This study presents the design and optimization of a test rig tailored for upcoming wind turbine design applications. Initial decisions were made regarding component selection, focusing on a gearbox, electric motor, and motor controller. Requirements included continuous power output of 300 kW from the electric motor and the gearbox's ability to handle specified torque and reduce input speed to match the structural limitations. Key challenges revolved around gearbox design and performance, necessitating a right-angle configuration for converting horizontal to vertical torque efficiently. To meet the rotational speed requirements, a 30 to 1 ratio gearbox was selected, ensuring compatibility with the maximum structural rotational speed of 50 revolutions per minute. The electric motor, pivotal in the drivetrain, was chosen based on a balance between economic viability and rotational speed, resulting in a four-pole motor configuration. Coupling mechanisms were employed to connect the motor and gearbox, facilitating energy transfer between shafts. A motor controller was integrated to regulate current flow, voltage application, and frequency modulation, enhancing operational control and adaptability to specific requirements. Radial ball bearings were selected to minimize energy expenditure during rotation, particularly due to downward compressive forces. The test rig setup, situated indoors on a concrete floor, mandated a metal plate foundation to ease component attachment without drilling into the floor. Data simulations were conducted to determine bolt specifications capable of withstanding motor-induced forces. Furthermore, collaboration with industry experts facilitated component selection and quotation analysis, ensuring an optimized drivetrain solution meeting both technical and economic criteria. This research contributes to the advancement of wind turbine design testing methodologies, providing insights into component selection, integration, and optimization for enhanced performance and reliability.
| Identifer | oai:union.ndltd.org:UPSALLA1/oai:DiVA.org:uu-532588 |
| Date | January 2024 |
| Creators | Carlberg Toulemonde, Leo, Norrblom, Tim |
| Publisher | Uppsala universitet, Elektricitetslära |
| Source Sets | DiVA Archive at Upsalla University |
| Language | English |
| Detected Language | English |
| Type | Student thesis, info:eu-repo/semantics/bachelorThesis, text |
| Format | application/pdf |
| Rights | info:eu-repo/semantics/openAccess |
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