Forces in Big Synchronous Machines

7.
Forces in big synchronous machines
- Torque generation
- Radial forces at centric rotor position
- Single sided magnetic pull at eccentric rotor position
- LORENTZ forces on slot conductors
- LORENTZ forces on winding overhang conductors
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Prof. A. Binder : Large Generators & High Power Drives

7/1
Institut fr Elektrische
Energiewandlung FB 18
7. Forces in big synchronous machines

7.1 Torque generation
dF ( x) dI ( x) B ( x) l l A( x) B ( x) dx
d
d
dM ( x ) dF ( x) l A( x) B ( x) dx
2
2
p
M 2 p dM p d l
x
i )
A( x) A sin(
p
x
B ( x) B 1 sin( )
A( x) B ( x) dx
A k w1 2 A
M l ( p p ) 2 A B 1 cos i /
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7/2

Tangential thrust
M l ( p p ) 2 A B 1 cos i /
Se
M syn
cos i
ESSON: Se
Air gap thrust: Force per surface:
2
2
k w1 A B 1 d 2 l n Ce d 2 l n
F /(d si l )
A B cos i / 2
Example:
AC-machines: kw1 0.95, A = 700 A/cm, maximum thrust at:
A B cos i / 2 94000 1 1 / 2 47000N/m2 0.5 bar
In reality: cosi ~ 0.9, so thrust for AC lower by 10%: 0.45 bar.
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7/3

7.2 Radial forces at centric rotor position
B1 = 1 T:
2
B
f 1
20
12
2 4 10 7
400 103 N/m 2

B ( x) B 1 sin(
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B2 ( x) B21
f ( x)
2 0
4 0
2x
1 cos
p

7/4

Double-frequent stator vibrations in 2-pole synchronous
machines (100 Hz or 120 Hz)
Feet
Original
Deformation
Node
Suspension between stator stack and housing
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7/5

Core spring mounting
Suspension
between stator stack
and housing
Source:
Siemens AG, Mlheim/Ruhr, Germany
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7/6

Electromagnetic acoustic noise and vibration
Acoustic noise
- The stator iron may be regarded as a steel

ring, whereas the rotor is a steel cylinder.
- Therefore the stator is less stiff than the rotor
and is bent by the force waves.
Vibration
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- As the iron surface is shaken with this

frequency, the surrounding air is compressed
and de-compressed with frequency fTon. So
acoustic sound waves are generated with that
tonal frequency fTon to be heard by e.g. human
beings.

7/7

Deformation of stator yoke
2r = 0 : Stator surface oscillates in phase along
stator circumference, so far reaching sound
wave is generated.
With increased node number sound pressure
is equalized easier.
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7/8

Resulting radial force on a stator stack segment
- Force per pole sector :
stator stack
segment
F d l f av
p2
p2
1
4
sin(
2p
- With increasing pole count the

force per pole sector decreases !
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7/9

Example: Two-pole single phase turbine generator for German railways
50 MVA, 16 2/3 Hz, 1000/min. The stator iron stack is made of two halves.
Mass per stator halve: m = 150 tons
Stack length: l = 5.0 m,
stator bore (in the middle of air gap): d = 1.6 m
Yoke cross section: Ays,tot = 3.0 m2

magnetic yoke cross section (without cooling ducts): Ays = 2.4 m2
Fundamental amplitude of air gap and yoke flux density: B1 = 1.0 T, Bys = 1.67 T
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7/10

Forces at the separation line in the yoke
- Gravitation force:
Fm
mg 150000
9.81 736kN
2
2
- Magnetic pull: Pulsation with 2x16.7 =

33.3 Hz between 0 and:
2
B ys
1.67 2
Fy
Ays
2.4 2663kN
7
2 0
2 4 10
- Magnetic pull of the rotor: depending
on rotor position. Pulsating with 2n = 2f
= 33.3 Hz.
2
F d l f av
p2
12
1.6 5 199 10
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7/11
1
4
sin(
1 0.25
2p
sin( / 2) 2122kN

Resulting force at the separation line in the yoke
FN Fm Fys Fr 736 2663 1061 4460kN

The resulting force is 6-times (!) of the gravitational force.
Pressure on the insulation foil in the separation:
FN
4460 3
10 1487kN/m 2
Ays,tot
3
Note:
Tensile strength of steel St37: 3.7 MPa = 3700 kN/m2.
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7/12

Resulting force at 45 rotor position
Magnetic pull
Magnetic pull leads to tangential force Q at the separation,

and to a bending torque MB.
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7/13

7.3 Single sided magnetic pull F at eccentric rotor position
Minimum
air gap
location
Pull is directed
to minimum air
gap.
2p 4:
e 2
F
d l B 1
4 0
2p = 2:
d l B21
8 0
For two-pole machines the

single sided pull due to rotor
eccentricity is only 50% of the
value for machines with higher
pole count.
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7/14

Static and dynamic eccentricity
Minimum air gap location
Static eccentricity:
Dynamic eccentricity:
Minimum air gap location is fixed.
Minimum air gap location rotates with n.
Rotor rotates around displaced rotor axis.
Displaced rotor axis rotates with n.
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7/15

