Design and Simulation of a Stand-alone Wind-Diesel Generator with a Flywheel
Energy Storage System to Supply the Required Active and Reactive Power.
I.J. Iglesias, L. Garcia-Tabares and A. Agudo.
Centro de Estudios y Experimentacion
de Obras Phblicas (CEDEX).
CiAlfonso XII.3 280 14 Madrid.SPAIN
Abstract-This paper presents the design and simulation of a
stand-alone generation plant, which combines a wind-diesel
generator with a flywheel energy storage unit. Without any
storage system, the diesel engine has to be continuously
operating, resulting in high fuel consumption. The flywheel is
designed to supply the rated power during 1.8 minutes. This
time is enough to compensate regular wind oscillations and
therefore to avoid a high number of motor diesel starting
operations. The Mnetic energy storage unit is based on a carbon-
fibber composite flywheel rotating at 30.800 rpm and storing 4.5
MJ. The rotating system is driven by a Switched Reluctance
Motor and connected to the network through a double Voltage
Source Inverter. The design and simulation with SABER@ of all
the complete system is presented in this paper
I. INTRODUCTION
This paper presents the design and simulation of a
Wind-Diesel generation plant with a kinetic energy storage
unit. This generation plant is conceived to supply electric
power to an isolated load not connected to the electrical
network. The main power generation system consists on a
wind asynchronous squirrel-cage generator. The reactive
power is supplied initially by a Diesel-Synchronous
Generator unit, which maintain the voltage supplied to the
isolated load. In the first designs of this kind of systems [ 11,
the Diesel motor supplies the active power demanded by the
load during a decreasing of the input wind power. This
implies that the diesel motor has to operate in a continuous
mode, resulting in high fuel consumption. The main objective
of this project consists on reducing the fuel consumption by
including a Flywheel or kinetic storage system, which
permits the switching-off of the diesel motor. This storage
system is capable of supplying the necessary active (and
reactive) power demanded by the load when the
asynchronous wind generator is not able to produce it. The
storage unit can act as a damper of the wind power
oscillations and allows the plant to be in operation without
the extra generation of the diesel motor. The rated power of
the first prototype will be 50 kW. For this power rate. the
kinetic storage unit to be implemented will store an energy of
4.5 MJ (1.25 kWh), based on a Flywheel rotating at 30.000
r.p.m., which is able to supply the rated power during 1.8
minutes. This is in principle enough to compensate regular
wind oscillations and therefore to avoid a high number of
motor diesel starting operations [2,3].
The kinetic storage unit is driven by a Switched
Reluctance Motor (SRM) of three phases and two poles. This
motor has been chosen due to its simplicity and robustness,
very appropriate for this kind of high-speed application. A
I. Cmz and L. Arribas
Centro de Investigaciones Energeticas, Medioambientales
y Tecnologicas ( Ciemat). Madrid. SPAIN.
double VSI converter connects the motor to the network:
First, an asymnetrical half-bridge topology has been selected
to drive the SRM, with two IGBTs and two diodes per phase.
Although this is the most expensive option, this is the most
flexible, and allows exploiting the full potential of the SRM.
A standard Voltage Source lnverter with variable hysteresis
current bands connects the drive to the network injecting the
required active and/or reactive power.
This paper presents the design and simulation of the
whole system by means of SABER@ simulator. First, the
kinetic storage system has been simulated by modelling both
the motor and the network side converters, the SRh4 (with a
template written in MAST, the HDL language provided with
SABER), the rotating flywheel and the control system based
on maintaining the DC capacitor voltage. Second, the
complete wind-diesel generator has been simulated with a1i
the elements working together: the asynchronous wind
generator, the diesel-synchronous generator group, the lunetic
storage unit and the complete control system which maintain
both the frequency and the voltage of the isolated network.
11. OVERALL SYSTEM CONFIGURATION
Figure 1 shows the ovcrall systcm configuration with
the asynchronous directly coupled wind-generator, the
