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SS-EMS-2500-WT

[2 MW 20 RPM SS-EMS For Direct Drive Wind Turbines]

 

With its superior Synchro-Sym electric machine system (SS-EMS) technology, BEM is specifically developing the SS-EMS-2500-WT, which is a self-contained "turn-key" electric generator system (e.g., real time electronic control included) that focuses on the direct drive wind turbine market. Designed in accordance with computer-aided-design tool of Best Electric Machine (BEM-CAD) [1], the SS-EMS-2500-WT is a high torque 2000KW Continuous Power axial-flux (or disk shape) amorphous core synchronous electric machine system that generates over 955,414 nm (704,713 ft-lb) of torque between a constant-torque speed range of 0-20 RPM (all within a 9 ft (2.7m) diameter by 43" (1.1 m) long by 28,000lb (14,000Kg) package that includes the integral brushless real time electronic controller). More details are provided in the table below.

 

The SS-EMS-2500-WT includes other unique state-of-art EMS technology. For instance, the SS-EMS-2500-WT will uniquely comprise highly efficient amorphous axial-flux cores [2] manufactured with MotorPrinter, which is the only 3D Printer of electric machines and the only practical method for manufacturing amorphous metal, axial-flux cores. The SS-EMS-2500-WT incorporates ports for active forced air cooling flow but with the wide range of applications preferring their own active cooling apparatus, the SS-EMS-2500-WT does not include active cooling apparatus. BEM has developed a cooling system to specifically cool SS-EMS technology for continuous operation at peak torque that is available to the customer at an optional cost.

 

Note: With patent-pending power stacking, SS-EMS Technology can be seamlessly stacked, which incrementally increases power and torque while preserving EMS diameter. For instance, power stacking (i.e., patent pending) five SS-EMS-2500-WT implements a 10 MW/20 RPM direct drive wind turbine generator that is less 9' (2.7m) in diameter, a little over 20' (7m) long, and less than 140,000 lb (70000 Kg). Power Stacking has other advantages: 

  • Resiliency: Stack of SS-EMS-2500-WT continues to operate at reduced power with failed SS-EMS(s);

  • Logistics: A single SS-EMS-2500-WT (28,000lb/14,000Kg) of the stack or individual rotor and stator components (14,000lb/7,000Kg) of the SS-EMS-2500-WT, which are the same component, can be conveniently hoisted to (or removed from) the nacelle and then assembled into the power stack with an integral gantry.

Note: A 2000KW/20RPM direct drive wind turbine electric generator was chosen for comparison with available competitor's 2-10MW direct drive wind Turbine generators.  

 

BEST ELECTRIC MACHINE

SYNCHRO-SYM Axial-Flux (or disk shape) Amorphous Core Electric Machine System

[SS-EMS-2500-WT] [2] [3]

 

 

Power (KW)

Constant-Torque

Speed (RPM)

Port Volt (V)

 

SS-EMS Power 

@ Constant-Torque Speed Range

1000.00

[4]

0 to 20 (+)

 

≈ 2400 [5]

 

Operation above 20 RPM enters the constant horsepower speed range.

SS-EMS Peak Power

@ 2X Constant-Torque

2000.00

[4]

SS-EMS Power 

@ 4X Constant-Torque

4000.00

[4]

Parameter

SI Units

 

Values

Comments and Descriptions

 

 

 

 

 

Poles

 

 

40.00

 

 

 

 

 

 

Torque

N-M

 

477707.01

INTEGRATED

ELECTRONIC CONTROLLER INCLUDED

ft-lb

 

353356.69

Peak Torque
@ 2X TORQUE

N-M

 

955414.01

ft-lb

 

704713.38

 

 

 

 

 

Power

KW

 

1000.00

INTEGRATED

ELECTRONIC CONTROLLER INCLUDED

HP

 

1340

Peak Power
@ 2X TORQUE

KW

 

2000.00

HP

 

2680.00

 

 

 

 

 

Power Density

KW/L

 

0.7

INTEGRATED

ELECTRONIC CONTROLLER INCLUDED

Power Density
@ 2X TORQUE

KW/L

 

1.39

 

 

 

 

