By Timo Heinonen (Finland)

作者 | Timo Heinonen（芬兰）

基于模拟的客户定制滑环装置

By Timo Heinonen (Finland)

作者 | Timo Heinonen（芬兰）

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.

滑环单元是双馈发电机的关键组件之一。

环境模拟使得滑环单元可以针对每个不同的场合来进行定制。

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.

风电机组设备制造商需要在从沿海地区到高海拔干燥地区等各种不同的环境下安装标准的风电机组。环境会影响发电机滑环单元运行和使用年限。如果能够模拟滑环单元的运行情况并根据模拟运行的结果对其进行定制生产，那么对最终客户大有益处。

The demanding SRU要求严苛的滑环单元

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.

双馈发电机馈送给电网的无功功率和有功功率由两部分组成，一部分来自定子，另一部分来自电流大温度高的转子。因转子是旋转的，所以需要有可靠的滑环将电能从发电机内部传输出来。滑环单元包括由三相集电环和导电杆组成的滑环、刷架和刷握、三相电刷以及转子电缆连接螺柱等几部分。不过针对不同场合来改进滑环单元的运行需要相当丰富的经验。设计一套可靠的滑环单元需要多方面的考虑，包括滑环和电刷的材料选取、除尘、高效冷却以及方便维护等等。不断变化的运行情况和定期维护的需求也使得滑环单元成为对最终用户而言最关键的部件之一。而其他因素诸如不同的电网规范和负载条件等也会影响滑环单元的大小和最佳结构。此外，风电机组设备制造商常使用变流器软件与硬件调试来输出更多的无功功率以满足电网的要求，且不同原始设备制造商的参数要求包括无功功率、转速范围和超速等也会影响滑环单元的性能。综上所述，选择正确的材料组合和滑环单元部件的配置是一个具有挑战性的任务。

New innovations in SRU design滑环单元设计亮点

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.

为了帮助风电机组设备制造商在安装现场应对常常未知的环境条件，ABB和行业领先的滑环单元制造商密切合作以便开发一种创新的模块化滑环设计。该设计旨在实现基于准确负载条件的负载优化和高效冷却。

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.

为了实现灵活的滑环单元标准化设计以便能为每个独立案例提供完美的优化，ABB开始了滑环单元的进一步开发设计。开发设计的重点是使滑环单元长期可靠地无故障运行并减少维护需求，从而实现利用率和发电量的最大化。

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.

该设计以一种全新的模块化结构为基础，该结构便于针对不同的负载条件进行优化，也有助于高效冷却和除尘。同时还包括一种先进的电刷结构设计，使电刷便于安装和维护。为了使不同负载条件下的结构标准化，对电刷规格进行了统一，对每相电刷数量也进行了优化，这是一个非常有成本效益的方案。此外，一个在大多数环境条件下都得到验证的知名电刷品牌被选定为标准选项。

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.

滑环单元结构简单且坚固，主要特点包括冷却效率高、易于维护且拥有耐受超速的刚性结构。包括电刷在内的所有主要部件都是由一家全球最大的成套滑环制造商制造的。

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.

滑环单元使用优质且抗局部放电的绝缘材料，可以耐受变流器工作时的电应力。每个滑环单元都会进行5kV的高压测试，还会进行局部放电试验以确保优异的绝缘性能。

Tailor made testing in simulated site conditions模拟现场条件来定制测试

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.

建立一个新的滑环单元测试实验室可以使研发部门在与实际安装现场一致的条件下进行全面的测试从而为客户提供支持。测试结果可用来根据负载和环境条件定制新的滑环单元组件。

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.

新的滑环单元测试实验室遵循《IEC 60068-1》标准（第七版）中有关环境测试过程的要求，同时根据《IEC 61400》标准模拟风电机组的负载条件。测试程序的制订则参考了以上这两个标准的要求，测试程序同样也可以包括客户的其他要求和现场情况。

“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风力发电机产品经理Raimo Sakki先生说：“在发电机设计过程中，我们始终和风电机组设备制造商密切合作，针对每个案例来寻找最佳方案。现在通过新成立的实验室，我们可以模拟真实的现场条件来定制滑环单元并可以帮助风电场管理人员实现运行时间最大化。”

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凭借在发电机、技术研究、环境条件和客户要求上的丰富经验能够模拟不同的环境和负载条件。在转子侧和电网侧使用独立的变流器，这样就可以测试所有风机的主要运行点同时可用气候模拟箱控制湿度和环境温度。

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.

测试会在一个真正的滑环室内并且在有风扇的条件下进行，这些测试条件模拟了一个在风机机舱内的完整的发电机。除超速试验和高电压试验外，这套完整的测试程序还包括局部放电认证、电刷磨损试验和为方便除尘而进行的气流测量。

Benefits for turbine OEMs and end users给风电机组设备制造商和最终用户带来好处

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.

根据测试的结果并通过优化相关参数如滑环尺寸、电刷数量、电刷与滑环的材料等等，可以确定配置合理的滑环单元组件。而负载优化则保证了安全的运行温度和有效的冷却。

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.

对于风电机组设备制造商和最终用户而言，如果使用经过预测试的组件，则不需要进行后期的设计变更，也可避免不必要的风电机组停机。针对特定场合的优化设计会大大减少相应的维护并能保证长期地运行，这样有利于连续地运行和最大化地产生电能。

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.

本文英文版由芬兰ABB公司Timo Heinonen先生（机械工程专业硕士）撰写，他在风力发电机领域拥有超过十五年的经验。中文版由ABB电机与发电机业务单元亚洲技术中心夏星晨先生和林然然先生负责翻译。

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电机与发电机业务单元亚洲技术中心的滑环单元实验室即将投入使用。敬请联系我们。

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

地址：上海市闵行区天宁路59号。 电话：021-34782835 / 34782505。