Two-pole machines: Pulsation of single sided magnetic pull
Single-sided pull:
At static eccentricity
NO single-sided pull:
At dynamic eccentricity
BA = BB
BA > BB
Radial force is pulsating between zero and F with f = 2n.
Pulsation is independent of static or dynamic eccentricity.
In case of dynamic eccentricity in d-axis direction the radial eccentricity force

vanishes.
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7/16

Example: Single sided magnetic pull for a salient pole synchronous machine
Four-pole hydro generator 1.12 MVA, rotor mass 1350 kg.
d si 0.555m, l 0.49m, B 1 0.90T, 7.5mm, e 0.6mm

Eccentricity : e / 0.6 / 7.5 0.08
- Single sided radial pull in direction of the minimum air gap:
e 2
F
d si l B 1
0.555 0.49 0.08 0.9 2 11013N
40
4 4 10 7
- Influence of iron saturation leads to reduction: here typically - 40 %:
F = 6 600 N
-Conclusion: Single sided magnetic pull: ca. 50% of rotor gravitational force:
6 600 N = ca. 0.5 x 1350xg = 0.5 x 13 240 N.
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7/17

Rotor bending natural frequencies
y
Vertical part of rotational bending oscillation:
-Lumped mass model: Rotor mass m, elasticity c:
mr y c y 0
Natural bending frequency:
1
c
fb
2
mr
Exciting centrifugal force due to static imbalance eS:

FU mr (2n) 2 eS
Vertical (y-)component):
FU , y FU sin( 2n t ) FU sin( m t )
Additional magnetic pull F due to dynamic eccentricity, caused by FU:

- Equivalent magnetic spring constant: k F / e
d l 2
B 1
4 0
The single sided pull reduces the natural bending

frequency:
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7/18
f b*
1
ck
2
mr

Salient pole generator
Turbine generator
1.12 MVA, 50 Hz, 2p = 4,

1500 / min
125 MVA, 50 Hz, 2p = 2,

3000 / min
B1 / T
0.7
0.8
d/l
0.555 m / 0.49 m
1.06 m / 5.6 m
/ mm
7.5
52.5
Rotor mass mr
1350 kg
47140 kg
Bending natural frequency fb
36.67 Hz ( 2200 /min)
18.17 Hz ( 1090 /min)
c / N/mm
71666
615088
k / N/mm
11105
22613
k/c
0.155
0.0368
Reduction of frequency
0.92
0.981
Static bending y
0.185 mm
0.75 mm
Static bending with pull y*
0.22 mm
0.78 mm
y*/
3%
1.5 %
Data:(f2*/f f) 2 m c / N/mm =
b
b b
Calculations:
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7/19

Influence of slotting on rotor bending in two pole machines
d
- Rotor stiffness in
d-axis bigger than
in q-axis due to
rotor slotting.
Axial slitting
- Rotor stiffness in y-direction varies with rotor position, hence with 2n.
- This leads to mechanical excitation of bending oscillation with 2n.
- Axial slitting of poles reduces d-axis stiffness; to be equal to q-axis stiffness.
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7/20
Finite element calculation of a two-pole rotor:

Bending and torsional deformations
Pole zone
Body centre
Body end
Slot zone
Finite element three-dimensional

model of ONE HALF of a two-pole
turbine generator rotor
Calculated torsional deformation:

Yellow/Red: Big torsion deformation
Blue: Small torsion deformation
Source: Alstom, Switzerland
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7/21

7.4 LORENTZ forces on slot conductors
Tangential force due to radial field of rotor
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Radial force due to slot leakage self field

7/22

Where is the tangential force localized ?
NOT at the conductor, but AT the tooth!
Tangential force per slot pitch:
F l Q B
Br 0 H d
Tangential force at the slot conductor: Ft l Q Br
Radial flux density in the slot:
Ft / F Br ,Q / B
Example: The force on the slot conductor is only 2% of the total force per slot pitch,
which mainly acts as tangential magnetic pull on the tooth side.
Ft / F Br ,Q / B 0.016 / 0.9 0.018 1 / 50

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7/23

Radial conductor forces hammer with 50 Hz on the slot
insulation
- Single layer winding, AC current:
QQ (t ) Q sin(t )
BQ (t ) 0
Q (t )
bQ
l 2
Fr (t ) l Q (t ) BQ (t )
Q sin 2 (t )
2 bQ
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7/24

Radial conductor forces hammer with 50 Hz on the slot
insulation
Peak pressure:
Q2
fr Fr /(bQ l ) 0 2
2 bQ
At sudden short circuit:
e.g. current is 12-times rated

current: 38 MPa !
- Single layer winding, AC current:
QQ (t ) Q sin(t )
BQ (t ) 0
Q (t )
bQ
l 2
Fr (t ) l Q (t ) BQ (t )
Q sin 2 (t )
2 bQ
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7/25

Double-layer winding: Radial hammering force is reduced
Single layer winding:
Double layer winding:
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7/26

1500 MVA, 4-pole turbine
generator, Biblis/Germany
Calculated amplitudes of
radial forces per axial length
on stator slot conductors, 27
slots per pole, qs = 9, ms = 3,
pitching W/p = 22/27
Fr/l
_ _ _ _ _ _ analytical calculation
_________ numerical calculation
Source: AEG, Germany
Stator slot no.

