WIND POWER ELECTRICAL DRIVE TRAIN

Optimized permanent magnet generator and full-power converter package

Table of contents
Switch up to superior PMG technology
The choice for more energy 4 5

Permanent magnet generators

PMG design advantages Topologies Windings and insulation Magnets Bearings

8 8 12 13 14 16 16 16 17

Capture power more effectively. Transform it into more energy.

In the race to harness the wind, turbine manufacturers are seeking the ideal drive train configuration to comply with stricter grid requirements, increase energy production and limit power losses.
The Switch DriveTM is a new-style drive train that features an optimized permanent magnet generator (PMG) and full-power converter (FPC) package to maximize the energy captured from highly variable wind speeds for reliable grid-quality electricity. By selecting this technology as our chosen area of focus, The Switch allows you to capture the power of the wind for future-proof grid compliance and maximized energy yield.
2

Segments Voltage Cooling

Full-power converters
FPC design advantages Hardware Grid performance Control

18 18 20 26 28

Testing and performance

30
33

Switch up to superior permanent magnet generator technology

GRIDPERFORMANCE

The choice for more energy

PMG technology

FIXED SPD

DOUBLE FED

PMG + fu-power coerter

When calculating the annual energy production for different drive train systems, PMG/FPC solutions come out on top every time, with the best system efficiencies achieved by direct driven and medium-speed PMGs. Even the high-speed PMG system offers remarkable efficiency over DFIG systems.

EICIENCY/RELIABILITY
Presenting The Switch DriveTM: Optimized permanent magnet generator and full-power converter package PMG technology has only recently become the obvious choice for the wind power industry. The worlds top turbine manufacturers, which earlier used only doublefed induction generator (DFIG) technology, have now launched PMG and FPC solutions. Moreover, several independent studies by industry specialists have concluded that PMGs and FPCs represent the preferred future drive train technology.
4

Although the DFIG is still the most commonly used generator technology, this is rapidly changing. The industry is now looking to move up to better overall system efficiencies, reliability and fault ride-through (FRT) capability. Specifically designed for the wind power business, The Switch DriveTM is an optimized PMG and FPC package. This unique drive train allows active power extracted from the turbine, as well as the reactive power produced, to be individually and precisely controlled over the entire operating speed range.

Better efficiency PMGs have distinct advantages over conventional doublefed machines. They typically produce efficiency levels up to 98% at the rated point. When used in low-speed, direct driven applications, generator efficiency is not as high, but the need for a gearbox is eliminated, creating excellent overall drive train efficiency. Better partial load rates The true strength of a PMG solution is in partial load situations the state in which turbines most often operate due to wind inconsistency. PMG efficiencies remain very high, close to nominal value, over a wide range of speeds. Plus, they produce much higher energy yields.

55

Permanent magnet generators

TAILORED
6.0 5.0

STANDARD

the active power that has to be injected into the DFIG rotor at sub-synchronous speeds, contributing to its loss of efficiency at low speed. No slip rings or brushes minimum maintenance Unlike DFIGs, PMG technology uses no slip rings or associated brushes, which significantly reduces the need for maintenance. Induced shaft voltages and bearing currents have caused many bearing failures in wind turbine drive trains. Moreover, the brushes create coal dust, a problem that does not exist with PMG technology. Magnetization retained during grid-loss stable operation The DFIGs magnetic field is provided by the rotors threephase winding supplied through the converter. Excitation for the DFIG requires external energy, which means additional losses and extra cooling. In grid-loss situations, the double-fed generator magnetization is lost. PMGs boast good operation in fault situations, as the excitation is retained in a grid-loss situation. Grid fault ride-through high grid compatibility FRT capability and 100% reactive power compensation capability are also reasons why PMG technology is superior. The active power extracted from the turbine, as well as the reactive power produced, together with the generator shaft torque, can be individually and precisely controlled over the entire operating speed range. The FPC enables the power to be delivered at unity or at a leading or lagging power factor, eliminating the reactive power voltage drop, which otherwise can contribute to system voltage instability during grid disturbances.
77

POWER (MW)

4.0 3.0 2.0 1.0

Features
Operational area from zero speed and power No windings in rotor Minimal losses Brushless operation Excitation is not lost in gridloss situation High pole count possible Rotor can be made partly hollow

Benefits
Energy production also at low wind speeds Less risks with bearing currents Maximize the energy No maintenance of slip rings Good operation in fault situation Nominal speed freely designable Reduced mass and inertia

LOW

MEDIUM
The Switch portfolio: any power, any speed.