Diesel-Synchronous generator unit, the Flywheel Storage
System and the load. A set of discharge resistors are also
included to dissipate thc cxtra input cncrgy whcn the storage
unit is fulfillcd and tliercforc it is not ablc to store morc
energy.
Asvnchmnous Generator
- .-.
... ..
..
Figure 1 . Overall System Configuration
 I1 KINETIC
ENERGY
STORAGE
SYSTEM
As a first stcp. a flywhecl prototypc has been designcd in
order to test its mechanical behaviour [4,5]. The main
characteristics of this flywheel are the following: Stored
energy: 0.6 kWh. Dimensions: ~ 1 5 mm. 4 R = 290 mm. L =
290 mm. Carbon Fibber mass: 12 Kg. Rated spced: 30.000
rpm
This flywheel rim has been designed with different
materials depending on the requirements of specific parts:
Isotropic inaterial as steel used to make the cylinder-
drum. both lads and hub.
0 Anisotropy material (extremely unidmctional and high
strength material), as composites winding on the
cylinder-drum. This is a hybrid design with two layers or
rings of different composite material in order to achieve
higher radial strength. Inncr ring: glass fibber and
polycstcr. Outcr ring: carbon fibbcr and epoxy rcsin.
This flywheel is proposed as a prototype 111 order to make the
spin test on it. Figure 2 represents the output of the rim
dynamic analysis based on FEM simulation. It represents the
stress map in thc tlywhecl, simulatcd spinning over 30,000
r.p.m. It is possiblc appreciatc the strain suffercd by thc
flywheel at high rotational speed. (It is remarkable
deliberately that the strains are exaggerated. in order to get a
better visual understanding).
tigure 2 Flywheel F t M simulation
B. Switched Reliictunre Motor
This kind of motor has been sclected mainly for two
reasons: First, the high speed and the difficulty to extract the
generated heat in the rotating parts (rotor will be in a vacuum
atmosphere), discard those motors with induced rotor
currents or with brushes. Second, thc cost of a SRM is
smaller than a Permanent Magnet Machine. and in this
project the cost impact of the kinetic unit over the complete
plant cost can bc unacccptablc and thercfore has to be
carcfully analysed. Both kind of machines can accomplish
with the required specifications, but the simplicity, robustness
and less cost of the Switched Reluctance Motor have been the
main reasons to be selected.
This motor has bcen specifically designed for this
application and it is now under construction at CIEMAT
facilities. In order to achieve high speed. a configuration with
0-7803-5692-6/00:$10.00(c) 2000 IEEE 1382
thrce stator poles and two rotor poles was sclccted, a
compromise to obtain high rotating speed with a relatively
low switching frequency and moderate torque ripple (61.
A new winding technique has been used based on the
concept of double pancake coils. This procedure uses a
spccial winding machine with two spools rotating in opposite
directions allowing a fast and precisc manufacturing of the
coils which can also be wound with spatial curvature (instead
of being flat) so that they can almost fill the space betwcen
stator polcs, thus allowing a very high filling factor and also a
high power density.
The electromagnetic design of the motor was carried out
using a standard finite element code, which basically
providcd thc polar inductance as a function of thc position,
taking into account iron saturation. This dcpcndencc was
introduced into the MAST model to simulate the machine
with the SABER simulator.
Main parameters of the machine are shown in table I:
Maximum Power I50 kW
Maximum Torque 115.9"
Active length [ 100"
Number of turns per pole I 40
Table I. Main Parameters of the SRM
Previous to this prototype, a 2 kW unit was built and
tested to validate some of the concepts involved in the design
of this type of machine, specially, those related to the
winding proccdure. Figurc 3 depicts thc winding machine
while winding a coil oftlie demonstrator.
Figure 3 . Winding machine for the SRM.
C. Power Converter. Desigil and siniulatiori.
Figure 4 shows the schen~aticsimulated in Saber with
the SRM model, and the power electronics converter. This
converter is composed by two parts: The motor side converter
presents a half-bridge topology with two IGBTs and two
diodes per phase. this topology allows the SRM to operate as
a motor and a generator with a total symmetry between these
two modes of operation. The network side converter is a
 Fig. 4. Saber Schematic of the SRM Drive.

