear ratio.
In general, the gear ratio correction techniques disclosed herein can effectively handle variations in gear ratio occurring during operation, e.g., as a result of rubber compression, wear, temperature variations, slips, and production tolerances.
Generally, as shown in
From the rotation of the encoder wheel 120, the generator rotation can be inferred, and so the generator electrical angle. For example, at an encoder count increment, ΔEncInput, the change in generator electrical angle will be:
Here, GR denotes gear ratio, GenPp is the number of generator pole pairs, EncMaxCount denotes the maximum count of encoder input representing 360 degrees (typically, this value is 40000 if the encoder has 10000 lines), and ΔEncInput is the count increment of encoder signal per processing cycle.
The generator electrical angle is calculated as:
Here, EncTheta0Last is the last scan of encoder angle, which can be initialized at the start of calculation by the HFI angle, for example.
Once the generator angle has been calculated, its speed can be derived with one of the conventional methods, such as (i) by the angle change between two scans (i.e., in the time period of processing cycle), or (ii) by the duration of time when the encoder count is changed by 1.
As the proposed technique with encoder control aims for zero or low speed operation, a low pass filter shall be applied to smooth out the above calculated speed.
Given a particular application, for example, with a generator of 90 pole-pairs, an encoder of 10000 lines, and a gear ratio GR of 32, the resolution of machine electrical angle by encoder measurement can be about 0.02 electrical degrees. This would allow high precision and high-performance motion control.
However, any uncertainty in the value of the gear ratio GR, due to tolerances in the wheel diameters, or compression of the rubber tire, will result in a corresponding speed measurement error, which in turn will result in an integrating angle measurement error and thus error in the machine electrical angle. This is handled effectively by the dynamic gear ratio correction described above.
Although the present invention has been disclosed in the form of embodiments and variations thereon, it will be understood that numerous additional modifications and variations could be made thereto without departing from the scope of the invention.
For the sake of clarity, it is to be understood that the use of “a” or “an” throughout this application does not exclude a plurality, and “comprising” does not exclude other steps or elements.
Number | Date | Country | Kind |
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22153334.2 | Jan 2022 | EP | regional |
This application is a national stage of PCT Application No. PCT/EP2022/087889, having a filing date of Dec. 27, 2022, which claims priority to EP Application Serial No. 22153334.2, having a filing date of Jan. 25, 2022, the entire contents both of which are hereby incorporated by reference.
Filing Document | Filing Date | Country | Kind |
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PCT/EP2022/087889 | 12/27/2022 | WO |