Pole pitch
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7/27

Calculation:
_ _ _ _ _ _ analytical
_________ numerical
Ft/l
1500 MVA, 4-pole

turbine generator,
Biblis/Germany
Calculated amplitudes of
tangential forces per
axial length on stator slot
conductors, 27 slots per
pole, qs = 9, ms = 3,
pitching W/p = 22/27
Stator slot no.
Pole pitch
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7/28

Monitoring of turbine generator stator wedges on-site
Wedge Tightness Carriage inspects

tightness of stator wedge; rotor is
removed (may also be in-situ).
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3D view of Carriage: Flexible

articulation of robotic carriage helps
access also in machines with narrow
axial clearances

7/29
Source:
Siemens AG,
Mlheim/Ruhr,
Germany

7.5 LORENTZ forces on winding overhang conductors
- LORENTZ forces between adjacent coil sides
- Attraction of coils sides of the same phase.
- Repulsion of coil sides of different phases.
- Extreme forces at sudden short circuit:

- e.g. 12 times rated current: 144-times of rated
forces.
0 L
F (t )
i1 (t ) i2 (t )
2 a
- L: length of conductor section
- a: distance between conductor centre lines
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7/30

Damage of winding overhang at phase separation after
sudden short circuit
Special fixations of the
winding overhang are
needed, especially in large,
two-pole machines !
Source:
BBC, Switzerland
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7/31

3D finite element model of stator end winding zone
Turbine generator

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7/32

Calculated four-node vibration mode of the stator end winding
Turbo generator
Calculated displacement grossly

exaggerated
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7/33

Generator end winding
modelling
3D finite element calculation of
end winding elliptical vibration
mode (4-node vibration mode)
Calculated displacement grossly

exaggerated
Source:
Siemens AG, Mlheim/Ruhr, Germany
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7/34
Large Generators and High Power drives
Thats all, folks !
I hope, you did enjoy it !
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7/35

Forces in Big Synchronous Machines

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7.

Forces in big synchronous machines

Prof. A. Binder : Large Generators & High Power Drives

7. Forces in big synchronous machines

Prof. A. Binder : Large Generators & High Power Drives

7. Forces in big synchronous machines

Air gap thrust: Force per surface:

Prof. A. Binder : Large Generators & High Power Drives

7. Forces in big synchronous machines

400 103 N/m 2

Prof. A. Binder : Large Generators & High Power Drives

7. Forces in big synchronous machines

Prof. A. Binder : Large Generators & High Power Drives

7. Forces in big synchronous machines

Prof. A. Binder : Large Generators & High Power Drives

7. Forces in big synchronous machines

- The stator iron may be regarded as a steel

- As the iron surface is shaken with this

Prof. A. Binder : Large Generators & High Power Drives

7. Forces in big synchronous machines

Prof. A. Binder : Large Generators & High Power Drives

7. Forces in big synchronous machines

- With increasing pole count the

Prof. A. Binder : Large Generators & High Power Drives

7. Forces in big synchronous machines

stator bore (in the middle of air gap): d = 1.6 m

Yoke cross section: Ays,tot = 3.0 m2

Prof. A. Binder : Large Generators & High Power Drives

7. Forces in big synchronous machines

- Magnetic pull: Pulsation with 2x16.7 =

Prof. A. Binder : Large Generators & High Power Drives

7. Forces in big synchronous machines

FN Fm Fys Fr 736 2663 1061 4460kN

Prof. A. Binder : Large Generators & High Power Drives

7. Forces in big synchronous machines

Magnetic pull leads to tangential force Q at the separation,

Prof. A. Binder : Large Generators & High Power Drives

7. Forces in big synchronous machines

For two-pole machines the

Prof. A. Binder : Large Generators & High Power Drives

7. Forces in big synchronous machines

Minimum air gap location is fixed.

Minimum air gap location rotates with n.

Rotor rotates around displaced rotor axis.

Displaced rotor axis rotates with n.

Prof. A. Binder : Large Generators & High Power Drives

7. Forces in big synchronous machines

In case of dynamic eccentricity in d-axis direction the radial eccentricity force

Prof. A. Binder : Large Generators & High Power Drives

7. Forces in big synchronous machines

d si 0.555m, l 0.49m, B 1 0.90T, 7.5mm, e 0.6mm

Prof. A. Binder : Large Generators & High Power Drives

7. Forces in big synchronous machines

Natural bending frequency:

Exciting centrifugal force due to static imbalance eS:

Additional magnetic pull F due to dynamic eccentricity, caused by FU:

The single sided pull reduces the natural bending

Prof. A. Binder : Large Generators & High Power Drives

7. Forces in big synchronous machines

1.12 MVA, 50 Hz, 2p = 4,

125 MVA, 50 Hz, 2p = 2,

Bending natural frequency fb

36.67 Hz ( 2200 /min)

18.17 Hz ( 1090 /min)