cowent ionaI h y steresi s-bands current controlled V SI capable decreasing is slower and permits a lower switching frequency
of injecting or absorbing both active and reactive power into to maintain the current close to the reference value.
the network. The same soft-switching technique can be applicd in thc
C-i.Switched Relicctatice Motor Side Converter generator operation. Firing-off both IGBTs --v&volts are
Figure 5 and 6 show some results of the SRM applied to decrease the phase current, and firing-on only one
simulation. Figurc 5 represcnts thc current supplicd to one IGBT 0 volts are applied causing a phasc currcnt increasing.
phasc by the motor side converter in the motor operation. The pulsc current has to bc maintaincd during thc
This pulsed current generates a motor torque given by increasing ramp inductance (60") for the motor operation and
equation: during the decreasing ramp (60") for the generator operation.
T = m1aeJ.r ,yi On and off angles have to be calculated to obtaining the
maximum torquc for a given currcnt pulsc amplitude.
To maintain constant the current a PWM techniquc is Simulations with Saber have been v c N usehl to calculate
applied to the IGBTs [7]. Two different modulations are such angles, because an analytical calculation of these is very
possible: the "hard switching" and the "soft-switching". In complex. By varying the firing time in several simulations
both types to increase the phase current all the DC voltage + the optimum on and off angles have been obtained. These
v d c is applicd to thc motor phasc by switching-on both upper
values, which h a w becn adjustcd by a polynomial function of
and lower IGBTs. However, to decreasc the phasc current the rotor spced, will be stored in a DSP to control thc SRM
there are two possibilities: 1 ) Switching-off both IGBTs inverter. Figure 6 shows the total torque aid the one-phase
causes the current to flow through the power diodes and torque when the machine is working as a motor. It can be
applying -Vdc volts to the motor phasc (hard-switching). 2) observed that in the decreasing current ramping a negative
Switching-off only one IGBT causes the current to flow torque (generator) appears, reducing the total average torque.
through the other IGBT and its corresponding power diodes By this reason is very important a carcfully adjustment of thc
and applying 0 volts to the motor phase (soft-switching). This off angle for the motor operation, and in the same way, an
second strategy has becn sclccted because the currcnt adjustment of the on angle for the generator operation [8].
................................... ...................

