US20110241630A1 - Power conversion system for a multi-stage generator - Google Patents

Power conversion system for a multi-stage generator Download PDF

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US20110241630A1
US20110241630A1 US13/062,191 US200913062191A US2011241630A1 US 20110241630 A1 US20110241630 A1 US 20110241630A1 US 200913062191 A US200913062191 A US 200913062191A US 2011241630 A1 US2011241630 A1 US 2011241630A1
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power
branch
branches
generator
stage
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Jonathan Ritchey
Edwin Nowicki
Richerd Chan
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Exro Technologies Inc
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Exro Technologies Inc
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Assigned to EXRO TECHNOLOGIES INC. reassignment EXRO TECHNOLOGIES INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: RITCHEY, JONATHAN, CHAN, RICHERD, NOWICKI, EDWIN
Publication of US20110241630A1 publication Critical patent/US20110241630A1/en
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D9/00—Adaptations of wind motors for special use; Combinations of wind motors with apparatus driven thereby; Wind motors specially adapted for installation in particular locations
    • F03D9/20—Wind motors characterised by the driven apparatus
    • F03D9/25—Wind motors characterised by the driven apparatus the apparatus being an electrical generator
    • F03D9/255—Wind motors characterised by the driven apparatus the apparatus being an electrical generator connected to electrical distribution networks; Arrangements therefor
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D15/00—Transmission of mechanical power
    • F03D15/10—Transmission of mechanical power using gearing not limited to rotary motion, e.g. with oscillating or reciprocating members
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K7/00—Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
    • H02K7/10—Structural association with clutches, brakes, gears, pulleys or mechanical starters
    • H02K7/116—Structural association with clutches, brakes, gears, pulleys or mechanical starters with gears
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K7/00—Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
    • H02K7/18—Structural association of electric generators with mechanical driving motors, e.g. with turbines
    • H02K7/1807—Rotary generators
    • H02K7/1823—Rotary generators structurally associated with turbines or similar engines
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P9/00—Arrangements for controlling electric generators for the purpose of obtaining a desired output
    • H02P9/02—Details of the control
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P2101/00—Special adaptation of control arrangements for generators
    • H02P2101/15—Special adaptation of control arrangements for generators for wind-driven turbines
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/70—Wind energy
    • Y02E10/72—Wind turbines with rotation axis in wind direction
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/70—Wind energy
    • Y02E10/76—Power conversion electric or electronic aspects

Definitions

  • This application relates to circuit topologies and associated control processes for converting power generated via an electromagnetic machine into usable power, and more particularly for converting power generated from a multi-stage electrical generator into a usable form of power for consumption by an electrical load, such as, but not restricted to, an electric utility power grid.
  • the amount of energy captured from the energy source may only be a fraction of the total of the energy that may be capturable over time. For example, in a typical wind farm, that fraction may be one half, or less.
  • variable-speed conventional turbine/generator/transformer system The power flow though a variable-speed conventional turbine/generator/transformer system is restricted in the range of power it can output, i.e., from a minimum output power to a rated output power, because of limitations of the generator, the power converter (if present), and the output transformer used within the system.
  • This restriction arises because a conventional electromagnetic generator has reduced efficiency at lower power levels, as does the power converter (if present) and particularly the transformer that couples power to the electrical load.
  • an engineering design decision is usually made to limit the power rating of the generator (and any associated power converter, power conditioner or power filter, if present) and the associated output transformer so as to optimize efficiency over a restricted range of power.
  • a multi-stage generator may be used in the turbine system.
  • a multi-stage generator is an electromagnetic machine operating as an electrical generator that takes mechanical energy from a prime mover and generates electrical energy, usually in the form of AC power.
  • Such a multi-stage generator is disclosed in U.S. Pat. No. 7,081,696 and U.S. Patent Application Publication No. 2008088200, which are both hereby incorporated by reference.
  • An advantage of a multi-stage generator over a conventional generator is that a multi-stage generator can be dynamically sized depending on the power output of the turbine.
  • a conventional generator is effective at capturing energy from the energy source over a limited range of fluid speeds, whereas a multi-stage generator is able to capture energy over an extended range of fluid speeds of the energy source, due to staged power characteristics.
  • the electrical power that is generated from a multi-stage generator is variable in nature, meaning the output power waveforms produced may vary from time to time, for example in: voltage amplitude; current amplitude; phase; and/or frequency.
  • a multi-stage generator may include a number of induction elements, each of which generates its own power waveform, which may differ in voltage amplitude, current amplitude, phase, and/or frequency, from that generated by other induction elements within the generator.
  • An electrical load such as an electric utility power grid may not be capable of consuming directly the electrical power that is generated by a multi-stage generator, as the power generated may not be in the correct form, for example, with respect to waveform shape as a function of time, voltage amplitude, current amplitude, phase, and/or frequency, as may be required by the electrical load.
  • An electrical load such as a utility power grid typically expects from a turbine electrical generation system a single-phase, or split-phase, or 3-phase voltage or current waveform that is usually sinusoidal, and relatively stable, but a multi-stage generator generates varying waveforms.
  • a power converter circuit may be used to transform electrical power waveforms from one form to another form.
  • Converters may be designed for a specific rating of the input voltage range (e.g. 1000 VAC-rms to 2000 VAC-rms) and input current range rating (e.g. 100 A-rms to 500 A-rms), but if the input voltage or input current (and therefore power level) do not meet or exceed the levels for which the converter is designed, then the converter may not be capable of operation, or the converter may operate in an inefficient manner.
  • a single power converter is unlikely to accommodate the widely varying voltage waveforms and power range that is generated.
  • a single power transformer delivering power to the electrical load, connected to one or more converters is unlikely to accommodate with reasonable efficiency the wide range of power that may be generated by a multi-stage generator.
  • the multi-stage generator To take advantage of the electrical energy generated by the multi-stage generator, it is desirable to provide a power conversion system that combines and converts a portion, or all, of the electrical power waveforms generated by the multi-stage generator into a usable form consumable by an electrical load.
  • the conversion system should maintain a high level of efficiency and facilitate the multi-stage generator to operate efficiently and effectively over the power range that the generator is capable of producing; meaning the power conversion process should not limit the range (from the lowest level to highest level) of power that may be generated by the multi-stage generator.
  • a suitable power conversion system including an associated control process, is desirable to take advantage of the benefits of using a multi-stage generator within a turbine electrical generation system, resulting in a higher energy capture of the energy source over a wider range of fluid speeds (or over a wider range of fluid flow-rates) compared to conventional turbine electrical generation systems.
  • a controller can be used to control the power conversion electronics that process the output power waveforms of the generator.
  • a controller can also allow the system to seek to maximize the amount of energy capture from the energy source by seeking to optimize the turbine's parameters, such as blade pitch and turbine yaw, in response to time-dependent characteristics of the energy source such as the fluid speed and direction of flow. Based on these and other inputs, the system's electronic power conversion process would choose the near-optimal conversion strategy for delivering power to the electrical load.
  • An electric power generation system including a power generator having a plurality of machine configurations, the configurations selectively engageable by a prime mover; and a plurality of branches for connecting the configurations to an electrical load, each of the branches having a switch for connecting or disconnecting the branch to the configuration.
  • a method of connecting a power generator having a plurality of stages, to an electrical load, is provided, each of the stages being connected to the load via a corresponding branch having a converter, each of the converters having a differing power range, including the steps of: (a) determining a power output of the generator; (b) selecting one of the branches, wherein the power output of the selected branch has a converter capable of accepting the power output; and (c) passing the power output to the electrical load along the selected branch.