The Switch PMG is a simple form of synchronous generator that requires no connections or energy feed to the rotor. Since permanent magnets are placed on the rotor to create excitation, PMGs do not require any separate excitation, which reduces costs, simplifies the system and improves system efficiency. The design virtually eliminates rotor losses. By driving the generator with an optimal power factor, stator-side losses are also minimized. When operating at lower speeds in partial loads, rotor losses are considerable in DFIG machines. DFIG machine losses are both copper and harmonic losses. In PMG machines, rotor losses are only harmonic losses, which are relatively small in comparison with DFIGs, which have higher harmonic losses due to the short air gap.
6

Wide range of speeds By allowing a wide range of speeds, the drive train can run at the optimized operational point for the turbine. Control is based on the optimum turbine curve and is not limited by the drive train, thereby providing better partial load rates. A double-fed machine has only a limited speed range that does not allow the turbine to fully adapt to actual site conditions. Instead, it has a quite high efficiency at full speed. The converter needed for variable speed operation is typically rated at only 30% of the full generator power. At partial speed, however, the PMG/FPC system efficiency is significantly higher. A major contributor is

Permanent magnet generators

Permanent magnet generator design advantages

With finite element calculations, it is possible to get Accurate loss distribution and machine efficiency, which then helps in designing the cooling system Short-circuit forces to determine the mechanical strength of the supporting structure Voltage waveform and all harmonic frequencies Currents during short circuit to properly dimension protective devices Parameters for different operational points Finite element analysis and machine calculations Finite element analysis (FEA) and advanced machine calculation programs optimize the PMG design, study worst-case scenarios and design the machine in a way that assures long life and reliable operation under all normal and abnormal conditions. This includes studies of 2-phase and 3-phase short circuits and how external fields affect the magnets.

Design tools and process In the design of every generator, The Switch quality depends on numerous details from the start. The design teams carefully select the proper materials to use for each component and accurately calculate the machine so that it functions flawlessly at all the different operational points. Design considerations The Switch considers worst-case scenarios in its designs, including three-phase short circuits at maximum operating temperatures, which can lead to demagnetization.
8

Todays PMG designs take advantage of the latest and best tools, such as the finite element method (FEM), advanced cooling methods, as well as the selection of stronger magnets, such as Neodymium-Iron-Boron (NdFeB). The first stage of the design includes rough calculations using well-known equations. The second stage finalizes the design and verifies both the design and machine dimensions using FEM.

Reduction of torque pulsations A properly designed PMG considers torque pulsations. Speed-controlled electrical drives and low-speed systems in particular may have severe vibration interactions with the mechanical system. The most difficult torque ripple frequencies are lower than a few hundred hertz. Any such remaining torque ripple in this frequency range may be amplified in the mechanical systems and cause mechanical resonance in the electrical machines. Therefore, dynamic interaction is reviewed to control these systems.
99

Permanent magnet generators

1.0

Magnet area
0.8

0.6 0.4

B (T)

Magnet outer surface Magnet inner surface

0.2 0.0

-0.2 -0.4

Demagnetization limit @ 80 C

Pole pitch

Inner and outer magnet flux density during a short circuit.

FEM showing PMG flux under normal conditions.