..... .................................................................................................

............................................
> . ,. . . , ,,

Figure5 SRM phase motor current. Motor operatmn Figure 6. Total torque (red) and one-phase torque (green)
Soft-swtching technique

1383
 Thc SRM inverter is controllcd in a very simple way:
First, the switching angles are stored in a Digital Signal
Processor to generate the switching times according with the
rotor speed. Second. the current pulse amplitude is obtained
from a PI control loop where the main objective is to
maintain thc DC voltage close to the nominal value. A
dccrcasing of this voltagc in thc motor operation will causc a
decreasing of the current amplitude reference, however a
decreasing of DC voltage. in the gcnerator opcration, will
cause an increasing of thc currcnt amplitude rcfercncc. The
change between the two niodes of operation (motor and
generator) is based on a hysteresis band around the rated DC
voltage. For example, if the SRM is working as a motor and
thc DC voltage dccrcases below the lower limit band, it will
change to the gcnerator mode to recover thc DC voltagc
inside the hysteresis band values. Thus the DC voltage is
used to balance the power between the network inverter and
the SRM inverter. Figure 7 shows the block scheme of this
control.
Fig. 7. ContTol ofthe SKM inverter.
C-2. Network Side Converter
Thc nctwork side converter is a hysteresis-bands
current controlled VSI as shown in figure 1. This converter is
capable of injecting the active and reactive power demanded
by the control system of the whole plant. The connection
betwecn the power injected by this convcrter and thc power
supplicd to the Flywhecl is done by means of controlling thc
DC voltage into a band around its rated value as explained
before. Figure 8 shows the current supplied by the inverter
during a change from motor to generator mode.
3 .A.
~ . . ., .
J J
Fig. 8. Current supplied by the Hysteresis-band current coiltrolled input
inverter (red). Line voltage (black). Current THD= 3%.
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111. EXPERIMENTAL
RESULTS OF THE FIRSTSRM PROTOTYPE.
A first prototype of the Switched Reluctance Motor
Drive has been developed and constructed at CEDEX Labs.
Figure 9 shows a photograph of the motor and the IGBTs
converter. This figure also shows thc system dcvelopcd for
measuring the specd and position [9], .m order to avoid the
implementation of a digital encoder capable to work lip to
30.000 rpm. This system is based on a disk with threc slots,
threc photodiodcs and threc phototransistors to detect the
change between each 60" sector. A high frequency intemal
clock serves to detemiine the exact position, by counting the
pulses after each change of sector and with the assumption
that in a high incrtia system, the spced variation betwcen one
sector and the following is vcry small.
Fin9. First Lab SKM Prototwe.
The main characteristics of this prototype are shown in
table 11.
Stator outer radius
Table 11. SRM Prototype Characteristics.
- . .
I
First tcsts of this prototype have bcen developed at
CEDEX, to check the behaviour of all the electronics
systenis. Figure 10 shows the current supplied by tile power
1384
convcrtcr to the SR motor while this prototypc is running at
3 100 rpm.
mt”,iMW*IXw
Fig I O First Lab SRM Prototype Curreiit supplied to
three phases of the motor and optical sensor signal
Iv. SIMULATION OF THE COMPLETE SYSTEM
In order to test the behaviour of the coniplete system
and the ability of the Kinetic Storage Unit (KSU) to
compensatc wind oscillations, a completc simulation h a w
becn carricd out with Saber@. Figure 1 1 shows the schematic
of all the complete system including not only the kinctic
storage unit but also the whole wind-generation system: the
wind asynchronous generator, the sclf-excited synchronous
gcnerator driven by thc diesel-motor, thc isolatcd nctwork
and the discharge resistors. Both the synchronous and
SYNCHRONOUS GENERRTOP
W I N O RSYNCHRONOUS GENERRT
Fig. 1 I . Complete System Simulation. Saber Schematic.
asynchronous generators have been simulated by means of
two models written in MAST language and based on the d-q
model of the electrical machines.
The developed simulation consists mainly on a starting
process in the following manner: 1 ) Diesel-Synchronous
Generator unit connection to create the isolated network. 2)
Connection of the asynchronous wind generator. 3 )
Disconnection of the Diesel Engine and connection of the
KSU to maintain both the ftequency and the voltage of the
network. 4) Sudden increase of the load to test thc ability of
the KSU to supply the required power necessary to maintain
the network parameters. 5) Sudden increase of the input
power to check the ability of the KSU to store the extra
power, or in the case when the KSU is full and it is not able
to store more energy, the extra energy will be dissipated in
the discharge resistors.
Figure 12 depicts the first case of a variation of
frequency when the asynchronous wind generator is
connected at 200ms (first spike in the curve) and when an
increment of the load occurs at 1.5 s (second spike in the
curve). Before this time, there is no any external load and tlie
wind turbine is generating a power of 30 kW, therefore the
kinetic unit is storing energy. At 1.5 s a 50 kW external load
is connected, while the input wind power remains constant at
30 kW. 111 this case the kinetic unit has to supply the
additional power and it begins to work as a generator. It can
be observed that such high increment of the load only gives a
variation of thc frequency up to 49.85 Hz. This small
decrease is due to the fast response of the kinetic unit.
 be dissipated into the discharge resistors and two diff’erent
1 . . . . . . . . . . . ,. . . . , . . .
I strategies can be adopted: The classical one consists on
. . = ... limiting the maximum frequency value and connecting in a
. . . . . ,... ...,.. ~ , . ~ . discrete foini the resistors by means of solid-state relays. The
second option, only possible in the case when a KSU is
implemented consists on a chopper connected to the DC link
of the SRM inverter. In this case, the power can be
continuously dissipated to the discharge resistors and
therefore the frequency can be continuously regulated around
its nominal value as it is shown in figure 14.

