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Wind energy has been the fastest emerging renewable energy source over the last decade. The overriding provisos to minimise greenhouse emissions and increasing concerns regarding energy security have been the major inducements for many countries to make a resolute transition to new and non-conventional power sources. Direct-drive systems for wind turbines are potentially a more reliable alternative to gearbox driven systems. Gearboxes are liable to significant accumulated fatigue torque loading with relatively high maintenance costs. It is with this in mind that the primary focus of this research is on direct-drive wind turbines. Generators in direct-drive wind turbines tend to be of large diameter and heavier due to the support structure required to maintain as small air-gap as possible between the stationary and rotating parts of the generator. Permanent magnet generators (PMGs) are the most common type to be used within direct-drive wind turbines nowadays. Generators and other drive-train components in wind turbines experience significant varying loads, which may lead to a bearing failure. These varying loads can lead to misalignment within the drivetrain producing eccentricity between the generator rotor and stator. Rotor eccentricity generates a magnetic force referred to as Unbalanced Magnetic Pull (UMP). The induced UMP for the same rotor eccentricity is much higher in PMGs than induction generators because of the higher permanent magnet magnetic field. UMP is an important issue requiring further research. A part of this study provides a more detailed treatment of UMP under varying rotor eccentricity regimes for various permanent magnet machine topologies. The effect of UMP in direct-drive PMGs on the lifetime of the main bearing is a topic that requires more research aimed at proposing design improvements and solutions. The hope being that the availability of such solutions can be applied to practical reductions in operating costs. In brief, identification of the root causes of failure and impacts on component lifetime remain a subject of research. Establishing analytical tools for studying the impact of UMP on component lifetime in direct drive wind turbines and identifying the prospects for air gap winding machines using single bearing configuration are the two key areas for further research. Firstly, this research aims to establish the relationship between bearing forces and different types of eccentricities and UMP in direct drive machines. It is intended to use such models for predicting bearing wear and fatigue. Secondly, this research aims to establish the analytical tools for studying static, dynamic and tilting eccentricity in air-gap winding direct drive generators. Such tools are used to increase the understanding of the dynamics of direct drive PM generators. The final step of this study is using a multi-body simulation software (SIMPACK) to initiate investigations and comparison by providing assessments of electromagnetic interaction and internal drive-train loading for four possible designs for a proposed 5MW direct-drive wind turbine in response to the loads normally seen by a wind turbine. The four designs include: (a) iron-cored PM direct-drive generator supported by two main bearings, (b) airgap winding PM direct-drive generator supported by two main bearings, (c) iron-cored PM direct-drive generator supported by a single main bearing, (d) airgap winding PM direct-drive generator supported by a single main bearing. An aero-elastic simulation code (HAWC2) is used to extract the hub loads for different wind speeds corresponding to the normal operation of the wind turbine. The dynamic eccentricity and its influence on the electromagnetic interaction and consequential effects on bearing loading for all four designs is examined to determine the most optimal support structural configuration for a direct-drive system. In summary, the main aim of this thesis is studying the effect of different types of rotor eccentricities in different types of direct drive PMGs on the main bearing arrangements. The results show that static rotor eccentricity has the maximum impact compared to the other types of eccentricities. The main result of an eccentricity is the induced UMP which applies directly as an extra force on the bearings. The influence of UMP on bearing wear is studied. This influence is found to be significant in PM machines and should be considered when designing the bearing stiffness. A 20% static rotor eccentricity in a PM machine is found to induce an UMP that roughly equals third the total weight of the machine. A single bearing design for a direct-drive wind turbine is proposed and compared with a conventional two-bearing design. The results show that the Iron-cored PM direct-drive generator supported by two main bearings design and airgap winding PM direct-drive generator supported by a single main bearing design have advantages over the other two designs in this study.

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In der Lehrveranstaltung Bewegungstechnik & Bewegungsdesign für Verarbeitungsmaschinen werden die Studenten in die Lage versetzt, Systeme zur Bewegung von Arbeitsorganen in Verarbeitungs- und Textilmaschinen konstruktiv zu entwerfen und zu dimensionieren. Im Blickpunkt stehen zyklische Bewegungen, zu deren Realisierung auch der Einsatz von Mechanismen sinnvoll ist. Die interdisziplinäre Betrachtung der Bewegungstechnik dient als Einführung in die Problematik und als Grundlage für nachfolgende Optimierungen.