  • a method of connecting a power generator having a plurality of stages, to an electrical load including the steps of: (a) determining a power output of the generator; (b) configuring at least one of the parallel series selector for the power output; (c) selecting one or more of the branches corresponding to the configured parallel series selectors; and (d) passing the power output to the electrical load along the selected branches.
  • An electric power generation system including a power generator having a plurality of stages, each of the stages having at least an induction element, the induction elements engaged by a turbine; a plurality of branches for connecting the stages to an electrical load, each of the branches having a switch for connecting or disconnecting the branch to the stages; a turbine; and a system controller.
  • FIG. 1 is a block diagram of an embodiment of a turbine/generator/converter (TGC) system
  • FIG. 2 is a block diagram of an embodiment of a multi-stage generator
  • FIG. 3 is a flowchart showing an example of a control process by which a bank of converters converts the electric power into a useable form
  • FIG. 4 is a block diagram of an alternative embodiment of a turbine/generator/converter system including a parser conversion topology
  • FIG. 5 is a block diagram of an alternative embodiment of a multi-stage generator illustrating induction elements that may not need to be hardwired for interface to a parser conversion topology;
  • FIG. 6 is a flowchart showing an example of a control process by which a parser conversion system converts electric power into a useable form
  • FIG. 7 is a block diagram of an embodiment of a turbine/generator/converter system wherein the interface includes a hybrid conversion topology
  • FIG. 8 is a block diagram of an embodiment of a multi-stage generator illustrating induction elements that may be hardwired to facilitate interface to a hybrid conversion topology
  • FIG. 9 is a flowchart showing an example of a control process by which a hybrid conversion system converts electric power into a useable form
  • FIG. 10 is a block diagram of an embodiment of a branch having a fork to allow selection of a converter
  • FIG. 11 is a block diagram of an alternative embodiment of a branch, wherein the branch has a fork to allow selection of a transformer;
  • FIG. 12 is a block diagram of a further alternative embodiment of a turbine/generator/converter system, wherein the interface includes a hybrid conversion topology employing a forked branch.
  • energy source means a fluid medium, for example such as air, water, or steam, in motion, possessing kinetic energy due to translational motion.
  • Prime mover means a device, such as a turbine or drive motor acted on by a power source, such as an energy source, to produce mechanical energy.
  • turbine means a device, usually including blades or fins, connected to a shaft, that are acted upon by an energy source to produce mechanical energy in the form of rotational motion of the shaft. It includes turbines used to harness energy from wind, tide, run-of-river and solar and other renewable energy sources.
  • multi-stage generator means an electromagnetic machine that converts mechanical energy from a turbine into electrical energy. Electrical power may be generated by a multi-stage generator from a number of induction elements that can each produce a voltage. Some induction elements may be hardwired, either within the multi-stage generator casing or external to the casing (although a casing need not be present). The multi-stage generator may be a motor operating in generation mode.
  • induction element means a coil of insulated metallic wire that generates a voltage across terminals as the wire passes though a magnetic field.
  • stage means a logical grouping of induction elements.
  • the induction elements within a stage may have an almost equal frequency of the voltage waveform.
  • a stage may have all induction elements operating in phase, or poly-phase induction elements may be present in the stage.
  • a stage may or may not have a phase equal to another stage.
  • machine configuration means the sizing and configuration of induction elements, and may including the staging of induction elements.
  • parallel series selector or “parser” means an electronic or mechanical or electro-mechanical switching device that connects induction elements together in a number of configurable arrangements of parallel and/or series combinations.
  • a parser may also be referred to as a “configurator”.
  • power converter or “converter” means an electronic circuit that changes the form (e.g. waveform shape as a function of time, voltage amplitude, current amplitude, phase, and/or frequency) of electrical power waveforms.
  • a converter may include a rectification step.
  • Turbine/generator/converter system or “TGC system” means a system including a turbine, an electrical generator (such as a multi-stage generator) and a power converter.
  • a TGC system may optionally further include some or all of the following components: ring gear or gearbox; parser(s); transformer(s); switch(es); and control system(s).
  • a TGC system transforms a portion of the kinetic energy of an energy source into electrical energy.
  • electrical load means a consumer of electrical energy, and may be a stand-alone off-grid application, for example electrical devices within a residence, commercial building or industrial process; or may be a micro-grid system providing electrical energy for an isolated rural village; or a large electric utility power grid; or other application.
  • power conversion topology means an arrangement of hardware components, such as one or more, parsers, power converters, transformers, and switches.
  • a power conversion topology may be used as an interface between a multi-stage generator and an electrical load.
  • power conversion system means a power conversion topology and its associated controller.
  • a power conversion system may be a subsystem of a TGC system.
  • branch means an arrangement including any, but not necessarily all, of the following elements: a parser, input switch or switches; a converter; a transformer; output switch or switches; connected in series.
  • a branch may be a subsystem of a power conversion topology.
  • bank of converters system means a power conversion system including a bank of converters topology and an associated controller.
  • parser conversion system means a power conversion system including a parser conversion topology and an associated controller.
  • hybrid conversion system means a power conversion system including a hybrid conversion topology with one or more branches, and an associated controller.
  • system controller means a computer, microcontroller, digital signal processor, embedded system, analog circuit or other implementation that performs monitoring functions and issues commands to various subsystems and/or components of a system, such as a TGC system.
  • a system controller may also monitor an energy source and/or electrical load, and may provide information to an electrical load (for example, if the electrical load is an electric utility power grid).
  • fluid flow-rate means the quantity of fluid, such as air, water or steam, per unit time that moves through a turbine, measured in units such as cubic feet per minute, gallons per minute, liters per second, or kilograms per second.
  • average-power means the mean power as evaluated over one or more cycles of power delivery, for example as evaluated over a period of 16.67 milliseconds in a 60 Hz system.
  • rated-power or “name-plate power” means the highest value continuous average-power that a device (e.g. turbine, generator, converter, power conversion system, transformer, or TGC system) is specified to deliver.
  • a device e.g. turbine, generator, converter, power conversion system, transformer, or TGC system
  • machine utilization means the proportion of an electromagnetic machine, such as a multi-stage generator, not including the machine casing, that is active and delivering power when the machine is operating at rated-power, i.e. at the maximum continuous average-power capability of the machine. This proportion may be specified in various manners, including the ratio of the weight, e.g. in Kg, of the active portion of the machine to the weight of the machine not including the machine casing, or the ratio of the number of active induction elements to the total number of induction elements within the machine.
  • maximum energy capture mode means a mode of operation of a TGC system wherein, for a given fluid flow-rate through the turbine, the system controller delivers as much power as possible (i.e. the designed-maximum continuous average-power at that fluid flow-rate) from the energy source to the electrical load up to and including the rated-power of the TGC system.
  • Maximum energy capture mode may also be referred to as “maximum power point tracking” (MPPT).
  • throttling means a mode of operation of a TGC system wherein the system controller limits and regulates the average-power delivered to the electrical load to a value less than that which may be delivered for a given flow-rate of fluid through the turbine.
  • throttling of a TGC system may sometimes be necessary; however extended use of such a mode of operation may considerably reduce the energy capture over time of a given TGC system. Note that in maximum energy capture mode, the TGC system enters throttling mode when the system is operating at its rated-power.
  • “functional” means a component of a system that is capable of performing its intended function.
  • a system controller may be used to automatically maintain the efficient conversion of power during operation of a multi-stage generator turbine/generator/converter system.
  • the system controller may exist as a single controller which controls all functions of the turbine/generator/converter system, or may be separated into a number of sub-controllers with their own functions.
  • a major function of the system controller is to control the turbine, such as monitoring and adjusting the pitch of the blades and the yaw of the turbine.
