Nonlinear Electrical Simulation of High-Power Synchronous Generator System

Jie Chen and Thomas Wu University of Central Florida Jay G Vaidya Electrodynamics Associates, Inc. James Tschantz
Air Force Research Laboratory, Wright-Patterson AFB

Copynght 0 2006 SAE lntemat~or~al

ABSTRACT

An innovative nonlinear simulation approach for high power density synchronous generator systems is developed and implemented. Due to high power density, the generator operates in nonlinear region of the magnetic circuit. Magnetic Finite Element Analysis (FEA) makes nonlinear simulation possible. Neural network technique provides nonlinear functions for system level simulation. Dynamic voltage equation provides excellent mathematical model for system level simulations. Voltage, current, and flux linkage quantities are applied in Direct-Quadrature (DQ) rotating frame. The simulated system includes main machine, exciter, rectifier bridge, bang-bang control, and PI control circuitry, forming a closed loop system. Each part is modeled and then integrated into the system model.
INTRODUCTION

Electrical simulation includes Finite Element Analysis (FEA), and system level simulation. FEA has been widely implemented to conduct electromagnetic simulation of individual machines. System level simulation can be done by combining FEA and other software tools. Sadowski combined finite element simulation and current inverters for [I]. Fardoun simulated motor simulation permanent-magnet machine drive system using SPlCE [2]. Natarajan simulated motor with Saber package [3]. Some commercially available software tools use the same scheme for motor transient simulations. These tools directly combine machine's FEA model and system circuitry models. Transient simulation can be done in this scheme. The simulation is accurate but time consuming. This work proposes and develops an innovative approach to simulate generator systems. Instead of directly combining machine's FEA model with its supporting circuitry, this work separates FEA simulation and system level simulation, and links them with neural network training results of FEA simulation. The benefit of this treatment is that FEA is not involved in each step of transient simulation. Therefore, simulation speed is greatly improved with high accuracy.

High power density of generator design requires operation under saturated magnetic circuit conditions. This paper focuses on electrical simulation of the system.

Neural network technique has been used in simulation for different purposes. Pillutla used neural network observers to estimate un-measurable rotor body currents [4] [5] [6]. Tsai used neural network based saturation model for synchronous generator analysis [7]. FEA simulation collects datasets of field currents and their flux linkages. Neural network builds a function with flux linkages as input and currents as outputs. System level simulation is based on dynamic voltage equation [I I] [12]. Dynamic voltage equation provides excellent mathematical model for machine simulation. Different techniques are combined to provide comprehensive solution for generator system simulation. Other parts of the system include PI control, rectifier' bridge, and bang-bang control. The proposed model provides flexibility for different system configuration. Transient simulation with varying load, speed and thermal conditions can be accomplished.

cos B

cos(H - 120")

cos(B + 120")

11s"1

(2)

where S stands for L , I or A . (1) is transformed as:

The inversion form of Park's transformation is given as:

PRINCIPLES OF GENERATOR MODELING

Flux linkage equation in matrix form can be written as [8] :

where Lmn is mutual inductance, L,,,, is the self inductance, Irn is the current of m phase, /ln is the flux linkage of m phase, and m, n = a, 6, c, f . The primary objective of FEA analysis is to get quantitative relationship between different current inputs and its flux linkages. Quantities in natural abc frame are time varying. Quantities in DQ rotating frame are constant under balanced load conditions. It is convenient to refer all the quantities in DQ rotating frame through alternative form of Park's transformation [8] [9] [ 101

For synchronous machine with balanced load, zerosequence components are set as zero. Quantities in DQ frame are dc values, which makes the analysis easier. Fig. 1 shows two poles of the main machine's FEA model. The Direct (D-) axis of the stator is aligned with the center line of the rotor pole. The stator is shifted from the rotor for ease of modeling.

(6) is the mathematical model of the simulation.