Modern electric machine drives, particularly three phase permanent magnet machine drive systems represent an indispensable part of high power density products. Such products include; hybrid electric vehicles, large propulsion systems, and automation products. Reliability and cost of these products are directly related to the reliability and cost of these systems. The compatibility of the electric machine and its drive system for optimal cost and operation has been a large challenge in industrial applications. The main objective of this dissertation is to find a design and control scheme for the best compromise between the reliability and optimality of the electric machine-drive system. The effort presented here is motivated by the need to find new techniques to connect the design and control of electric machines and drive systems. A highly accurate and computationally efficient modeling process was developed to monitor the magnetic, thermal, and electrical aspects of the electric machine in its operational environments. The modeling process was also utilized in the design process in form finite element based optimization process. It was also used in hardware in the loop finite element based optimization process. The modeling process was later employed in the design of a very accurate and highly efficient physics-based customized observers that are required for the fault diagnosis as well the sensorless rotor position estimation. Two test setups with different ratings and topologies were numerically and experimentally tested to verify the effectiveness of the proposed techniques. The modeling process was also employed in the real-time demagnetization control of the machine. Various real-time scenarios were successfully verified. It was shown that this process gives the potential to optimally redefine the assumptions in sizing the permanent magnets of the machine and DC bus voltage of the drive for the worst operating conditions. The mathematical development and stability criteria of the physics-based modeling of the machine, design optimization, and the physics-based fault diagnosis and the physics-based sensorless technique are described in detail. To investigate the performance of the developed design test-bed, software and hardware setups were constructed first. Several topologies of the permanent magnet machine were optimized inside the optimization test-bed. To investigate the performance of the developed sensorless control, a test-bed including a 0.25 (kW) surface mounted permanent magnet synchronous machine example was created. The verification of the proposed technique in a range from medium to very low speed, effectively show the intelligent design capability of the proposed system. Additionally, to investigate the performance of the developed fault diagnosis system, a test-bed including a 0.8 (kW) surface mounted permanent magnet synchronous machine example with trapezoidal back electromotive force was created. The results verify the use of the proposed technique under dynamic eccentricity, DC bus voltage variations, and harmonic loading condition make the system an ideal case for propulsion systems.

In der Lehrveranstaltung Bewegungstechnik & Bewegungsdesign für Verarbeitungsmaschinen werden die Studenten in die Lage versetzt, Systeme zur Bewegung von Arbeitsorganen in Verarbeitungs- und Textilmaschinen konstruktiv zu entwerfen und zu dimensionieren. Im Blickpunkt stehen zyklische Bewegungen, zu deren Realisierung auch der Einsatz von Mechanismen sinnvoll ist. Die interdisziplinäre Betrachtung der Bewegungstechnik dient als Einführung in die Problematik und als Grundlage für nachfolgende Optimierungen.