  • a second major function of the system controller may be to monitor and control the power conversion electronics to provide an efficient and controlled transfer of power between the output of the multi-stage generator and the electrical load.
  • a system controller can be used to facilitate communication between components of the system; for example, in some embodiments it monitors sensors and/or receives information about system components and/or about the electrical load; it provides the relevant components with the necessary information to operate near-optimally and correctly; it instructs subsystems and components by providing adjustments and/or command signals.
  • Inputs for the system controller may include, but are not restricted to, fluid speed; fluid direction; fluid statistical information; the position information and/or the derivatives of position information for casing or supporting structural elements; turbine position and/or speed and/or acceleration; blade pitch angle; turbine pitch and/or yaw; current, voltage, power, reactive power, distortion, measurements at various points within the system or of the electrical load; sensory or data information about characteristics of the electrical load.
  • the system controller typically receives sensor and/or data information and issues commands to the turbine and components of the power conversion system to ensure the safe and efficient transfer of power from the turbine to the electrical load.
  • the system controller may initiate and activate power generated from a stage, including the engagement, transfer, and disengagement of power through any given stage.
  • the system controller preferably provides a smooth transfer of power between stages and an uninterrupted power flow to the electrical load, and when desirable may do so in such a way as to increase or maximize the energy capture from the fluid that is flowing through the turbine.
  • FIG. 1 Illustrated in FIG. 1 is a TGC system, which includes one embodiment of a power conversion topology, referred to here as a bank of converters topology 10 x .
  • Bank of converters topology 10 x has one or more converters 20 in different branches 30 that are each connected to a stage of induction elements within multi-stage generator 40 x.
  • FIG. 2 Shown in FIG. 2 is an illustration of multi-stage generator 40 x that may be interfaced with bank of converters topology 10 x .
  • multi-stage generator 40 such as 40 x
  • induction elements 50 which can be grouped into two or more different logical groupings referred to as stages 60 , such as 60 i , 60 j , 60 k in FIG. 2 .
  • a logical grouping means that the induction elements within a group 60 , for example stage 60 i , share a common set of characteristics, primarily spatial locality, so that the generated voltage amplitude and phase of a single induction element 50 will match those of other induction elements 50 within the grouping 60 .
  • stage 60 i Within one stage of a multi-stage generator 40 , the possibility exists for single-phase, split-phase, 3-phase, 4-phase, 6-phase or other poly-phase arrangements of induction elements 50 .
  • induction elements 50 within a stage 60 may be hardwired and connected together into a combination of parallel and/or series connections.
  • Induction element terminals 70 may be hardwired within the casing of multi-stage generator 40 , or induction element terminals 70 may be hardwired external to the casing of multi-stage generator 40 .
  • no casing is needed and terminals 70 may be hardwired within multi-stage generator 40 or external to multi-stage generator 40 .
  • there may be any practical number of induction elements 50 within a stage 60 possibly in poly-phase arrangements, and a variety of series, parallel, or mixed series-parallel connections are possible; also there may be no hardwiring of induction elements 50 .
  • the output terminal-block 80 from each stage 60 may connect to a branch 30 , which may include input switch 90 , converter 20 , optional transformer 100 , and output switch 110 , all connected in series.
  • the outputs of each branch 30 may be connected to electrical load 120 .
  • Each input switch 90 such as 90 i
  • Each output switch 110 includes several poles of switches, which may close or open simultaneously, to accommodate the terminals of electrical load 120 .
  • the power rating of converter 20 and/or transformer 100 may increase geometrically from one stage to the next, so that if at the first stage 60 i a relatively low power converter 20 i is required, the next stage 60 j may require a significantly higher power converter 20 j , etc.
  • this allows for stage 60 j to contain many more induction elements 50 than that of stage 60 i , and similarly stage 60 k may have many more induction elements than stage 60 j , etc.
  • Turbine 130 acting as a prime mover, may be directly connected to a multi-stage generator 40 or there may be a ring-gear or gearbox 140 coupling turbine 130 to multi-stage generator 40 .
  • Turbine 130 as the prime mover, engages multi-stage generator 40 thereby inducing a voltage across induction elements 50 .
  • Components and/or subsystems of the TGC system may be interfaced to a system controller 150 , such as 150 x , including but not limited to the following components: turbine 130 , induction elements 50 , branches 30 , input switches 90 , converters 20 , transformers 100 , output switches 110 and electrical load 120 .
  • system controller 150 may provide commands to control the pitch of the turbine blades.
  • System controller 150 may also monitor the fluid medium, for example sensing the speed of the fluid at various possible locations in and around the turbine.
  • System controller 150 may also monitor the rotational speed of turbine 130 and/or of multi-stage generator 40 .
  • System controller 150 may also monitor power variables at various points in the TGC system.
  • System controller 150 may also monitor various current, voltage, phase angle, power or other variables of electrical load 120 and may also provide information to electrical load 120 .
  • System controller 150 or a dedicated sub-controller (not shown), may also synchronize the output voltage or current of branch 30 with the voltage waveform of electrical load 120 , which may be an electric utility power grid.
  • multiple converters 20 and/or transformers 100 may be used in a TGC system.
  • these multiple converters 20 and/or transformers 100 are arranged so that power flows, with reasonably high efficiency, through one branch 30 corresponding to a given power level range that may be generated by a given stage 60 of multi-stage generator 40 x , (except during a transition period when power is being transferred from one branch to another branch, such as from 30 i to 30 j ).
  • the top value of the power range for stage 60 i may be a small percentage higher than the lowest value of the power range for stage 60 j .
  • the top value of the power range for branch 30 i may be a small percentage higher than the lowest value of the power range for branch 30 j .
  • the overlap of power ranges aids system controller 150 to effect a smooth transfer of power flow from one stage (branch) to the next stage (branch) as the power level of the prime mover, i.e. the turbine, varies with time.
  • Input switch 90 such as 90 i
  • An output switch 110 such as 110 i
  • Output switches 110 also act as a fail-safe to prevent power being delivered to electrical load 120 from inactive converter branches 30 , and may facilitate the transfer of power from one branch 30 to another branch 30 , and provide additional isolation (with manually operated circuit breakers) for maintenance purposes.
  • system controller 150 may perform the monitoring of variables, such as, but not restricted to, the monitoring of power flow from a multi-stage generator 40 (multi-stage generator 40 power output may also be obtained by measurement of the input power to power conversion topology 10 ).
  • System controller 150 also makes decisions and executes tasks, using a control process outlined in the flowcharts, such as illustrated in FIG. 3 .
  • the control process that is used generally seeks to maximize energy capture mode when, for a given fluid flow-rate, it is desirable to deliver as much power as possible from the energy source to electrical load 120 , up to and including the rated-power of the TGC system.
  • a variation of the maximum energy capture mode of operation is a throttling mode wherein a system controller 150 is instructed by an operator (which may be a person or another controller, for example a controller that governs operation of a wind farm) to deliver a limited and/or regulated average-power to electrical load 120 that may be less than the rated-power of the TGC system. Even in maximum energy capture mode, once the rated-power delivery of the TGC system is obtained, system controller 150 may enter a throttling mode wherein the average output power of the TGC system is regulated to be the rated-power of the TGC system, and multi-stage generator 40 is operating at its rated-power level.
  • FIG. 3 is a flowchart showing an embodiment of a control process by which system controller 150 x may control bank of converters topology 10 x to transform the electric power produced by multi-stage generator 10 x into a useable form for electrical load 120 .
  • the bank of converters system may be in a standby mode (step 300 ) when there is no power output from the multi-stage generator 40 x .