Electromagnetic calculation tools 2D or 3D finite element method The Switch uses commercial 2D or 3D FEM calculations or other specially tailored programs to confirm its PMG designs. These ensure the highest possible end-product quality and long operational life. By optimizing the cooling system in the design phase, we are able to achieve better overall efficiency for our customers. In addition, careful thermal modeling shortens the prototypes lead-time, allowing faster product delivery times. Customized software Additionally, we have our own customized software for the complete electromagnetic design used in the PMGs. These programs provide accurate dimensioning of active parts, magnet shapes and

dimensions, the winding layout and cogging torque. They also calculate electrical parameters, such as current, efficiency, losses, power factor, equivalent circuit parameters and other. Mechanical calculation and design tools 3D modeling program Mechanical strength calculation programs Bearing calculation programs Fluid dynamic calculations for thermal design computational fluid dynamics (CFD) simulations All designs are made with 3D drawings.
11

Thermal calculation for cooling Thermal calculations are implemented at an early design phase to ensure that the generator design is highly reliable. The Switch calculates the overall heat flow together with the cooling air flow using sophisticated methods.
10

Permanent magnet generators

Topologies
Machine construction
Inner rotor

Windings and insulation

Turbine topology
Direct driven

Cooling arrangement
IP54 air-to-air heat exchange IP54 air-to-liquid heat exchange IP23

Magnet assembly
Surface mounted magnets Magnet assembly on rotor surface Buried magnets

Winding
Form wound coils

Superior insulation To ensure the highest possible quality, The Switch is working together with one of the worlds leading insulation manufacturers. As part of the close collaboration, the partner company makes a precise analysis of the type of insulation used in each generator type. A mica-based insulation system with vacuum-pressure impregnation (VPI) has been selected for all applications, because it alleviates any elevated voltage stress coming from the frequency converter.

Outer rotor

Semi-geared

Random wound (round wire) Litz wire winding Roebel-bar winding

Traditionally geared

The Switch offers three different topologies to cover all applications with the widest portfolio of PMG and FPC packages available. Each of these three main topologies is designed for a particular wind generation application with special magnet arrangements to match the specific conditions. Low-speed, direct driven permanent magnet generators No gearbox Very low spherical rotor speed Medium-speed permanent magnet generators Typically with a single- or two-stage gearbox Optionally, highly integrated version for optimized solution High-speed permanent magnet generators To be used with three-stage gearbox
12

Outer/inner rotor The Switch offers both outer and inner rotor generators for direct driven turbines. Outer rotor generator: New platform for easy turbine integration The new outer rotor machine features highly integrated components built to last. Requiring minimal maintenance, the simple, straightforward design integrates the main shaft, main bearings, gearbox and mechanical brake into a single generator combination with reduced weight. The generator shares a common bearing with the turbine itself, and the turbines brake system is integrated as part of the generator. Benefits are simplicity, fewer components and therefore, higher reliability. For newcomers to modern wind power technology, The Switch outer rotor generator offers a fasttrack way to make a high-performance turbine. It enables the best possible energy yield in varying wind conditions, thereby maximizing annual energy production. Inner rotor generator: The choice for geared applications The most typical or traditional electrical motor type is radial, where a cylindrical rotor rotates inside a stator tube. With a geared application, the traditional inner rotor is a typical choice. It also enables integrated construction together with the gear.

Winding options Form wound Most standard winding option in the market Over 75 years of proven reliability in operation Better utilization of copper Litz wire Minimized skin effect for high-frequency applications Ideal option for high-speed applications
13 13

Permanent magnet generators

Magnets
q S N S

d N S N S
S N S q

d N S N S

The development of permanent magnet material has been rapid during the last few decades. The increase in energy density of the NdFeB materials has not been radical, but significant improvements have been reached in corrosion resistance and temperature tolerance. Thanks especially to the high remanence and coercivity, the NdFeB magnets are the choice for industrial motors, including the generators used in wind power turbines. Therefore, such high-quality magnets are used in every The Switch PMG. These rare-earth magnets allow for relatively high temperatures and have high remanence flux. Magnet availability Despite the term rare-earth magnets, an estimated 8 million tons of Neodymium, one of the main elements in these super-strong magnets, are available in known sources, primarily in China, but also in other countries such as Canada and Australia. According to some studies, there is a sufficient amount of rare-earth magnets for
14