V. CONCLUSIONS

Fig. 12. Frequency control for a network A complete simulation of a wind-diesel generation
load 130 kW) sudden variation. plant with a flywheel cnergy storage unit has bcen
developed showing the ability of the Kinetic Storagc
Figure 13 shows a detail of the network voltage and the Unit (KSU) to conipensate the wind power
current supplied by the KSU in the same case. It can be oscillations.
obscrved as at 1.5 s. power factor varics from 1 to -1 The KSU is able to supply both active and reactive
showing thc motor to gencrator transition of the SRM. power to compensate both the frequency and the
Current change its phase from 0“ to 180” in one cycle. voltage of the network. This unit is dcsigned to
supply the total power during a period of 1.8 rmnutes.
A 50 kW. Prototypc is now under construction
including the Flywheel, the Switched Reluctance
Motor and the Power Convcrter.
Simulation and design of the powcr convertcr have
been carried out and dcnionstratc the good behaviour
of this system in the followiiig aspects: I ) Low
harmonics level injected iiito the network, 2 ) Very
fast response time to compensate transient
phcnomcna and 3) Ability to dissipatc the cxtra
encrgy into the discharge resistors by mcans of a DC
chopper, keeping the network frequency very close to
its nominal value.

REFERENCES

I. Ray Hunter & George Elliot (1994) “Wind Diesel Systems. A Guide to
the Technology and its Implementation”. Edited by Cambridge
Finally, figure 14 shows the frequency when a sudden University Press.
2. Bilkis, C.E. (19%) “Batteries for the 21“ Century: Composite
increase of the input wind power occurs and the KSU is not Flywheel” Engineered Materials and Systems, Pensilvania State
able to store more energy. In this case the extra power has to University.
3. Grudkowski. T.W., Dennis. A.J. Meyer. T.G.& Wavmonek, P.13.
(1096) *‘ Flywheel for energy storage” SAMPE Joumal Vol. 32 N” 1, p.
,
“...........-... . . . . . .,ll”l.ll 65-69.
4. Ha, S.K...Choi, S.K., Kim, D.J. & Clin, L..I. (1999) “Stress Analysis of
a Hybrid Flywheel Rotor Using a Modified Generalized Stress
Assumption” XI1 ICCM, Paris.
_
5 . Ha S.K..,Kim, D.J. & Choi, S.K. (1999) ‘. Optimal Design of an
Hybrid Composite Flywheel Rotor Using Finite Element Methods”
Intemational SAMPE Symposium, p. 21 19-1169.
6. Cossar C. & Miller T.J.E. (1992) Electromapetic Testing of Switched
Reluctance Motors. International Conference on Electrical Machines.
Manchester, September 15-17, pp470-474
7. Miller. T.J.E. (1993) “Switched Reluctance Motors and their control”.
MaLma Physics Publishing & Clarendon Presss. Oxford.
8. Bass .T.J. Bass, Ehsani. M & Miller. T.J.E. “Robust Torque Control of
Switched Reluctancer Motors without a shalt position sensor”, IEEE
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!!.!i.!~..-rr__”-___..::_:_- ................................................... 9. Ehsani. M. Husain,I, Ku1kami.A.B.. “Elimination of Discrete Position
Sensor and Current Sensor in Switched Reluctance Motor Drives”
Fig. 14. Frequency variation in a sudden increase of the input wind lEEE Trans. on Indus. Applic. Vol28, Jan 1992, pp 128-135
power. .External discharge resistors (blue) or intemal discharge
resistors (red).

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