  • standby mode all branches 30 may be disconnected from electrical load 120 , i.e. input switches 90 may all be open and output switches 110 may be all open.
  • a power conversion topology 10 such as bank of converters topology 10 x , remains inactive and in standby mode (step 300 ) until multi-stage generator 40 produces power exceeding a pre-defined threshold level, defined herein as “P 1 +” (step 305 ), where P 1 + is generally a small percentage greater than the minimum operating input power of power conversion topology 10 , defined herein as “P 1 ⁇ ”.
  • switch 90 i connected to the lowest level stage 60 i , may close and under control of system controller 150 x branch 30 i becomes active, including converter 20 i and/or transformer 100 i , but no power is yet flowing to electrical load 120 .
  • the power level for the currently active converter branch 30 decreases past a certain level (which, referring to the “ ⁇ ” notation, may be slightly less than the threshold necessary to begin power flow in that branch), then the flow of power is transferred to the preceding branch. If there is no previous branch then the bank of converters topology 10 x and system controller 150 x return to standby mode. Likewise, if the power level for the currently active converter branch 30 increases past a certain level (referring to the “+” notation), then flow of power is transferred to the next branch having a higher power rating (for example branch 30 j may be capable of transforming power at higher levels than branch 30 i ).
  • a multi-stage generator 40 such as 40 x
  • P max is the rated-power of a multi-stage generator 40 , such as 40 x , corresponding to and slightly greater than the rated-power of the TGC system, due to losses in power conversion topology 10 .
  • system controller 150 X monitors the output power level of multi-stage generator 40 x (step 320 ), and if the power level drops below P 1 ⁇ , the system returns to standby mode (step 300 ), meaning that power flow in branch 30 i is reduced to zero by system controller 150 x and then switches 110 i and 90 i are opened, preferably in that order.
  • system controller 150 x may return the system to standby from other steps, such as, but not restricted to, steps 345 or 382 .
  • step 320 If (at step 320 ) the power level is between P 1 ⁇ and P 2 +, then system controller 150 x retains the power flow through branch 30 i (step 315 ). If (at step 320 ) the power level exceeds P 2 +, then the switches for the next branch 30 , branch 30 j , switches 90 j and 110 j , are closed, preferably, but not necessarily, in that order (step 325 ). Power flow is then transferred by system controller 150 x to branch 30 j (step 330 ), and at least one of switches 110 i and 90 i are opened (step 335 ), and power flows only through branch 30 j (step 340 ).
  • system controller 150 x monitors the output power level of multi-stage generator 40 x (step 345 ), and if the power level is between P 2 ⁇ and P 3 +, then the system controller 150 x retains the power flow through branch 30 j (step 340 ).
  • step 345 system controller 150 x returns power flow in bank of converters topology 10 x to branch 30 i , possibly using the following sequence of steps.
  • Switches 90 i and 110 i are closed (step 350 ), then system controller 150 x causes power flow to transfer to branch 30 i (step 355 ), after which switches 110 j and 90 j are opened (step 360 ).
  • step 345 If (at step 345 ) the power level exceeds P 3 +, then switches 90 k and 110 k are closed (step 365 ), and power is transferred by system controller 150 x from branch 30 j to branch 30 k (step 370 ), following which switches 110 j and 90 j are opened (step 375 ) so that the transfer of power from branch 30 j to branch 30 k is complete and power flows only though branch 30 k (step 380 ).
  • system controller 150 x monitors the output power level of multi-stage generator 40 x (step 382 ), and if the power level is between P 3 ⁇ and P max , then system controller 150 x retains the power flow through branch 30 k (step 380 ). Note that when power level P max is obtained system controller 150 x may enter a throttling mode (also step 380 ).
  • system controller 150 x If (at step 382 ) the power level drops below P 3 ⁇ , system controller 150 x returns power flow in bank of converters topology 10 x to branch 30 j possibly using the following sequence of steps. Switches 90 j and 110 j are closed (step 384 ), then system controller 150 x causes power flow to transfer to branch 30 j (step 386 ), after which switches 110 k and 90 k are opened (step 388 ).
  • step 382 If (at step 382 ), or at other steps including, but not restricted to, steps 320 and 345 , an emergency condition arises (for example a storm or hurricane winds applied to a wind turbine), it may be necessary for system controller 150 x to shut down operation of the TGC system by setting power flow through the TGC system to zero and preferably stopping rotation of turbine 130 (step 390 ).
  • an emergency condition for example a storm or hurricane winds applied to a wind turbine
  • system controller 150 If the fluid flow-rate in turbine 130 exceeds a threshold value, herein designated “f max ”, corresponding to the power rating P max , and possibly also corresponding to a specific speed of the fluid at some point in or around the turbine, system controller 150 then enters a throttling mode and regulates the power flow through the TGC system to be at the maximum level of P max (hence the “ ⁇ ” condition in the monitoring and decision step 382 of FIG.
  • f excess a second threshold value, herein designated “f excess ” (possibly corresponding to a specific speed of the fluid at some point in or around the turbine that may be measured by system controller 150 , or possibly corresponding to a specific rotational speed of the shaft of turbine 130 or a specific shaft speed of multi-stage generator 40 , any of which may be measured by system controller 150 ), then the fluid flow-rate may be excessive for turbine 130 to maintain its mechanical integrity.
  • f excess a second threshold value
  • the activation or deactivation of a branch 30 may be initiated when a power threshold is crossed (e.g. for the bank of converters power conversion system there may be a transfer of power flow from branch 30 i to branch 30 j initiated when multi-stage generator 40 x output power exceeds P 2 +).
  • a system controller 150 may initiate the activation or deactivation of a branch 30 using system variables other than the power from a multi-stage generator 40 , such as but not restricted to: the speed of fluid flowing in or around turbine 130 ; the rotational speed of turbine 130 ; the rotational speed of a multi-stage generator 40 ; the output voltage of stages 60 as measured at a terminal-block 80 or directly across one or more induction elements 50 of multi-stage generator 40 ; and/or the input voltage to a power conversion topology 10 .
  • system variables other than the power from a multi-stage generator 40 such as but not restricted to: the speed of fluid flowing in or around turbine 130 ; the rotational speed of turbine 130 ; the rotational speed of a multi-stage generator 40 ; the output voltage of stages 60 as measured at a terminal-block 80 or directly across one or more induction elements 50 of multi-stage generator 40 ; and/or the input voltage to a power conversion topology 10 .
  • the transfer of power from one branch 30 to the next branch 30 may be initiated when the voltage output from a given stage exceeds (or drops below) a voltage threshold (e.g. for the bank of converters power conversion system there may be a transfer of power flow from branch 30 i to branch 30 j when the output voltage of stage 60 i exceeds a voltage threshold defined herein as “V 2 +”, following which stage 60 i could be inactivated).
  • a voltage threshold e.g. for the bank of converters power conversion system there may be a transfer of power flow from branch 30 i to branch 30 j when the output voltage of stage 60 i exceeds a voltage threshold defined herein as “V 2 +”, following which stage 60 i could be inactivated.
  • the above discussed embodiment of a power conversion system has an elegance of process control as only one stage 60 and one corresponding branch 30 is active at a given time, aside from periods when power is being transferred from one branch 30 to another branch 30 .
  • P max there are unused inactive stages 60 within the multi-stage generator 40 .
  • the highest power stage 60 which may be stage 60 k as in FIG.
  • machine utilization of multi-stage generator 40 x may be less than 100%, for example on the order of 75% at a rated-power on the order of one megawatt to ten megawatts, meaning that 75% of induction elements 50 within multi-stage generator 40 x are activated and 25% are inactive when the TGC system is operating at its rated-power level (when multi-stage generator 40 x is operating at its rated-power level P max ).