ELECTRICAL SYSTEM MODELING

The electrical system includes two machines, the main and the exciter. Circuit models can be extracted for each individual machine. Fig. 2 shows the circuit diagram of an individual machine. In this figure, a constant dc voltage is applied to the field winding, which includes a field winding resistance ( R , ) and a field winding inductance ( L , ). The Fig. 1 Two poIes of main machine with aligned stator's DQ frame and rotor's Values of current in the stator and the rotor vary from very small to large. Since the power factor is not known, different D-, Q-axis currents are simulated. Together with field current, a current matrix is formed which represents thousands of setups. FEA simulations are conducted for each set, and the same number of flux linkage sets is extracted. Each set of current inputs corresponds to one particular set of flux linkage. The modeling of individual machine is based on the voltage equation [1 1] [12]:
-

armature circuit consists of three phase inductance and three phase winding resistance. The three phase output is connected to a rectifier bridge, which converts ac voltage to dc output. The load is connected to the dc output terminals.

'

Lf

3
Zload

I k

V , V ,
vc

-R,
-

O O O I U
0 0 1 ,

Fig. 2. Circuit diagram of the individual machine

0-R,

4.1
(5)
-

0 R

The main machine and the exciter share the same model. Fig. 3 shows the block diagram of the simulation model for individual machine.

-v/-

-O O O R , -

where V, is the voltage of rn phase, and m,n = a,b,c, f . The voltage equation in DQ frame can be written as:

Olitp~lt = pzrrelin(w3 * (w2 * tansig( wl *Input + bl) + b2) + b3)

RESULTS

Fig. 3 Individual Simulink model After modeling individual machine, a closed loop system can be modeled. Fig. 4 shows the block diagram of the system. The main machine provides the output of the system. The exciter provides output power, which is the field input power for main machine. The field input to the exciter is dc. The output voltage of the main machine is connected to PI control block. The output of the PI control block is the field command current, which turns on and off the exciter field power supply.

Fig. 5 shows the transient response of the closed loop system. During 0 to 0.12s, the load of the system is 2.5 MW. The load changes to 0.25MW at 0.12s, and changes back at 0.4s. This figure shows the overshoot, undershoot and the transient time. These parameters are all within specifications.

; loon
L ,

rn
4

Fig. 5 Transient response Fig. 6 shows the steady state voltage output of the closed loop system with 2.5 MW loads. The voltage varies between 1650 to 1670 Volts. It is very small ripple for this high voltage output.

Fig. 4 System diagram

In this work, the nonlinear relationship between flux linkage and current is expressed by neural network functions. Nonlinear treatment is crucial to the accuracy of saturating machine simulation. The neural network takes the inputs to calculate results based on selected functions and compares them with target values. Error message is used to adjust weight and bias values. The result of a typical 3layer neural network can be written as:

Fig. 6 Steady state voltage output with 2.5MW load

Fig. 7 shows the steady state current outputs of the closed loop system with 2.5 MW load. Because of the rectifier bridge, the current output has ripples with a frequency 3 times higher than the system frequency.

o 11

n.iins

TI rr~ e (s)

n 111

0 1115

Fig. 9 Steady state field current of the exciter with 2.5 MW load
CONCLUSION

Fig. 7 Steady state current output with 2.5 MW load Fig. 8 shows field current of the main machine under steady state condition with 2.5 MW load. It varies around 55A with less than 3A ac current ripple.

An innovative nonlinear simulation approach is used to analyze a high power density synchronous generator system under steady-state and transient load conditions. Principles of system level simulation are introduced. The Simulink models of synchronous machine and associated control system are presented. Neural network technique is introduced. Performance results in simulations are shown.
ACKNOWLEDGMENTS

The funding for this work was provided by Electrodynamics Associates, Inc., Oviedo, FL under US Air Force Research Laboratory Contract Number F33615-02-C-22 16.
REFERENCES

Fig. 8 Steady state field current of main machine with 2.5 MW load Fig. 9 shows the field current of the exciter under steady state condition. It varies around 9.6A with 0.6A ac current ripple. The behavior of the ripple is controlled by bang-bang control design.

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