the next 1,000 years, without even taking recycling into consideration. Approximately, only 7,000 tons per year are currently used for todays present applications. Magnet selection Careful magnet selection is important to ensure a long operational life and high availability. The Switch makes calculations to project the lifetime of magnets during the initial design phase. Dimensioning and modeling of magnets eliminate cogging, especially with low-speed applications. Magnet demagnetization The flux density of NdFeB magnet material is somewhat sensitive to temperature. Therefore, an adequate margin is essential for all normal and abnormal operating conditions to safeguard the design against demagnetization. Due to this, a proper selection of the correct magnet quality for each of the applications is essential.

Protection against corrosion Although the magnetic materials have developed remarkably, it is still important to protect them against humidity. A phenomenon called white corrosion emerges when the magnets are exposed to hydrogen, which causes the magnetic material to turn into white powder and lose its properties. All magnets used by The Switch are always coated against corrosion and typically are also hermetically sealed to maximize safety. Magnet arrangements Magnet arrangement depends primarily on the generators spherical speed. Therefore, each arrangement is based on the chosen topology. The magnet mountings, shapes and volume also determine the motor properties, such as air-gap flux density distribution, the effective amount of permanent magnet material, cogging torque and others.

The magnets must be firmly attached to resist centrifugal forces. Arranging the magnets with careful design effectively counterbalances torque for a much smoother operating result. Reaching lower cogging is especially important because of lower mechanical vibrations, less noise and longer operational life of the gearing and other mechanics. Surface-mounted magnets for low- and medium-speed machines allow the maximum power to be captured from the magnet. This arrangement takes advantage of the full magnetic excitation in low spherical speed machines. The magnets are typically protected with a module construction, eliminating any risk of power leakage or corrosion. Embedded magnets for high-speed machines built inside a sealed corrosion-resistant metal enclosure increase mechanical strength. The hermetic seal provides perfect protection from the environment.

15

Permanent magnet generators

Bearings
The main cause for undesirable bearing currents in frequency converter driven machines is the common voltage caused by the switching in the semiconductors. Insulated bearing solutions work to minimize bearing currents.

Segments
One approach from The Switch for direct driven generators is based on a patented segmented structure. The machine stator consists of several independent stator segments that can be driven by different converters. Such a segmented structure provides redundancy for the drive, and the turbine may even remain operable in cases of minor faults in one of the segments.

Cooling
Even though the losses in a PMG rotor are only a fraction of those with a DFIG, it is necessary to cool the rotor to eliminate hot spots. The inner circulation adjusts the cooling with external cooling fans to optimize the cooling power and effect. This ensures the correct amount of cooling in the different parts of the machine. A secondary circuit may be air or liquid cooled. A heat exchanger can be used for air-to-air or air-to-liquid cooling. The effective cooling concept from The Switch ensures A longer lifetime Better protection against demagnetization Fewer losses in the machine Other cooling options are available on request. The IP54-class generator is fully closed to effectively protect against corrosion, enabling the cooling concept to be safe for offshore applications.

The Switch offers three ways to insulate the bearings inside a PMG to reduce bearing currents Ceramic ball bearings Insulated bearings Separate insulated bearing housing We use a special program for bearings that calculates a full lifetime analysis of the bearing operation under both normal and extreme conditions.
16

Voltage
The Switch PMGs typically have a low voltage of 690 V. Especially with a FPC, a low voltage layout (up to 5 MW) is less expensive and does not affect the energy output. The Switch has also delivered medium voltage machines.