  • FIG. 4 Another embodiment of a power conversion system, which may have up to 100% machine utilization of a multi-stage generator 40 is referred to herein as a parser conversion system, and includes parser conversion topology 10 y and its associated controller, system controller 150 y , as shown in FIG. 4 .
  • multi-stage generator 40 y may require no hardwiring of induction elements 50 , i.e., all induction element terminals 70 within a stage 60 , such as 60 i , are connected to terminal-block 80 , such as 80 i , as indicated in FIG. 5 .
  • a corresponding process control flowchart that could be employed by system controller 150 y in the control of parser conversion topology 10 y is shown in FIG. 6 .
  • parser conversion topology 10 y includes one or more branches 30 .
  • branches 30 may include a parser 170 , an input switch 90 , a converter 20 , an optional transformer 100 , and an output switch 110 , all connected in series.
  • the output switch 110 from each branch 30 is connected to electrical load 120 , which may be an electric utility power grid.
  • electrical load 120 which may be an electric utility power grid.
  • a key concept of the parser conversion topology 10 y is the modular design, in that each branch 30 may be substantially identical in form with all other branches, i.e.
  • parsers 170 i , 170 j , 170 k may be substantially identical, as may be input switches 90 i , 90 j , 90 k , converters 20 i , 20 j , 20 k , transformers 100 i , 100 j , 100 k , and output switches 110 i , 110 j , 110 k.
  • FIG. 5 shows a multi-stage generator 40 y which may have any practical number of stages 60 , each of which may be substantially identical, each stage 60 including a number of induction elements 50 .
  • multi-stage generator 40 y may also have a modular design.
  • the modularity of parser conversion topology 10 y and of the multi-stage generator 40 y enables one stage-branch pair to function in place of a second stage-branch pair should the latter be damaged.
  • stage 60 j and branch 30 j may provide power flow to electrical load 120 in place of stage 60 i and branch 30 i , as decided by system controller 150 y , after the performance of diagnostic tests to determine the functionality of stages 60 and branches 30 .
  • Such replacement of damaged stages 60 and/or branches 30 is facilitated by input switches 90 and output switches 110 , permitting normal TGC system operation or a reduction in TGC system operation until repairs are affected.
  • input switch 90 i and output switch 110 i may both be kept open isolating the damaged component from electrical load 120 , or in the specific case of a damaged stage 60 , isolating that stage 60 from its branch 30 of parser conversion topology 10 y.
  • Parsers 170 are used to configure the terminals 70 of the induction elements 50 such that the voltage outputs for parser 170 are within an acceptable level for the corresponding converter 20 in branch 30 . For example, at a low power level range (for example from P 1 ⁇ to P 2 +) perhaps one or more sets of induction elements 50 within an active stage 60 , such as 60 i , are connected in series by parser 170 .
  • Parser 170 may be used to arrange induction elements 50 within a stage 60 to meet the voltage requirements of a corresponding converter 20 as needed. If a higher voltage level is required by converter 20 then parser 170 arranges the induction elements 50 in a more series-like manner; likewise if a lower voltage level is required then induction elements 50 are arranged in a more parallel-like manner.
  • the configuration of each parser 170 is a function of system controller 150 y , responding to changing variables such as fluid speed or turbine 30 rotational speed, or generator 40 rotational speed, or direct measurement of voltages at terminal block 80 .
  • FIG. 6 is a flowchart showing an embodiment of a control process by which system controller 150 y may control parser conversion topology 10 y to transform the electric power produced by multi-stage generator 10 y into a useable form for electrical load 120 .
  • System controller 150 y or a delegated sub-controller, makes decisions and executes tasks as outlined in the flowchart shown in FIG. 6 .
  • the illustrated control process generally seeks maximum energy capture mode and includes throttling of parser conversion topology 10 y when multi-stage generator 40 y is delivering its rated-power of P max to parser conversion topology 10 y.
  • the parser conversion system may be in a standby mode (step 600 ) when there is no power output from multi-stage generator 40 y .
  • standby mode all branches 30 of parser conversion topology 10 y are disconnected from electrical load 120 , i.e., input switches 90 and output switches 110 are open, and parsers 170 may be pre-configured for a parallel-like arrangement of induction elements 50 (this is a fail-safe configuration that prevents excess voltage application to converters 20 in the event of accidental closing of input switch 90 ).
  • An internal diagnostic system check may be performed by a system controller 150 , such as 150 y , to determine if any of the induction elements 50 or branches 30 in the TGC system is malfunctioning (step 603 ). If a malfunctioning induction element 50 or malfunctioning branch 30 is found then it is disabled, by keeping open at all times the associated input switch 90 and output switch 110 (until a suitable time can be found for repair of the malfunctioning part).
  • system controller 150 Under control of a system controller 150 , such as 150 y , voltage may be induced in induction elements 50 if there is sufficient fluid flow in turbine 130 to rotate of the shaft of multi-stage generator 40 .
  • System controller 150 y maintains all branch output switches 110 in an open state (steps 600 and 603 ) until a multi-stage generator 40 , such as 40 y , is capable of producing power exceeding a pre-defined threshold level, P 1 + (step 606 ), when a functional branch 30 , for example branch 30 i , may be selected (step 609 ) by system controller 150 y and the corresponding parser 170 i is configured for the lowest power level P 1 , i.e.
  • parser 170 i is configured for power level range P 1 ⁇ to P 2 + (step 612 ). This typically means that parser 170 i may connect one or more sets of induction elements 50 within stage 60 i in a series-like arrangement since at low power it is likely that the voltage across individual induction elements is relatively low and placing the elements 50 in series increases the voltage applied to converter 20 i . The corresponding input and output switches 90 i and 110 i may then be closed, preferably in that order (step 615 ) and power begins to flow from multi-stage generator 40 y though the stage 60 i and branch 30 i to electrical load 120 (step 618 ).
  • system controller 150 y monitors the output power level of multi-stage generator 40 y (step 621 ), and if the power level is between P 1 ⁇ and P 2 +, then system controller 150 y retains the power flow through branch 30 i (step 618 ).
  • step 621 If (at step 621 ) the power level drops below P 1 ⁇ , the system returns to standby mode (step 600 ), meaning that power flow in branch 30 i may be reduced to zero, and switches 110 i and 90 i , may be opened, preferably in that order. Note that in general it may be possible for system controller 150 y to return the system to standby from other steps such as but not restricted to steps 648 or 679 .
  • step 621 If (at step 621 ) the power level exceeds P 2 +, another functional branch that is not currently active, for example branch 30 j , is selected (step 624 ) and its parser 170 j configured for power level range P 2 ⁇ to P 3 + (step 627 ). Then switches 90 j and 110 j may be closed (step 630 ). Power flow may be transferred out of branch 30 i by system controller 150 y to branch 30 j (step 633 ) temporarily, so that switches 110 i and 90 i may be opened if necessary (step 636 ), and system controller 150 y may now configure parser 170 i for the next higher power range P 2 ⁇ to P 3 + (step 639 ).
  • Input and output switches 90 j and 110 j may be then closed (step 642 ), and power is controlled by system controller 150 y to flow though both branches 30 i and 30 j (step 645 ).
  • the above steps may be performed by system controller 150 , such as 150 y , in such a way that there is no interruption of power delivery to electrical load 120 .
  • system controller 150 y monitors the output power level of multi-stage generator 40 y (step 648 ), and if the power level is between P 2 ⁇ and P 3 +, then the system controller 150 y retains the power flow through branches 30 i and 30 j (step 645 ).