Brennstoffzellentechnologien gelten als effizient, lokal CO2-neutral und können vielfältig eingesetzt werden. Dennoch stellen sie bislang keine kostengünstige Lösung dar und kommen in PKW selten vor. Um Entwicklungs- und Produktionskosten zu reduzieren und gleichzeitig eine höhere Systemsichtbarkeit zu erreichen, widmen sich die Autoren der Erstellung eines Modularisierungskonzepts für ein Brennstoffzellensystem zu dessen Nutzung in verschiedenen Anwendungen. Ziel ist es, ein modulares Brennstoffzellensystemkonzept zu entwickeln, das den Anforderungen aus der Kopplung verschiedener Anwendungsszenarien gerecht wird. Unter Berücksichtigung der Bauraumanforderungen sowie mechanischer und elektrischer Schnittstellen zwischen den Modulen und den Anwendungen wird ein Design für das Integrationskonzept des modularen Brennstoffzellensystems vorgeschlagen. Der Target Weighing Ansatz (TWA) wird herangezogen, um Leichtbaupotenziale auf Systemebene zu erkennen und zu bewerten. Zur Optimierung ausgewählter Komponenten wird die Methode der Topologieoptimierung angewandt, um bei gegebener Massenreduktion die Steifigkeit zu maximieren. Thermische Simulationen zeigen zudem die Wärmeabfuhr der Brennstoffzellen aus dem System unter Last. / Fuel cell technologies are considered efficient, locally CO2-neutral and can be used in a variety of ways. Nevertheless, they have not yet been a cost-effective solution and are rarely used in passenger cars. In order to reduce development and production costs and at the same time to achieve higher system visibility, the authors are dedicated to the creation of a modularization concept for a fuel cell system for its use in various applications. The aim is to develop a modular fuel cell system concept that meets the requirements arising from the coupling of different application scenarios. Considering the installation space requirements as well as me-chanical and electrical interfaces between the modules and the applications, a design for the integration concept of the modular fuel cell system is proposed. The Target Weighing Approach (TWA) is used to identify and evaluate lightweighting potentials on system level. The topology optimization method is applied to optimize selected components to maximize stiffness for a given mass reduction. Thermal simulations also show the heat dissipation of the fuel cells from the system under load.

This work demonstrates the capability of a power electronic based power hardware-inthe- loop (PHIL) platform to emulate electric machines for the purpose of a motor drive testbench with a particular focus on induction machine emulation. PHIL presents advantages over full-hardware testing of motor drives as the PHIL platform can save space and cost that comes from the physical construction of multiple electric machine test configurations. This thesis presents real-time models that were developed for the purpose of PHIL emulation. Additionally, real-time modeling considerations are presented as well as the modeling considerations that stem from implementing the model in a PHIL testbench. Next, the design and implementation of the PHIL testbench is detailed. This thesis describes the design of the interface inductor between the motor drive and the emulation platform. Additionally, practical implementation challenges such as common mode and ground loop noise are discussed and solutions are presented. Finally, experimental validation of the modeling and emulation of the induction machine is presented and the performance of the machine emulation testbench is discussed. / Master of Science / According to the International Energy Agency (IEA), electric power usage is increasing across all sectors, and particularly in the transportation sector [1]. This increase is apparent in one's daily life through the increase of electric vehicles on the road. Power electronics convert electricity in one form to electricity in another form. This conversion of power is playing an increasingly important role in society because examples of this conversion include converting the dc voltage of a battery to ac voltage in an electric car or the conversion of the ac power grid to dc to power a laptop. Additionally, even within an electric car, power converters transform the battery's electric power from a higher dc voltage into lower voltage dc power to supply the entertainment system and into ac power to drive the car's motor. The electrification of the transportation sector is leading to an increase in the amount of electric energy that is being consumed and processed through power electronics. As was illustrated in the previous examples of electric cars, the application of power electronics is very wide and thus requires different testbenches for the many different applications. While some industries are used to power electronics and testing converters, transportation electrification is increasing the number of companies and industries that are using power electronics and electric machines. As industry is shifting towards these new technologies, it is a prime opportunity to change the way that high power testing is done for electric machines and power converters. Traditional testing methods are potentially dangerous and lack the flexibility that is required to test a wide variety of machines and drives. Power hardware-in-the-loop (PHIL) testing presents a safe and adaptable solution to high power testing of electric machines. Traditionally, electric machines were primarily used in heavy industry such as milling, processing, and pumping applications. These applications, and other applications such as an electric motor in a car or plane are called motor drive systems. Regardless of the particular application of the motor drive system, there are generally three parts: a dc source, an inverter, and the electric machine. In most applications, other than cars which have a dc battery, the dc source is a power electronic converter called a rectifier which converts ac electricity from the grid to dc for the motor drive. Next, the motor drive converts the dc electricity from the first stage to a controlled ac output to drive the electric machine. Finally, the electric machine itself is the final piece of the electrical system and converts the electrical energy to mechanical energy which can drive a fan, belt, or axle. The fact that this motor drive system can be generalized and applied to a wide range of applications makes its study particularly interesting. PHIL simplifies testing of these motor drive systems by allowing the inverter to connect directly to a machine emulator which is able to replicate a variety of loads. Furthermore, this work demonstrates the capability of PHIL to emulate both the induction machine load as well as the dc source by considering several rectifier topologies without any significant adjustments from the machine emulation platform. This thesis demonstrates the capabilities of the EGSTON Power Electronics GmbH COMPISO System Unit to emulate motor drive systems to allow for safer, more flexible motor drive system testing. The main goal of this thesis is to demonstrate an accurate PHIL emulation of a induction machine and to provide validation of the emulation results through comparison with an induction machine.

