基于模擬的客戶定制滑環裝置

By Timo Heinonen (Finland)

作者 | Timo Heinonen（芬蘭）

基于模擬的客戶定制滑環裝置

By Timo Heinonen (Finland)

作者 | Timo Heinonen（芬蘭）

The slip ring unit (SRU) is one of the key components in doubly-fed (DF) generators. Environmental simulation enables it to be customized for each site.

滑環單元是雙饋發電機的關鍵組件之一。

環境模擬使得滑環單元可以針對每個不同的場合來進行定制。

Turbine OEMs install their standard wind turbines in many different environments, ranging from coastal areas to dry, high altitude locations. Environmental conditions affect the operation and service life of the generator SRU. Significant benefits can be achieved for end users if the operation conditions are simulated and the results used to customize the SRU for the specific site where the generator is installed.

風電機組設備制造商需要在從沿海地區到高海拔干燥地區等各種不同的環境下安裝標準的風電機組。環境會影響發電機滑環單元運行和使用年限。如果能夠模擬滑環單元的運行情況并根據模擬運行的結果對其進行定制生產，那么對最終客戶大有益處。

The demanding SRU要求嚴苛的滑環單元

In DF generators reactive and active power is fed to the grid not only from the stator but also from the rotor, which involves high currents and high temperatures. Because the rotor is rotating, reliable slip rings are needed to get the power out from inside the generator.

The SRU comprises a hub with phase slip rings and current rods, a brush rocker with brush holders, phase brushes, and rotor cable connecting studs. Improving the operation of the SRU in different site conditions requires considerable experience. Designing a reliable SRU involves many important factors, including material selection between the slip ring and the brushes, dust removal, efficient cooling and easy servicing. The changing operation condition cycles and need for regular servicing also make this one of the most critical components for the end user.

Many other factors - such as different grid codes and load conditions - affect the size and optimum construction of the SRU. Turbine manufacturers also use the software and hardware configuration of the converter to deliver more reactive power in order to comply with grid support requirements. Different OEM specs involving reactive power, speed range and overspeed affect the performance of the SRU.

Selecting the correct material combinations and setup for the SRU components can therefore be a challenging task.

雙饋發電機饋送給電網的無功功率和有功功率由兩部分組成，一部分來自定子，另一部分來自電流大溫度高的轉子。因轉子是旋轉的，所以需要有可靠的滑環將電能從發電機內部傳輸出來。滑環單元包括由三相集電環和導電桿組成的滑環、刷架和刷握、三相電刷以及轉子電纜連接螺柱等幾部分。不過針對不同場合來改進滑環單元的運行需要相當豐富的經驗。設計一套可靠的滑環單元需要多方面的考慮，包括滑環和電刷的材料選取、除塵、高效冷卻以及方便維護等等。不斷變化的運行情況和定期維護的需求也使得滑環單元成為對最終用戶而言最關鍵的部件之一。而其他因素諸如不同的電網規范和負載條件等也會影響滑環單元的大小和最佳結構。此外，風電機組設備制造商常使用變流器軟件與硬件調試來輸出更多的無功功率以滿足電網的要求，且不同原始設備制造商的參數要求包括無功功率、轉速范圍和超速等也會影響滑環單元的性能。綜上所述，選擇正確的材料組合和滑環單元部件的配置是一個具有挑戰性的任務。

New innovations in SRU design滑環單元設計亮點

To help turbine OEMs meet the often unknown environmental conditions at installation sites, ABB has worked with leading SRU manufacturer to create an innovative modular slip ring design which enables load optimization and effective cooling based on exact load conditions.

為了幫助風電機組設備制造商在安裝現場應對常常未知的環境條件，ABB和行業領先的滑環單元制造商密切合作以便開發一種創新的模塊化滑環設計。該設計旨在實現基于準確負載條件的負載優化和高效冷卻。

A development initiative was launched with the aim of achieving a flexible standardized design which would enable perfect optimization for each individual case. The focus was on reliable, troublefree operation with long service intervals and low maintenance needs in order to maximize availability and kWh production.

為了實現靈活的滑環單元標準化設計以便能為每個獨立案例提供完美的優化，ABB開始了滑環單元的進一步開發設計。開發設計的重點是使滑環單元長期可靠地無故障運行并減少維護需求，從而實現利用率和發電量的最大化。

The design was based on a new modular construction which can be easily optimized for each load case. This also contributed to efficient cooling and dust removal. At the same time an advanced brush set up was also developed which enables easy brush installation and maintenance. To standardize the construction for different load cases, the same brush size is used and the number of brushes needed for each phase is optimized, resulting in a cost effective solution. A widely known brush grade, proven in most environmental conditions, was selected as the standard option.

該設計以一種全新的模塊化結構為基礎，該結構便于針對不同的負載條件進行優化，也有助于高效冷卻和除塵。同時還包括一種先進的電刷結構設計，使電刷便于安裝和維護。為了使不同負載條件下的結構標準化，對電刷規格進行了統一，對每相電刷數量也進行了優化，這是一個非常有成本效益的方案。此外，一個在大多數環境條件下都得到驗證的知名電刷品牌被選定為標準選項。

The unit is straightforward and robust, and it features efficient cooling, easy maintenance and a rigid structure for high overspeed endurance. All the main components, including the brushes, are made by one of the biggest global turn-key slip ring manufacturers.