  • step 648 the controller returns power flow in parser conversion topology 10 y to branch 30 i possibly using the following sequence of steps. All power is transferred temporarily from branch 30 i to 30 j (step 651 ). Switches 110 i and 90 i are opened (step 653 ). Parser 170 i is reconfigured for power level range P 1 ⁇ to P 2 + (step 655 ). Switches 90 i and 110 i are closed (step 657 ). All power is transferred from branch 30 j to 30 i (step 659 ). Switches 110 j and 90 j are opened (step 661 ), and power now flows through branch 30 i (step 618 ).
  • step 648 If (at step 648 ) the power level exceeds P 3 +, another functional branch, for example branch 30 k , may be selected (step 663 ) and parser 170 k configured for power level range P 3 ⁇ to P max (step 665 ). Then switches 90 k and 110 k are closed (step 667 ). All power flow in branch 30 i is transferred out of branch 30 i and into branch 30 j (step 669 ) temporarily, so that switches 110 i and 90 i are opened if necessary (step 671 ), and system controller 150 y now configures parser 170 i for the next higher power range P 3 ⁇ 0 to P max (step 671 ).
  • branch 30 k may be selected (step 663 ) and parser 170 k configured for power level range P 3 ⁇ to P max (step 665 ). Then switches 90 k and 110 k are closed (step 667 ). All power flow in branch 30 i is transferred out of branch 30 i and into branch 30 j
  • Input and output switches 90 i and 110 i are then be closed (step 671 ), and the power flowing in branch 30 j is now temporarily transferred from branch 30 j to 30 i (step 673 ), so that switches 110 j and 90 j may be opened (step 675 ), and system controller 150 y now configures parser 170 j for the next higher power range P 3 ⁇ 0 to P max (step 675 ).
  • Input and output switches 90 i and 110 i may then be closed (step 675 ), and after transferring some power to branch 30 j (from either or both of branches 30 i and 30 k ), power is controlled by system controller 150 y to flow though all branches, such as branches 30 i , 30 j , and 30 k (step 677 ).
  • system controller 150 y monitors the output power level of multi-stage generator 40 y (step 679 ), and if the power level is between P 3 ⁇ and P max , then system controller 150 y retains the power flow through all branches, such as branches 30 i , 30 j , and 30 k (step 677 ).
  • P max is the rated-power of multi-stage generator 40 y , and hence system controller 150 y may enter throttling mode when this power level is achieved.
  • system controller 150 y returns power flow in parser conversion topology 10 y to branches 30 i and 30 j (i.e., deactivating branch 30 k ) possibly using the following sequence of steps. All power is transferred temporarily from branch 30 i to branches 30 j and 30 k (preferably with equal power levels in branches 30 j and 30 k ) (step 681 ). With no power in branch 30 i , switches 90 i and 110 i are opened if necessary (step 683 ) and parser 170 i reconfigured for power level range P 2 ⁇ to P 3 + (step 683 ). Switches 90 i and 110 i are then closed (step 683 ).
  • All power in branch 30 j is then transferred from branch 30 j to branch 30 i (step 685 ). With no power in branch 30 j , switches 90 j and 110 j are opened if necessary (step 687 ) and parser 170 j reconfigured for power level range P 2 ⁇ to P 3 + (step 687 ). Switches 90 j and 110 j are then closed (step 687 ). Power may then be transferred out of branch 30 k , possibly to branch 30 j (step 689 ), so that power flow in branches 30 i and 30 j is approximately equal and switches 110 k and 90 k are opened (step 691 ), and power now flows through branches 30 i and 30 j (step 645 ).
  • step 679 If (at step 679 ) or for that matter at other steps, including but not restricted to steps 621 and 648 , an emergency condition arises, it may be necessary for system controller 150 y to shut down operation of the TGC system by setting power flow through the TGC system to zero and preferably stopping rotation of turbine 130 (step 693 ).
  • the activation or deactivation of a branch may be initiated when a power threshold is crossed, however, system controller 150 y may alternatively initiate the activation or deactivation of a branch 30 using other system variables such as, but not restricted to: the speed of fluid flowing in or around turbine 130 ; the rotational speed of turbine 130 ; the rotational speed of a multi-stage generator 40 y ; the output voltage of stages 60 as may be measured at a terminal-block 80 or directly across one or more induction elements 50 of a multi-stage generator 40 ; and/or the input voltage to parser conversion topology 10 y.
  • system controller 150 y may alternatively initiate the activation or deactivation of a branch 30 using other system variables such as, but not restricted to: the speed of fluid flowing in or around turbine 130 ; the rotational speed of turbine 130 ; the rotational speed of a multi-stage generator 40 y ; the output voltage of stages 60 as may be measured at a terminal-block 80 or directly across one or more induction elements 50 of a multi-stage generator
  • parser conversion system may be extended (or simplified) to the case where there are more than (or fewer than) three branches. In general, there may be any practical number of branches 30 within a parser conversion topology 10 y.
  • An issue with a parser conversion system is that at a low power level (at or near P 1 for example), it may be difficult to maintain high efficiency of the one branch 30 in operation. At a loss of some modularity, this issue may be remedied by allowing one branch 30 to fork into two sub-branches, each sub-branch having a converter and/or an optional transformer. Thus, at low power operation (at or near P 1 for example), the sub-branch with the lowest power rating, which has been designed for high efficiency at that lower power level, may be the only branch activated. In this embodiment, one stage, such as stage 60 i , could have two branches, branch 30 i 1 and branch 30 i 2 , as shown in FIG.
  • branch 30 i 2 may have a higher rated-power specification than that of branch 30 i 1 . It may be reasonable to set the rated-power of branch 30 i 2 to be equal to the remaining branches 30 , such as branch 30 j , branch 30 k etc, which are configured as shown in FIG. 4 .
  • branch 30 j branch 30 j , branch 30 k etc, which are configured as shown in FIG. 4 .
  • branch 30 j branch 30 k etc.
  • parsers 170 j , 170 k , etc. may have a simpler structure than parser 170 i.
  • branch 30 i could have input switch 90 i followed by (i.e. in series with) converter 20 i , following which is the fork with optional multi-pole switch 180 i 1 in a fork prong connected to lower power transformer 100 i 1 , and optional multi-pole switch 180 i 2 connected to higher power transformer 100 i 2 on the other prong.
  • Another variation in the forking embodiment is that there may be three or more sub-branches, for example 30 i 1 , 30 i 2 , 30 i 3 , etc., or in the case of the fork taking place following a converter, three or more sub-transformers, for example 100 i 1 , 100 i 2 , 100 i 3 , etc. Also, there is the possibility that more than one stage 60 may employ forked branches or forked transformers.
  • parser conversion system has the advantage of permitting the design of a multi-stage generator 40 , such as 40 y , that has almost, if not all, 100% machine utilization at rated power.
  • design of parser 170 for some or all of stages 60 may require a large number of switches within the parser, and this may add to the construction cost of parser conversion topology 10 y , and may also reduce the reliability of the parser conversion system.
  • the hybrid power conversion system discussed below is an embodiment of a power conversion system for a turbine driven multi-stage electrical generator. With this embodiment, very high machine utilization may be achievable for a multi-stage generator 40 , and with significantly simplified parsers 190 (as seen in FIG. 7 ) by comparison to parsers 170 of the parser conversion system.
  • parser 190 may be significantly less than that of a parser 170 because each parser 190 may need only arrange sets of partially hardwired induction elements 50 in perhaps just two or three possible arrangements (each arrangement corresponding to a power range of multi-stage generator 40 z ) instead of a potentially much larger number of arrangements as may be the case for a parser 170 of the parser conversion system. For example consider that there may be N induction elements 50 in one set of induction elements of one phase of stage 60 , then it is reasonable to construct a parser 170 for parser conversion topology 10 y that has up to 3(N ⁇ 1) switches for that set of induction elements.