17 17

Full-power converter design advantages

Dynamic electric brake Generator inverter Line inverter Liquid-cooled DU/DT filter

Full-power converters

Generator breaker Generator cabling entry

Filter capacitors

Grid cabling entry

Control electronics

Filter inductor

Why a full-power converter? The Switch FPC is optimized to work with a range of PMG concepts to give the best overall system efficiency. Designed for the highest-level reliability, the robust line inverter ensures future-proof electricity quality to meet the most stringent international network requirements for harmonics, flicker and FRT. By feeding reactive power, The Switch FPC enables easy and adjustable power factor control and grid voltage support. This means that all the current can be used for active or reactive power generation, allowing a 100% reactive power feed, even in the absence of wind. Flexible active power and torque control ensure smooth
18

turbine operation in normal energy production and especially during grid disturbance, as the FPC decouples the generator from the grid. For turbine manufacturers, The Switch design quality and redundancy guarantee the highest possible availability and grid compliance. For their customers, this offers maximized energy yield. Modular design to match wind conditions The Switch FPC features lightweight construction and modular power packs with liquid cooling to match all turbine designs and wind conditions. The modular platform offers a full range of options. Power increases simply by increasing the number of cabinets.

High-quality electricity: Designed for the highest level of performance and lowest demands on the grid. The rugged The Switch FPC design provides exceptional fault tolerance and grid support through fully tested FRT functionality, overvoltage and other operational performance features. Harmonics and flicker are extremely low. Exceptional thermal management: The Switch FPC offers exceptional thermal management and cooling functionality. Extended lifetime: Through thermal management for increased operational reliability and longer component life. The Switch FPC uses only state-of-the-art components.

For environmentally challenging sites: Proven performance reliability in high temperature and humid conditions with optional active air-conditioning. Optimized software and hardware: Designed specifically for wind turbine applications. Easy maintenance: Together with remote monitoring allows for the highest availability. Redundancy: The modular design assures full redundancy. If one converter fails, this does not cause turbine downtime. The turbine continues operating at a lower power production rate. Both standard and tailor-made solutions are available.
19

Full-power converters

Hardware for reliable operation

DU/DT filter As a result of optimal generator control, the generator No DU/DT filter inverter creates a pulse-width modulation > 2000 V/(PWM) s voltage waveform from the generator inverters output. Voltage is formed by utilizing fast switching insulated gate bipolar transistors (IGBT). The role ofperformance the DU/DT Medium DU/DT filter filter is to smoothen the fast voltage transients caused ~ 1000 V/ s by switching and a sudden change in voltage level. As part of The Switch PMG/FPC optimized package, the DU/DT filter works so that bearing currents are High performance DU/ DT bearing filter negligible. Without bearing currents, wear is < 500V/ s non-existent, and generator lifetime is significantly extended. The Switch DU/DT filter offers a balance between reduced losses, while not endangering the generators insulation, which results in costly maintenance or complete turbine failure. Customers have a choice of the preferred medium-performance DU/DT filter or the highperformance DU/DT filter, recommended only for special operational circumstances.

No DU/DT filter >2000 V/s

Medium-performance DU/DT filter ~1000 V/s

High-performance DU/DT filter <500 V/s

Varying speed generation to match fixed requirements Todays turbine manufacturers seek to match electricity network regulations that are becoming ever more stringent. A variable speed wind turbine with a synchronous PMG needs a power electronic converter to convert the generated electrical power to meet the given power quality requirements of every public distribution network. This power conversion is necessary because the frequency and amplitude of the generator output voltage vary due to the changing rotational speed of the turbine. Inverters The Switch has years of combined experience in designing, manufacturing and supplying inverters for

all types of industrial use. Based on this expertise, we have been able to combine just the right key design elements for a successful wind power generation converter. Generator inverter On the generator side, The Switch has introduced a number of enhancements, including a new liquid-cooled DU/DT filter to smoothen generator waveforms. The generator inverter converts electricity from AC to DC as well as controls generator torque. A controlled, compact generator breaker isolates the PMG from the converter when the turbine is at a standstill.