 

Specific Power

Kw/kg

 

0.14

INTEGRATED

ELECTRONIC CONTROLLER INCLUDED

Specific Power
@ 2X TORQUE

Kw/kg

 

0.28

 

 

 

 

 

SS-EMS Efficiency [6]

%

 

89.0

INTEGRATED

ELECTRONIC CONTROLLER INCLUDED

 

SS-EMS Efficiency [6]

@ 2X TORQUE

%

 

89.0

SS-EMS Efficiency [6]

@ 4X TORQUE

%

 

57.4

CORE OD (/w end windings)

ft

 

8.37

 

mm

 

2551.28

inches

 

100.44

Total CORE Depth

mm

 

281.40

 

inches

 

11.08

TOTAL "CORE" WEIGHT & HFRT

lb

 

14385.32

 

Kg

 

7121.45

TOTAL OD

ft

 

8.79

INTEGRATED

ELECTRONIC CONTROLLER INCLUDED

mm

 

2678.84

inches

 

105.47

TOTAL Length

mm

 

1076.77

INTEGRATED

ELECTRONIC CONTROLLER INCLUDED

inches

 

42.39

TOTAL WEIGHT       

lb

 

27939.30

INTEGRATED

ELECTRONIC CONTROLLER INCLUDED

Kg

 

13831.34

 

 

 

 

 

Inner Axle Outside Diameter

mm

 

979.00

 

inches

 

38.54

ft

 

3.21

 

 

 

 

 

Temperature Rise [7]

Seconds

 

2248.98

Ambient without active cooling

and at stall speed [7]

 

INTEGRATED

ELECTRONIC CONTROLLER INCLUDED

Temperature Rise

@ 2X Torque [7]

Seconds

 

575.69

 

Ambient without active cooling

and at stall speed [7]

 

INTEGRATED

ELECTRONIC CONTROLLER INCLUDED

Temperature Rise

@ 4X Torque [7]

Seconds

 

145.43

Ambient without active cooling

and at stall speed [7]

 

INTEGRATED

ELECTRONIC CONTROLLER INCLUDED

 

 

 

 

 

 

 


[1] Best Electric Machine designed the SS-EMS-2500-WT with our Best Electric Machine Computer Aided Design tool (BEM-CAD) based on approximate dimensions extrapolated from online images of Teslamotors induction motor. There are additional design requirements that have not been vetted, such as the compatible mounting frame, etc.

[2] Given the availability of materials, our intention is to manufacture amorphous metal cores or at least thin magnetic ribbon cores.

[3] Best Electric Machine Computer Aided Design tool (BEM-CAD) has been verified, which includes verification against existing electric machine systems, such as the Roadster's Induction Electric Machine System.  Although always outperforming cost-performance of any other electric machine system, some parameters of the production SS-EMS may vary upto 20% from the initial parameters calculated with BEM-CAD because of material substitution (e.g., to reduce cost), design compensation for cooling restrictions, etc.

[4] BEM chose the SS-EMS-2500-WT size because the larger size offers better standalone cooling potential at stall (i.e., zero) speed and ambient temperature.

[5] Port Voltage is based on the Roadster battery voltage as the de facto voltage for EV(s).

[6] SS-EMS-2500-WT efficiency includes electronic controller, core, and electrical losses but does not include friction losses or active cooling.

[7] Because of the symmetrical dual-ported transformer circuit topology, only SS-EMS can achieve maximum torque of more than eight times constant-torque.   But like any electric machine system operating at peak torque during EV acceleration or deceleration (for instance), efficiency is reduced under high current or maximum torque with the expectant temperature rise.  For equitable comparison with the competition, the 25o temperature rise time from ambient of 50o C without cooling and at stall speed with maximum torque is given. In consideration, a compact, low pressure, high efficiency active droplet cooling method based on variable ultrasonic nebulizer and variable speed blower combination is available from BEM that provides continuous operation at any torque.

 


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Note: The Radial Flux prototyping of the Advanced Brushless Wound-Rotor Synchronous Doubly-Fed Electric Motor Or Generator System is shown as our Icon, which predates the axial-flux SS-EMS Technology.

 

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