  • parsers 190 of the hybrid power conversion topology 10 z , may contain as few as just three switches for the same set of N induction elements. Note that for either parser 170 or parser 190 , each switch therein may require that electrical current be capable of flowing in either direction through the switch, which would then be a requirement of the physical realization of the switches in the construction of the parser.
  • hybrid conversion topology 10 z includes one or more branches 30 .
  • Each branch 30 may include a parser 190 if needed, an input switch 90 if needed, a converter 20 , an optional transformer 100 , and an output switch 110 , all connected in series.
  • the output switch 110 from each branch 30 is connected to electrical load 120 , which may be an electric utility power grid.
  • a key concept of hybrid conversion topology 10 z is that a given stage 60 of multi-stage generator 40 z may be partially hardwired so that the stage may deliver power over more than one power range but not necessarily over the entire power range of the multi-stage generator 40 z (for example stage 60 i may operate over power range P 1 ⁇ to P 2 + as well as power range P 2 ⁇ to P 3 + but perhaps not power range P 3 ⁇ to P max ), thus two or more stages 60 may be delivering power simultaneously through two or more corresponding branches 30 of hybrid conversion topology 10 z .
  • the intention with this hybrid power conversion system embodiment is that when the TGC system is operating at its rated-power with multi-stage generator 40 z operating at its rated-power, P max , multiple high-power stages 60 (each containing a large number of induction elements 50 ) are actively delivering power, and hence the high machine utilization of multi-stage generator 40 z.
  • FIG. 8 is an illustration of a partially hardwired multi-stage generator 40 z .
  • the partial hardwiring of induction element terminals 70 may be done within the casing of multi-stage generator 40 z , or external to the casing. Alternatively, no casing is needed and terminals 70 may be within multi-stage generator 40 or external to multi-stage generator 40 .
  • partial hardwiring it can be seen in FIG. 8 that in low power stages such as 60 i , many induction elements 50 may be hardwired in a series-like manner.
  • parser 190 i may have the relatively simple task, under control of system controller 150 z , of connecting two (or more) subsets of induction elements 50 (two subsets are illustrated within stage 60 i in FIG. 8 ) in an extended series arrangement at the lower power levels, or the induction element subsets may be arranged in more parallel-like arrangements as the power increases from multi-stage generator 40 z .
  • Such reconfiguring of induction elements may be done to maintain the voltage to a converter 20 , such as 20 i , within a restricted range.
  • parser 190 j has the task, under control of system controller 150 z , of connecting two (or more) subsets of induction elements 50 (two subsets are illustrated within stage 60 j in FIG. 8 ) in a series arrangement, or the subsets may be arranged in a more parallel-like arrangement as power increases from multi-stage generator 40 z , to maintain the voltage to converter 20 j within a restricted range.
  • the hardwired connections shown in FIG. 8 are purely illustrative, and in general there may be any practical number of induction elements 50 within a stage 60 , possibly in poly-phase arrangements, and a variety of series, parallel, or mixed series-parallel connections are possible.
  • the power rating of converter 20 and/or transformer 100 may increase geometrically from one stage 60 to the next, so that if at first stage 60 i a relatively low power converter 20 i is required, the next stage 60 j may require a significantly higher power converter 20 j , etc.
  • stage 60 j it is possible for stage 60 j to contain many more induction elements 50 than that of stage 60 i , and similarly stage 60 k might have many more induction elements than stage 60 j .
  • the power rating for converters 20 and transformers 100 within a hybrid conversion topology 10 z may be higher than in the case of the bank of converters topology 10 x , but there may be fewer branches in the hybrid conversion topology 10 z given a specified power of the multi-stage generator 40 .
  • a parser 190 may not be needed for the highest power stage 60 , such as 60 k ; a set of induction elements 50 of the highest power stage 60 , such as 60 k , may be connected in a hardwired manner, for example all induction elements 50 within one set of induction elements 50 for one phase of stage 60 k may be hardwired in parallel as illustrated in FIG. 8 .
  • FIG. 9 is a flowchart showing an embodiment of a control process by which system controller 150 z may control hybrid conversion topology 10 z to transform the electric power produced by multi-stage generator 10 z into a useable form for electrical load 120 .
  • System controller 150 z or its delegated sub-controller, makes decisions and executes tasks as outlined in the flowchart shown in FIG. 9 .
  • the illustrated control process generally seeks maximum energy capture mode and includes throttling of hybrid conversion topology 10 z when multi-stage generator 40 z is delivering its rated-power of P max to hybrid conversion topology 10 z.
  • the hybrid conversion system begins in a standby mode (step 900 ) when there is no power output from the multi-stage generator 40 z .
  • standby mode all branches 30 of hybrid conversion topology 10 z are disconnected from electrical load 120 , i.e. input switches 90 and output switches 110 are all open, and any parsers 190 are pre-configured for a parallel arrangement of sub-sets of induction elements 50 (this is a fail-safe configuration that prevents excess voltage application to converters 20 in the event of accidental closing of input switch 90 ).
  • An internal system check may be done to determine if any of the induction elements 50 or branches 30 in the TGC system is malfunctioning. If a malfunctioning induction element 50 or branch 30 is found, it is disabled by keeping open at all times associated input switch 90 and output switch 110 , and the induction element 50 or branch 30 is not used during power delivery (until a suitable time can be found for repair of the malfunctioning part).
  • system controller 150 z Under control of system controller 150 z voltage is induced in induction elements 50 if there is sufficient fluid flow in turbine 130 to rotate of the shaft of multi-stage generator 40 z .
  • System controller 150 z maintains all branch input switches 90 open and/or all branch output switches 110 open (step 900 ) until multi-stage generator 40 z produces power exceeding pre-defined threshold level, P 1 + (step 903 ), when parser 190 i is configured for the lowest power level P 1 , i.e. parser 190 i is configured for power level range P 1 ⁇ to P 2 + (step 906 ). Therefore parser 190 i may connect one or more sub-sets of induction elements 50 within stage 60 i in a series-like arrangement.
  • the corresponding input and output switches 90 i and 110 i then are closed, preferably in that order (step 909 ) and power begins to flow from multi-stage generator 40 z though the stage 60 i and branch 30 i to electrical load 120 (step 912 ).
  • system controller 150 z monitors the output power level of multi-stage generator 40 z (step 915 ), and if the power level is between P 1 ⁇ and P 2 +, then the system controller 150 z retains the power flow through branch 30 i (step 912 ).
  • step 915 If (at step 915 ) the power level drops below P 1 ⁇ , the system returns to standby mode (step 900 ), meaning that power flow in branch 30 i is reduced to zero and switches 110 i and 90 i are opened, preferably in that order. Note that in general it may be possible for system controller 150 z to return the system to standby from other steps such as, but not restricted to, steps 939 or 978 .
  • parser 190 j is configured for power level range P 2 ⁇ to P 3 + (step 918 ). Then switches 90 j and 110 j are closed (step 921 ). Power flow is transferred out of branch 30 i by system controller 150 z to branch 30 j (step 924 ) temporarily, so that switches 110 i and 90 i are opened if necessary (step 927 ), and system controller 150 z now configures parser 190 i for the next higher power range P 2 ⁇ to P 3 + (step 930 ).