20

21

Full-power converters

Without dynamic electric brake Wiout dynamic electric ake

Grid voltage Speed

Light duty dyn

Line inverter

Filter unit Grid

Dynamic electric brake The dynamic electric brake consists of a DC chopper module and resistors that protect the DC link from overvoltage during a sudden grid loss and allows smooth torque control through the event. The primary function of the dynamic electric brake is to ensure turbine grid connection during a fault event by enabling converter control to handle energy flow in an optimal event-by-event manner and adding protection against Wiout dynamic electric ake possible transient voltages.
Grid voltage

Torque

To

Time

Light-duty dynamic electric brake ake Light duty dynamic electric

Grid voltage

Heavy duty dyn

DC link Between the generator and line inverters, a capacitor bank forms an intermediate DC link. The FPC includes a DC pre-charging circuit that prevents excessive in-rush currents during start-up. The DC link capacitors are integrated in the inverters, making the module compact and easily cooled. Line inverter Line-side performance has been significantly improved, with FRT and lower grid harmonic content. Improved synchronization means that the in-rush current is lower when the converter connects to the grid. Further, the line inverter converts electricity from DC to AC and controls the DC link by feeding generator power to the grid.

Grid filter The new grid LC filter, with its choke and capacitor bank, smoothens grid waveforms. The Switch grid filter cleans the line inverter output power to match the utility grid regulations. The preferred topology is a LC filter, which consists of capacitors and a liquid cooled inductor. Optionally, advanced and high-performance topologies are available to meet todays strictest requirements. The LC filter has been carefully designed to work as an integral part of The Switch PMG and FPC package resulting in extremely low harmonic distortion. In addition, it helps to determine the quality of the power output to the grid.

The concept of the dynamic electric brake is expandable Speed Speed up to full-power braking within a certain time range. In a longer full-power electric braking scheme, the generator and gearbox are not affected by events on Torque Torque the utility grid, as the converter keeps the torque constant during ride-through. In addition to smooth ride-through functionality, careful dimensioning of Time Time resistors enables a cost-effective way to restore power production back to the pre-fault level in a very short Heavy duty dynamic electric dynamic electric brake ake Light duty dynamic electric akeHeavy-duty Wiout time. dynamic electric ake Smart protective components Grid voltage Grid voltage With smart protection management, the failure of Speed Speed one component does not impact other components. Protective components include the main circuit breaker, Torque which provides isolation from the grid and integrated Torque digital protection relay, and fast semiconductor fuses that protect the converter in case of failure.
Time Time Grid voltage Speed Torque

Time

22

23 23

Full-power converters

Cabinet The Switch cabinet frame design is exceptionally rugged. Cabinet construction is of class IP54 to withstand harsh environmental conditions, humidity and high temperatures. The cabinet features easy access for maintenance needs. As a default, an in-built cabinet condition monitoring system provides corrective actions to prevent the converter from starting in case of excessive humidity, condensation or if the converter is exceeding the allowed temperature range. The Switch FPC cabinet is fully enclosed without any vents to the outside air. This prevents dust from entering the cabinet and allows the FPC to operate reliably where winds blow strong. Piping and other wear parts used with air cooling systems are eliminated, making the liquid-cooled cabinet virtually maintenance-free. Therefore, the solid liquid cooling construction is stronger and more dependable. Liquid cooling for high reliability The IP54-class converter cabinet is fully liquid cooled. Internal air-to-liquid heat exchangers cool the cabinet air for any non-liquid cooled components. This has become the preferred choice in the industry because it allows a better power density.

Connection choices The Switch can tailor the grid-generator connection according to your specific needs. Design limitations are minimal. Based on our experience, we can select the connection that will perform best for the turbines operating environment. Breakers The Switch FPC is default equipped with grid and generator breakers. The breakers have integrated digital protection relays to safeguard the system from serious damage in the case of failure or overload. With the breakers, it is also possible to isolate the converter system from the turbines electric system when service or maintenance work takes place.

24

25 25

Full-power converters

World-class grid performance

Terminal blocks of power cables LPZ2

LPZ1 All cable terminations with a 360 shielding LPZ1

Converter
LPZ2 Cable raceways of open structure

Terminal blocks of auxiliary equipment LPZ2

LPZ1 LPZ1

LPZ1 Shielded cables shown with a continuous white

Separate sensors

Generator
LPZ2

Turbine controller
LPZ2

Grid code compliance of The Switch FPC.

