Electric Machine Signature Qualification Without Full-Load Testing

Solution Overview

Problem

The high cost and resource-intensive nature of full-load testing for large electric machines, particularly in wind turbines, necessitates a more efficient method for ensuring the reliability and performance of generators without the need for extensive dynamic testing.

Innovation Solution

A virtual machine testing system that generates a test signature by measuring key parameters in static tests, comparing them to a reference signature from a fully qualified machine, allowing for the evaluation of electric machines without the need for full-load testing, using stimuli to simulate operating conditions across magnetic, electrical, thermal, and mechanical domains.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional full-load testing is performed on large electric machines, then reliability of testing results is improved, but testing cost and time increase significantly

Engineering Contradiction:

Improvereliability of testing resultsVSAvoidtesting time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent creates a virtual copy of the physical test machine through digital twins and simulation models. The virtual machine replicates the mechanical, electrical, and control system behaviors, allowing testing to be performed on the digital replica rather than the physical machine. This copying approach maintains testing reliability while eliminating the need for actual full-load dynamic testing, thereby reducing testing time and costs.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces the physical mechanical testing system with a virtual simulation system. Instead of mechanically coupling the generator to a motor for full-load testing, the system uses computer-based simulations to replicate the mechanical loading conditions. This substitution eliminates the need for expensive test equipment and reduces testing time while maintaining the ability to assess machine reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If conventional full-load testing is performed on large electric machines, then reliability of testing results is improved, but testing cost increases significantly

Engineering Contradiction:

Improvereliability of testing resultsVSAvoidtesting equipment complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent creates a virtual copy of the physical test machine through digital twins and simulation models. The virtual machine replicates the mechanical, electrical, and control system behaviors, allowing testing to be performed on the digital replica rather than the physical machine. This copying approach maintains testing reliability while eliminating the need for actual full-load dynamic testing, thereby reducing testing time and costs.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces the physical mechanical testing system with a virtual simulation system. Instead of mechanically coupling the generator to a motor for full-load testing, the system uses computer-based simulations to replicate the mechanical loading conditions. This substitution eliminates the need for expensive test equipment and reduces testing time while maintaining the ability to assess machine reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If static testing with parameter measurement is performed, then testing cost and time are reduced, but measurement precision requirements increase

Engineering Contradiction:

Improvetesting efficiencyVSAvoidparameter measurement precision

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent creates a virtual copy of the physical test machine through digital twins and simulation models. The virtual machine replicates the mechanical, electrical, and control system behaviors, allowing testing to be performed on the digital replica rather than the physical machine. This copying approach maintains testing reliability while eliminating the need for actual full-load dynamic testing, thereby reducing testing time and costs.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent implements a universal virtual testing platform that can simulate multiple operating conditions and test scenarios within a single system. The digital twin framework allows the same virtual model to be used for various types of testing (steady-state, transient, fault conditions), reducing the need for multiple specialized test setups and improving measurement efficiency while maintaining precision through consistent virtual instrumentation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12117482B2Virtual machine testing of electrical machines using physical domain performance signatures

Publication Date: 2024.10.15 VESTAS WIND SYSTEMS AS

AI summary

Systems, methods, and computer program products for virtual machine testing of an electric machine. A test signature including parameter values measured during one or more static tests of the electric machine is compared to a reference signature generated by performing a similar series of static tests on a reference machine. The reference machine is then validated by subjecting the reference machine to full-load dynamic testing. The test and reference signatures may include a plurality of parameters each characterizing a physical property of the respective machines in one or more physical domains. The parameters are selected so that the electric machine can be qualified for operation in the field by comparing the test signature to the reference signature, thereby avoiding the need for full-load dynamic testing of the electric machine.