Nos últimos 20 anos, o inversor de frequência PWM passou a ser largamente utilizado. Dentre as razões principais de sua ampla difusão, cita-se a introdução do IGBT que, devido à sua capacidade de comutação rápida, possibilitou a redução de perdas, tamanho e custo dos conversores, ao mesmo tempo em que permitiu o uso do motor de indução em aplicações que demandam alto desempenho dinâmico. Porém, esta mesma característica que trouxe tais benefícios, contribuiu para acentuar os efeitos relacionados a fenômenos eletromagnéticos, devido à rápida transição que produz sinais em alta frequência, responsáveis por tornar os sistemas de acionamentos potenciais fontes de interferência eletromagnética. Os principais fenômenos desta natureza são a tensão de onda refletida, associada a ruídos de modo diferencial, e a corrente de modo comum. De maneira geral, a corrente de modo comum tem maior potencial de contribuição para a emissão radiada que a de modo diferencial e, em sistemas de acionamento, constitui a principal fonte de interferência eletromagnética. Esta não é resultado apenas da rápida comutação dos IGBTs, mas, também, da configuração do sistema, que propicia o surgimento das tensões de modo comum. Este trabalho visa estudar alternativas que minimizem, naturalmente, estas tensões através de sua configuração, reduzindo-se a necessidade de novos componentes, como filtros passivos ou circuitos ativos. Ressalta-se, assim, que o primeiro passo consistiu-se na compreensão do problema de geração da tensão de modo comum. Visando atingir os propósitos anteriormente mencionados, foi idealizado um inversor, composto de duas pontes chaveando em oposição, chamado de duplo-trifásico. A partir de simulações, avaliou-se seu potencial e definiu-se sua implementação, a partir de dois inversores idênticos. Testou-se o protótipo contra um terceiro módulo de mesmo tipo, em iguais condições. A comparação dos resultados indicou que a configuração proposta pode ser eficiente no controle do ruído de modo comum, obtendo-se valores de redução de 86%. Nota-se que o comportamento observado via o protótipo, permite um melhor entendimento dos fenômenos relativos à circulação da corrente de modo comum. Desta forma, à luz da pesquisa realizada, nota-se que, conceitualmente, a solução proposta se destaca das demais apresentadas na literatura pela sua exequibilidade e simplicidade. / Over the last 20 years, the PWM frequency inverter has become widely used. Among the main reasons for its widespread distribution is the introduction of the IGBT, due to its ability for fast switching allowing the reduction of losses, size and cost of the converters, and the use of the induction motor in applications that demand high dynamic performance. However, this same characteristic that brought such benefits, stressed the effects related to electromagnetic phenomena, due to the fast transition that produces high frequency signals, responsible for turning drive systems, potential sources of electromagnetic interference. The main phenomena of this nature are the reflected wave overvoltage, associated with differential mode noise, and the common mode current. In general, the common mode current has greater potential of contribution to the emission of radiated interference than the differential mode current and is the main source of electromagnetic interference in drive systems. The common mode current is not just the result of the fast transitions of IGBTs, but also of the system configuration, which produces common mode voltages. This work aims to study alternatives that minimize, naturally, those voltages through its configuration, reducing the need for additional components, such as passive filters or active circuits. It is pointed, that the first step consisted in the understanding of the problem of the common mode voltage generation. In order to address this objective, an inverter composed of two bridges, switching in opposition, called double-three-phase was designed. Its potential for noise mitigation, as well, its implementation, with two identical inverters was evaluated by simulations. The prototype was tested against a third module of the same type, under the same conditions. The comparison of the results indicated that the proposed configuration can be efficient in the common mode noise control, with 86% reduction. The behavior observed through the prototype allows a better understanding of the phenomena involving common mode current. Thus, in the light of the research, we note that, conceptually, the proposed solution stands out for its practicality and simplicity, from the others presented in the literature.