Nacelle
LPZ1

Tower
LPZ1

Non-shielded cables shown with a broken line

Full power The advantage of The Switch FPC is that all energy coming from the generator goes through a converter and is thus well under control. In addition to 100% reactive power feed capacity even in the absence of wind, the full-power conversion enables smooth FRT operation by means of smart control. Reactive power support The Switch FPCs reactive power control supports grid stability by supplying reactive power on demand or on a scheduled basis. This automatically maintains the predetermined grid voltage levels and power quality within a fraction of a second. It also reduces the risk of voltage collapse and minimizes the impact of grid
26

disruptions, making it particularly useful in weaker grids or larger turbine installations. Fault ride-through copes with voltage drops There is simply no way to avoid grid transmission disturbances caused by bolts of lightning, equipment failures or power lines that are down. Wind turbines have traditionally responded to these voltage drops by switching off-line to protect their functions until grid recovery. Conventional double-fed turbines with the stator directly connected to the grid do not have any built-in ability to ride smoothly over disturbances. This is why they suffer during grid fault events from heavy mechanical and electrical stress, loss of control or even component failure.

FRT, however, provides an alternative approach to cope with these disturbances, and can be used effectively in PMG and FPC packages. The converter stays connected during all kinds of grid faults and even includes zerovoltage ride-through capability. Continuous torque and active power control are ensured. The Switch FPC supports the grid with reactive current during the dip and stabilizes grid voltage and frequency. Optionally, it can distribute active current to the network. The Switch has fully tested the FRT performance of its FPC for symmetrical and asymmetrical voltage drops as well as phase jumps with extremely good results. Current harmonics/flicker Recently, there have been increasing regulations on current harmonics and flicker, or voltage fluctuation, especially as this has been a growing concern in the wind industry.

Using both the generator inverter DU/DT filter and the line inverter LC filter ensure the highest possible electricity quality. This results in a proven total harmonic distortion (THD) of <2%, whereas most competitors come in at around >5%. In addition, The Switch flicker co-efficient is extremely stable. The exceptionally low THD and stable flicker co-efficient place fewer demands on the electricity network and allow for better connectivity with a wider range of networks. Lightning protection The Switch lightning protection concept is based on the generic IEC 62305 series lightning protection standard and the IEC TR 61400-24 product specific technical report. These represent the maximum level of safety in the case of lightning strikes.

27

Full-power converters

Control flexible and robust

The wind turbine controller (WTC) communicates through a fieldbus (Profibus DP, CanOpen, Modbus, Modbus over TCP/IP). Digital and analog input/output (I/O) available for control and signals (e-stop, run enable, etc).

Although commissioning is usually performed quickly with the PC, an alphanumeric LCD display panel that supports Cyrillic and Chinese letters, is also included as a backup and enables software updates in the field. Features in The Switch FPC control panel include Startup wizard Multi-monitoring Default page Copy function Back-up function RS-232 communication Remote management The Switch remote management allows online monitoring for service personnel to gain quick information for rapid decision-making. The functionality of PC-based commissioning tools, remote connectivity and the server platform create a toolset for maintaining a comprehensive database of the products field performance and service history over the entire lifetime. Remote management consists of Remote terminal inside converter cabinet Controller area network (CAN) based communication from remote terminal to converter control Optional I/O ports for sensor data Remote management client software Server for communication with remote terminal and data storage (at The Switch premises) Our customers only need to provide a safe gateway for Ethernet communication.
29

HMI operating panel for each inverter unit. Commissioning and service tools for PC.

Internet

Remote diagnostics and online monitoring.

interface to optimize the converter performance for varying conditions. Additionally, customer-specific functions or special interfaces can be built into the application, giving the turbine manufacturer one more degree of freedom when designing the turbine concept. All software is compatible with the IEC 61131-3 standard.