滑環單元結構簡單且堅固，主要特點包括冷卻效率高、易于維護且擁有耐受超速的剛性結構。包括電刷在內的所有主要部件都是由一家全球最大的成套滑環制造商制造的。

High quality, partial discharge resistant insulation materials are used so that the SRU can withstand the voltage stresses encountered in converter duty. Every SRU will undergo a 5 kV HV test. A partial discharge test is also performed in order to verify the high quality of the insulation.

滑環單元使用優質且抗局部放電的絕緣材料，可以耐受變流器工作時的電應力。每個滑環單元都會進行5kV的高壓測試，還會進行局部放電試驗以確保優異的絕緣性能。

Tailor made testing in simulated site conditions模擬現場條件來定制測試

A new slip ring testing laboratory was built to enable R&D to support customers by performing comprehensive testing with the exact installation site conditions. The results are used to customize the setup of the new SRU components according to the load and environmental conditions.

建立一個新的滑環單元測試實驗室可以使研發部門在與實際安裝現場一致的條件下進行全面的測試從而為客戶提供支持。測試結果可用來根據負載和環境條件定制新的滑環單元組件。

The new SRU testing laboratory follows the conditions of IEC standard 60068-1 7th edition on environmental testing procedures. Wind turbine load conditions can be emulated based on IEC 61400. The requirements of these two standards can be combined to create tailored test programs, which can also incorporate the customer's other requirements and site conditions.

新的滑環單元測試實驗室遵循《IEC 60068-1》標準（第七版）中有關環境測試過程的要求，同時根據《IEC 61400》標準模擬風電機組的負載條件。測試程序的制訂則參考了以上這兩個標準的要求，測試程序同樣也可以包括客戶的其他要求和現場情況。

“We work with turbine OEMs throughout the generator development process to find the best solutions for each case. And now with our new R&D lab we can customize the SRU for the exact site conditions and help wind park operators to maximize their production time,” says Raimo Sakki, product manager for wind power generators at ABB.

ABB風力發電機產品經理Raimo Sakki先生說：“在發電機設計過程中，我們始終和風電機組設備制造商密切合作，針對每個案例來尋找最佳方案。現在通過新成立的實驗室，我們可以模擬真實的現場條件來定制滑環單元并可以幫助風電場管理人員實現運行時間最大化。”

Different environmental and load parameters can be simulated based on ABB's broad experience in generators, research studies, environmental conditions and customer specifications. Using separate converters in both the rotating and feeding system sides it is possible to test all major turbine operation points while the climate chamber controls the humidity and ambient temperature.

ABB憑借在發電機、技術研究、環境條件和客戶要求上的豐富經驗能夠模擬不同的環境和負載條件。在轉子側和電網側使用獨立的變流器，這樣就可以測試所有風機的主要運行點同時可用氣候模擬箱控制濕度和環境溫度。

The tests are performed with a real SRU housing and fans, in a configuration similar to a complete generator in wind turbine nacelle conditions. In addition to overspeed and high voltage tests, the comprehensive test program also includes verification of partial discharge, brush wear and air flow measurement for easy dust removal.

測試會在一個真正的滑環室內并且在有風扇的條件下進行，這些測試條件模擬了一個在風機機艙內的完整的發電機。除超速試驗和高電壓試驗外，這套完整的測試程序還包括局部放電認證、電刷磨損試驗和為方便除塵而進行的氣流測量。

Benefits for turbine OEMs and end users給風電機組設備制造商和最終用戶帶來好處

The test results are used to select the correct combination of SRU components by optimizing parameters such as the slip ring size and number of brushes, as well as the brush and ring material. Load optimization ensures safe operation temperatures and effective cooling.

根據測試的結果并通過優化相關參數如滑環尺寸、電刷數量、電刷與滑環的材料等等，可以確定配置合理的滑環單元組件。而負載優化則保證了安全的運行溫度和有效的冷卻。

For turbine OEMs and end users the main benefit of using pretested components is that it eliminates the need for design changes and avoids unnecessary turbine shut downs. Using site specific optimization also minimizes maintenance and enables long service intervals. This results in continuous operation and maximized kWh production.

對于風電機組設備制造商和最終用戶而言，如果使用經過預測試的組件，則不需要進行后期的設計變更，也可避免不必要的風電機組停機。針對特定場合的優化設計會大大減少相應的維護并能保證長期地運行，這樣有利于連續地運行和最大化地產生電能。

The English version of this article was written by Timo Heinonen (MSc. Mech. Eng.), who has over 15 years of experience in wind power generators at ABB Oy, Finland. The Chinese version was translated by Xingchen Xia and Ranran Lin, who work at Technology Center (Asia), ABB Business Unit Motors and Generators.

本文英文版由芬蘭ABB公司Timo Heinonen先生（機械工程專業碩士）撰寫，他在風力發電機領域擁有超過十五年的經驗。中文版由ABB電機與發電機業務單元亞洲技術中心夏星晨先生和林然然先生負責翻譯。

A slip ring unit laboratory will come into use soon at Technology Center (Asia), ABB Business Unit Motors and Generators. Please feel free to contact us.

ABB電機與發電機業務單元亞洲技術中心的滑環單元實驗室即將投入使用。敬請聯系我們。

Visiting address: No.59, Tianning Rd., Minhang District, Shanghai, China. Phone: 0086 21 3478 2835 / 3478 2505.

地址：上海市閔行區天寧路59號。 電話：021-34782835 / 34782505。