计及电磁-传热影响的蒸发冷却风力发电机定子铁心穿管结构优化设计研究

doi:10.19595/j.cnki.1000-6753.tces.230024

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摘要

采用自循环式蒸发冷却技术是提升大容量风力发电机组散热能力和可靠性的一种经济且有效的方式,然而在传统电机的分析设计和性能预测过程中,往往会忽略定子局部穿管结构的改变对电机电磁性能的影响,同时也会忽略这部分接触热阻在热传导过程中对电机冷却性能的影响。对此,本文首先基于风力发电机的运行特性和单元灵敏度方法分析了定子铁心穿管结构对电机电磁及冷却性能的影响,之后通过小倾角自循环管道换热实验以及接触热阻温升实验对空心圆铜管的换热能力以及接触热阻进行了分析和测试,最后建立了以电磁及传热性能为优化目标的铁心穿管结构优化策略,并以一台10MW永磁直驱式风力发电机为研究对象,对定子铁心穿管结构开展了优化设计研究。通过优化方案的有限元分析验证说明,本文中提出的优化策略可以准确且有效地满足电机电磁和冷却性能的设计要求,同时从电磁和散热两个维度来评估,所提出的优化策略同样适用于相同应用场景下的其他永磁同步电机。

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关键词 ：蒸发冷却风力发电机, 定子铁心穿管冷却, 电磁及冷却特性, 接触热阻, 单元灵敏度分析, 优化设计

Abstract：

In recent years, with the rapid development of the field of renewable energy, the capacity of wind generators is increasing, and the problems of loss and heating are becoming more and more serious. Excessive temperature operating temperature will bring serious harm to the safe operation of wind generators. To solve these problems, evaporative cooling technology can greatly improve the generator’s cooling efficiency. The whole system has many advantages, such as simple maintenance, safety, reliability, etc. Recently, many scholars have made a lot of research on the electromagnetic and cooling performance analysis modeling and the optimization of wind generators, but the influence of the small change of the stator local structure on the electromagnetic performance and the part of the contact thermal resistance on the cooling performance of the generator cooling structure is ignored. To address these issues, a collaborative optimization strategy of electromagnetic and cooling performance is proposed based on the electromagnetic and heat transfer sensitivity analysis of the design unit. Through experiments, the thermal contact resistance between the hollow cooling tube and the core interface is measured, and the heat transfer characteristics of the hollow cooling tube under the self-circulation characteristics of a small dip angle are analyzed. The optimization design of a 10MW direct drive wind turbine is carried out, and the correctness and effectiveness of the optimization results are analyzed and verified by finite element analysis.
Firstly, the influence of stator core cooling pipe structure on the electromagnetic and cooling performance of wind generators is analyzed based on the operating characteristics of wind generators and the element sensitivity method. Secondly, the heat transfer capacity and contact thermal resistance of hollow round copper pipe are analyzed and tested through the heat transfer experiment of self-circulating pipe with a small dip angle and the temperature rise experiment of contact thermal resistance. Thirdly, the optimization model of the stator core cooling structure is established with the aim of electromagnetic and heat transfer performance. Finally, the optimization design of the stator core cooling structure is studied and verified by finite element analysis. It is verified that the optimization strategy proposed in this paper can meet the design requirements of electromagnetic and cooling performance accurately and effectively.
The self-recirculating cooling system with a small dip angle experiment shows that, the critical heat flux of a 1500 mm hollow copper tube is 8303 W/m² when the condenser height is 900 mm and the inlet temperature of cooling water is 20℃. The variation trend of the convective heat transfer coefficient of evaporative cooling medium with heat flux is revealed by experiments data and the standard deviation of the fitted curve is 2.05. The contact thermal resistance experiment shows that, when the hole/shaft matching accuracy is H7/h7, the roughness of DW470-50 is Ra 3.2μm, the heat flux is 9549 W/m², the contact thermal resistance between the iron core and the hollow copper tube with the roughness of Ra 1.6μm, Ra 3.2μm, and Ra 6.4μm is 7.6448×10^-5 m²·K/W, 8.9015×10^-5 m²·K/W, and 9.4251×10^-5 m²·K/W, respectively. Finally, evaporation cooling wind generators of three different configurations using stator core pipe structure are optimized based on the design unit sensitivity analysis strategy to verify the effectiveness of this cooling technique.
The following conclusions can be drawn from the simulation analysis:( 1) The established influence analysis model can obtain the influence of the design element of stator cooling tube area on the electromagnetic and cooling performance of wind generators based on sensitivity. (2) Based on the small-dip self-circulation test platform and the contact thermal resistance test platform, the relationship between the cooling performance of the core tube and the loaded heat flux is obtained, and it shows that the new evaporative cooling technology for wind generators has good thermal conductivity. (3) The finite element simulation method verifies that the three optimization schemes can meet the requirements of electromagnetic and winding maximum temperature rise constraints, and illustrate the feasibility and effectiveness of the optimization scheme and the evaporative cooling technology.

Key words： Evaporative cooling wind generators stator core cooling pipe structure electromagnetic and cooling characteristics thermal contact resistance element sensitivity analysis optimization design

PACS:

TK89

基金资助:

国家自然科学基金（U22A20219）资助项目

通讯作者: 阮琳女,1976年生,研究员,博士生导师,研究方向为电力设备新技术;大电机内综合物理场仿真研究;流体流动与传热分析。E-mail：rosaline@mail.iee.ac.cn

作者简介: 程自然男,1993年生,博士研究生,研究方向为电力设备新技术;电机设计及优化。E-mail：chengziran1993@hun.edu.cn

引用本文:

程自然, 王宇, 高剑, 黄守道, 阮琳. 计及电磁-传热影响的蒸发冷却风力发电机定子铁心穿管结构优化设计研究[J]. 电工技术学报, 0, (): 20235425-20235425. Cheng-Ziran, Wang-Yu, Gao-Jian, Huang-Shoudao, Ruan-Lin. Optimization design of stator core pipe for evaporative cooling wind generators considering the influence of electromagnetic and heat transfer. Transactions of China Electrotechnical Society, 0, (): 20235425-20235425.

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