Nos últimos 20 anos, o inversor de frequência PWM passou a ser largamente utilizado. Dentre as razões principais de sua ampla difusão, cita-se a introdução do IGBT que, devido à sua capacidade de comutação rápida, possibilitou a redução de perdas, tamanho e custo dos conversores, ao mesmo tempo em que permitiu o uso do motor de indução em aplicações que demandam alto desempenho dinâmico. Porém, esta mesma característica que trouxe tais benefícios, contribuiu para acentuar os efeitos relacionados a fenômenos eletromagnéticos, devido à rápida transição que produz sinais em alta frequência, responsáveis por tornar os sistemas de acionamentos potenciais fontes de interferência eletromagnética. Os principais fenômenos desta natureza são a tensão de onda refletida, associada a ruídos de modo diferencial, e a corrente de modo comum. De maneira geral, a corrente de modo comum tem maior potencial de contribuição para a emissão radiada que a de modo diferencial e, em sistemas de acionamento, constitui a principal fonte de interferência eletromagnética. Esta não é resultado apenas da rápida comutação dos IGBTs, mas, também, da configuração do sistema, que propicia o surgimento das tensões de modo comum. Este trabalho visa estudar alternativas que minimizem, naturalmente, estas tensões através de sua configuração, reduzindo-se a necessidade de novos componentes, como filtros passivos ou circuitos ativos. Ressalta-se, assim, que o primeiro passo consistiu-se na compreensão do problema de geração da tensão de modo comum. Visando atingir os propósitos anteriormente mencionados, foi idealizado um inversor, composto de duas pontes chaveando em oposição, chamado de duplo-trifásico. A partir de simulações, avaliou-se seu potencial e definiu-se sua implementação, a partir de dois inversores idênticos. Testou-se o protótipo contra um terceiro módulo de mesmo tipo, em iguais condições. A comparação dos resultados indicou que a configuração proposta pode ser eficiente no controle do ruído de modo comum, obtendo-se valores de redução de 86%. Nota-se que o comportamento observado via o protótipo, permite um melhor entendimento dos fenômenos relativos à circulação da corrente de modo comum. Desta forma, à luz da pesquisa realizada, nota-se que, conceitualmente, a solução proposta se destaca das demais apresentadas na literatura pela sua exequibilidade e simplicidade. / Over the last 20 years, the PWM frequency inverter has become widely used. Among the main reasons for its widespread distribution is the introduction of the IGBT, due to its ability for fast switching allowing the reduction of losses, size and cost of the converters, and the use of the induction motor in applications that demand high dynamic performance. However, this same characteristic that brought such benefits, stressed the effects related to electromagnetic phenomena, due to the fast transition that produces high frequency signals, responsible for turning drive systems, potential sources of electromagnetic interference. The main phenomena of this nature are the reflected wave overvoltage, associated with differential mode noise, and the common mode current. In general, the common mode current has greater potential of contribution to the emission of radiated interference than the differential mode current and is the main source of electromagnetic interference in drive systems. The common mode current is not just the result of the fast transitions of IGBTs, but also of the system configuration, which produces common mode voltages. This work aims to study alternatives that minimize, naturally, those voltages through its configuration, reducing the need for additional components, such as passive filters or active circuits. It is pointed, that the first step consisted in the understanding of the problem of the common mode voltage generation. In order to address this objective, an inverter composed of two bridges, switching in opposition, called double-three-phase was designed. Its potential for noise mitigation, as well, its implementation, with two identical inverters was evaluated by simulations. The prototype was tested against a third module of the same type, under the same conditions. The comparison of the results indicated that the proposed configuration can be efficient in the common mode noise control, with 86% reduction. The behavior observed through the prototype allows a better understanding of the phenomena involving common mode current. Thus, in the light of the research, we note that, conceptually, the proposed solution stands out for its practicality and simplicity, from the others presented in the literature.