Rotary Machine Closed-Loop Test Bench
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Solution Overview
Problem
Testing rotary machines, such as gas turbines, under real network conditions is challenging due to the need for precise conditions, high resource requirements, potential disruptions to electricity supply, and noise concerns, especially when conducting tests outside the rated frequency or on a large scale.
Innovation Solution
A system and method involving a variable load coupled to a rotary machine's shaft, regulated by a controller to simulate load variations, allowing for closed-loop control and determination of response times, enabling testing without connecting to the electrical network, using a compressor or alternator with adjustable air flow or resistive load to balance power production and consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If testing is conducted on an actual electrical network, then the test reflects real operating conditions, but it causes disruptions to electricity supply and requires high resources
Solution Approach 1:
The patent introduces a test bench as an intermediary device between the rotary machine and the electrical network. The test bench includes a variable load coupled to the machine's shaft through a coupling, allowing tests to be conducted on the shaft rather than through the generator and network connection. This intermediary setup enables realistic testing of the machine's response to frequency variations without disrupting the actual electrical network.
2Adaptability or versatility
If testing is conducted outside the rated frequency of the network, then the test covers transient phenomena, but it requires deliberate network degradation which is not feasible in normal operation
Solution Approach 1:
The patent creates a simplified copy of the electrical network's frequency control mechanism through the controller. The controller is configured to simulate network frequency variations by adjusting the variable load on the test bench, allowing the rotary machine to be tested under transient conditions without actually degrading the electrical network. This copying approach enables comprehensive testing while maintaining normal network operation.
3Measurement precision
If large scale testing is conducted, then the test provides comprehensive data, but it affects network users and requires considerable resources
Solution Approach 1:
The patent segments the testing process from the actual electrical network by using a dedicated test bench with a variable load. This segmentation allows comprehensive testing of the rotary machine's response to various frequency scenarios without involving the broader electrical network and its users. The test bench isolates the testing activities, requiring minimal resources while providing complete test data.
4Reliability
If testing is conducted on the electrical network, then the test validates network integration, but it requires network connection which limits testing flexibility
Solution Approach 1:
The test bench acts as an intermediary that preserves the essential network integration validation while removing the constraint of actual network connection. By coupling the variable load directly to the rotary machine's shaft, the system can validate frequency response and primary reserve capabilities without requiring network connection, thereby maintaining reliability validation while achieving complete testing flexibility.
Data Source
AI summary
A system for testing a rotary machine includes a variable load coupled to a shaft driven by the rotary machine, and a controller configured to regulate the rotary machine and the variable load in a closed loop. A variation in a load value of the variable load causes a variation in a power produced by the rotary machine. The controller is further configured to determine a response time required for the power produced by the rotary machine and a power consumed by the variable load to be balanced.