Since The Switch FPC is not as sensitive to changes in the network as traditional converters, it offers advantageous control flexibility for adapting to ever-changing operating conditions. The Switch software solutions have been designed for robust control in tough conditions. We know you need connectivity, intelligence and communication with your wind turbine system to know what is really going on when you cannot be there. Wind turbine control connectivity The turbine controller communicates through the fieldbus, giving converter torque, power or speed reference and control commands. Compatible fieldbuses include Profibus DP, CanOpen, Modbus, Modbus over TCP/IP and virtually all other industrial buses. As a default, The Switch FPC offers a configurable data exchange interface to the turbine controller, supporting varying needs of different turbine models and allowing easy integration of the converter as a part of the wind turbine.
28

Digital and analog I/Os are available for control and signals, such as safety chain, interlocks and the possibility to collect process measurement signals from the converter to the main control unit. Application software Our software engineering team is experienced and has in-depth knowledge of wind power applications and control. They understand your demands and tailor the software based on the unique requirements to make the best possible solution. Among many others, application features include converter self-protection against climatic issues, a rotating function to turn the rotor to a locking position and an automatic alternation of power generating modules for low wind situations. Application packages include a comprehensive parameter

On-board diagnostics In the case of an unexpected event, the converter stores a perfect set of data for further analysis. Converter power modules have their own fault event buffers, which store the last 30 alarms and faults with the most important status and monitoring values, and a possible real-time stamp. The converter also has an inclusive data logger function, which stores eight signals for a few seconds with one millisecond sampling time as a default. For very fast event hunting, the data logger sampling can be set even down to 140 microseconds. Commissioning tools The PC-based commissioning tool offers easy startup, parameter setting, either as a single parameter or by downloading the entire parameter set, and documentation. The commissioning tool includes the ability to monitor signals, read fault logs as well as set and read the internal data loggers.

Testing and performance

Testing
Our philosophy is that absolutely everything relevant to reliability will be tested. The Switch has all necessary equipment to be able to test everything itself in its factories. Full-power testing is performed on the different machine types before they leave the factory. This includes testing, for example, of the coil constructions. Simultaneous tests for the integrated outer rotor model, which has no bearings of its own, can be run at the test bench for high and medium speeds. Detailed type testing The Switch type testing is a series of more detailed tests, compared with the routine testing that is carried out for every generator. These tests provide more in-depth analysis about the generator to verify the machine performance. Measurement equipment The Switch has invested in highly accurate measurement equipment specifically tailored to such demanding type testing. The specially designed test field in The Switch Lappeenranta factory accurately simulates the operating conditions for a wind turbine nacelle, with ambient and coolant temperatures, as well as other challenging operating conditions. As part of the system test, the PMG and FPC can be tested as a package. This allows The Switch to optimize the drive so that customers get the highest efficiency from the system.
30

Performance

Performance with The Switch DriveTM allows you to harness more wind power and turn it into more high quality energy for the grid. The performance and reliability of our PMG and FPC packages are unsurpassed by any measure. Efficiency: The Switch PMG offers excellent efficiency throughout the entire range, starting immediately from zero. Operation at partial loads is especially advantageous compared with a double-fed model. Cogging: The electromagnetic design of The Switch PMG ensures torque ripple below 1%, offering smooth

operation, low noise and extended gear and machine lifetime. Fault ride-through control: The active power extracted from the turbine and the reactive power produced can be individually and precisely controlled with the FPC over the entire operating range. Low-maintenance operation: Our PMG and FPC packages have been designed for minimal maintenance and maximum reliability.

31

THE WORLD OF

THE SWITCH

WE AIM TO BE THE TECHNOLOGY LEADER FOR ELECTRICAL POWER CONVERSION BY SWITCHING ONE TURBINE AT A TIME WHEREVER ENERGY IS GENERATED.

Barcelona, Spain (Office) Beijing, China (Office) Chennai, India (Office) Deyang, China (Production) Gumi-City, Korea (Office) Hamburg, Germany (Office) Hangzhou, China (Service hub)

Hong Kong, China (Office) Hudson, US (Production) Lappeenranta, Finland (Production) Luan, China (Production) Silkeborg, Denmark (Office) Vaasa, Finland (Production) Vantaa, Finland (Headquarters)