  • Input and output switches 90 i and 110 i are then closed (step 933 ), and power is controlled by system controller 150 z to flow though both branches 30 i and 30 j (step 936 ), possibly with approximately equal power in each branch. All the above steps (and those discussed below) may be conducted by system controller 150 z so that there is no interruption of power delivery to electrical load 120 .
  • system controller 150 z monitors the output power level of multi-stage generator 40 z (step 939 ), and if the power level is between P 2 ⁇ and P 3 +, then the system controller 150 z retains the power flow through branches 30 i and 30 j (step 936 ).
  • step 939 system controller 150 z returns power flow in hybrid conversion topology 10 z to branch 30 i possibly using the following sequence of steps. All power is transferred temporarily from branch 30 i to 30 j (step 942 ). Switches 110 i and 90 i are opened (step 945 ). Parser 190 i is reconfigured for power level range P 1 ⁇ to P 2 + (step 948 ). Switches 90 i and 110 i are closed (step 951 ). All power is transferred from branch 30 j to branch 30 i (step 954 ). Switches 110 j and 90 j are opened (step 957 ), and power now flows through branch 30 i (step 912 ).
  • switches 90 j and 110 j are closed (step 960 ).
  • Power flow may be transferred out of branches 30 i and 30 j by system controller 150 z to branch 30 k (step 963 ) temporarily, so that switches 110 j and 90 j are opened if necessary (step 966 ), and system controller 150 z now configures parser 190 j for the next higher power range P 3 ⁇ to P max (step 969 ).
  • Input and output switches 90 j and 110 j are then closed (step 972 ), and power is controlled by system controller 150 z to flow though branches 30 j and 30 k (step 975 ), possibly with approximately equal power in each branch.
  • system controller 150 z monitors the output power level of multi-stage generator 40 z (step 978 ), and if the power level is between P 3 ⁇ and P max , then system controller 150 z retains the power flow through branches 30 j and 30 k (step 975 ).
  • P max is the rated-power of multi-stage generator 40 z , and hence system controller 150 z may enter throttling mode when this power level is achieved.
  • step 978 the controller returns power flow in hybrid conversion topology 10 z to branches 30 i and 30 j possibly using the following sequence of steps. All power is transferred temporarily from branch 30 j to 30 k (step 981 ). Switches 110 j and 90 j are opened (step 984 ). Parsers 190 j and 190 i are reconfigured for power level range P 2 ⁇ to P 3 + (step 987 ). Switches 90 j and 110 j are closed (if desirable, some power transfer into branch 30 j may begin at this time) and also switches 90 i and 110 i are closed (step 990 ). All power is transferred from branch 30 k to branches 30 j and 30 i (step 993 ).
  • Switches 110 k and 90 k are opened (step 996 ), and power now flows through branches 30 i and 30 j (step 936 ). Note there may be variations in how system controller accomplishes this transfer of power to branches 30 i and 30 j , for example power transfer from branch 30 k to branch 30 i may take place first, followed by a transfer of power from branch 30 k to branch 30 j.
  • step 978 If (at step 978 ) or for that matter at other steps, including, but not restricted to, steps 915 and 939 , an emergency condition arises, it may be necessary for system controller 150 z to shut down operation of the TGC system by setting power flow through the TGC system to zero and preferably stopping rotation of turbine 130 (step 998 ).
  • the activation or deactivation of a branch may be initiated when a power threshold is crossed, however, system controller 150 z may alternatively initiate the activation or deactivation of a branch 30 using other system variables such as, but not restricted to: the speed of fluid flowing in or around turbine 130 ; the rotational speed of turbine 130 ; the rotational speed of a multi-stage generator 40 z ; the output voltage of stages 60 as may be measured at a terminal-block 80 or directly across one or more induction elements 50 of a multi-stage generator 40 ; and/or the input voltage to hybrid conversion topology 10 z.
  • system controller 150 z may alternatively initiate the activation or deactivation of a branch 30 using other system variables such as, but not restricted to: the speed of fluid flowing in or around turbine 130 ; the rotational speed of turbine 130 ; the rotational speed of a multi-stage generator 40 z ; the output voltage of stages 60 as may be measured at a terminal-block 80 or directly across one or more induction elements 50 of a multi-stage generator 40
  • hybrid conversion system may be extended (or simplified) to cases where there are more than (or fewer than) three branches.
  • parser 190 i may reconfigured the arrangement of induction elements 50 within stage 60 i for power range P 2 ⁇ to P max . This means that the partial hardwiring of stage 60 i and the design of parser 190 i both accommodate this possibility.
  • stages 60 and branches 30 designed for the lower power ranges for example stage 60 i and branch 30 i , are each inherently less efficient in power transformation than the higher power stages and branches.
  • the advantage of using parser 190 i to extend the power range over which stage 60 i and branch 30 i may operate is compromised, particularly at the lowest power levels, such as P 1 ⁇ or P 1 +.
  • stage 60 i and branch 30 i may be designed to operate over power range P 1 ⁇ to P 2 + as well as over range P 2 ⁇ to P 3 +, thus at power level P 1 ⁇ , the efficiency of stage 60 i and/or branch 30 i may be poor.
  • a variation of the hybrid conversion system may employ no parser within the lowest power branch(es) 30 of the hybrid conversion topology.
  • a hybrid conversion topology that includes three branches may be constructed such that branch 30 i may be structured as shown in FIG. 1 and branches 30 j and 30 k may be structured as shown in FIG. 7 .
  • stage 60 i and branch 30 i of this hybrid conversion topology may operate only over power range P 1 ⁇ to P 2 + and will likely be much more efficient than the stage 60 i and branch 30 i pair of FIG. 7 designed to operate over power range P 1 ⁇ to P 3 +.
  • this variation of the hybrid conversion system there is, once again, no theoretical restriction on the number of stages or the number of branches.
  • Another variation of the hybrid conversion system is to employ forked branches for one or more stages 60 .
  • an embodiment may have a hybrid conversion topology with four branches: 30 h , 30 i , 30 j , and 30 k .
  • Branch 30 h the lowest power branch, may be structured to have no parser.
  • Branch 30 i may be forked with two sub-branches, sub-branch 30 i 1 and sub-branch 30 i 2 .
  • Branches 30 j and 30 k may be structured as in FIG. 7 .
  • An example of this variation of the hybrid conversion system is shown in FIG. 12 .
  • sub-branch 30 i 2 , branch 30 j and branch 30 k may all be active and delivering power to electrical load 120 .
  • this variation of the hybrid conversion system there is, once again, no theoretical restriction on the number of stages or the number of branches.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Control Of Eletrric Generators (AREA)
US13/062,191 2008-09-03 2009-09-03 Power conversion system for a multi-stage generator Abandoned US20110241630A1 (en)

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US11081996B2 (en) 2017-05-23 2021-08-03 Dpm Technologies Inc. Variable coil configuration system control, apparatus and method
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US10644511B2 (en) * 2017-11-06 2020-05-05 Caterpillar Inc. Multi-engine optimizer zone strategy
US11722026B2 (en) 2019-04-23 2023-08-08 Dpm Technologies Inc. Fault tolerant rotating electric machine
US11708005B2 (en) 2021-05-04 2023-07-25 Exro Technologies Inc. Systems and methods for individual control of a plurality of battery cells
US11967913B2 (en) 2021-05-13 2024-04-23 Exro Technologies Inc. Method and apparatus to drive coils of a multiphase electric machine

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CN102160277A (zh) 2011-08-17
US20150188317A1 (en) 2015-07-02
WO2010025560A1 (fr) 2010-03-11
EP2329581A4 (fr) 2013-12-04
EP2329581A1 (fr) 2011-06-08
US9379552B2 (en) 2016-06-28
CA2773040A1 (fr) 2010-03-11

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