Although the recently wide propagated trend mainly known as digital twin is an essential step for optimal design and reliable functioning of large generators in the future, but no serious strategy and comprehensive study have been yet proposed. There is not even a standard description of this concept. This paper discusses the necessity and challenges of digital twin models of large renewable energy generators and introduces a comprehensive modeling strategy for developing a multi-domain live simulation platform of large generators for wind and hydro power plants.

Challenges of developing a digital twin model of renewable energy generators

Transverse flux permanent magnet (TFPM) machines are a potential candidate for direct-drive wind power application due to high torque and power densities. The operating principle of TFPM machines is firstly described with various topologies available in literature, with the placement of magnets as a criterion for the classification of TFPM machine topologies. This review includes characteristics, power factor improvement, cogging torque minimization, material consideration, modelling techniques, and scalability. Different wind turbine concepts with direct-drive machines, control techniques and power converter topologies are also considered in this paper.

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A Review on Transverse Flux Permanent Magnet Machines for Wind Power Applications

For applications with high torque demand, gearboxes are commonly used to convert torque and speed in order to receive higher specific values for torque and power. This causes additional losses, cost, inaccuracies, effort, and noise. Eliminating the need of a mechanical gear and the associated disadvantages, Transverse Flux Machines with their high torque density are a very promising alternative. Despite a high torque density and a high efficiency, these types of machines are not commonly used. Due to the complex structure, challenges with mechanical design, and modeling of the machine behavior arise. Additionally, there are high requirements for the inverter due to the low power factor. This paper provides an overview of the state of the art including the potentials and advantages but also the problems and hindrances of these types of machines. Relating to linear and rotary machines from research and industry, the machine is introduced with its history, application and classification. Further, the general technical aspects, the influence of materials for flux guidance, the methods of modeling, methods for a minimization of torque ripples, as well as methods for power factor improvement are presented. 

Transverse Flux Machine—A Review

This paper investigates a transverse flux machine (TFM) with regard to the simulation of the occurring iron loss over the full operating area and to the applied Maximum Torque per Ampere (MTPA) control strategy. Furthermore, a way to determine different torque-speed maps, which are used for the design process of a TFM or for the implementation of the control strategy in form of lookup tables, is presented. The simulated results are compared to measurements. Moreover, the potential of a Maximum Efficiency (ME) control strategy applied to the investigated TFM is estimated. It can be shown, that a combination of different loss calculation methods for stator and rotor domain is suitable. Furthermore, for the investigated machine, using the ME control strategy provides only slight improvements compared to the MTPA control strategy. Also, the expected torque-speed characteristics which are determined with the presented method are verified by measurements.

Investigation of Maximum Torque per Ampere and Maximum Efficiency Control Strategies of a Transverse Flux Machine

Electrically excited synchronous machines do not require expensive and temperature-dependent permanent magnets. Therefore they offer more safety, because there is no induced voltage when the excitation current has been turned off. For these reasons, electrically excited synchronous machines are getting interesting for different applications like electrical vehicles. For reaching higher torque and power density, an operation with high flux density is necessary. Hence, the behavior of the electrical machine is nonlinear. Through the possibility of varying the rotor excitation there is an additional degree of freedom for the determination of the operating point. For reaching high efficiencies at high speed, besides the copper losses, the iron losses have to be taken into account.Hence, this paper presents a method for calculating the iron losses based on nonlinear flux linkage maps. Based on this model, an efficiency optimized control strategy is introduced. The method is verified through measurements on the test bench and compared with the maximum torque per ampere control. The measurements show that the losses in partial-load operation can be significantly decreased, up to 20 %.

Applying a Measurement-Based Iron Loss Model to an Efficiency Optimized Torque Control of an Electrically Excited Synchronous Machine

In order to increase torque and power density, novel electrical machines with a 3D magnetic flux path are used. One of them is the transverse flux machine, which offers high torque at low speed and therefore is predestined for use as near-wheel drive in an electrical vehicle or as a joint drive for a robot arm. In contrast to typical machines, such as a synchronous machine, the magnetic flux has a component transverse to the radial plane. Additionally, the materials are highly saturated to achieve the high power density. The aim, beside high power and torque density, is to reach high efficiency. This is especially necessary for mobile applications with batteries, such as an electrical vehicle or a mobile robot. Hence, the losses have to be calculated during the machine optimization process in finite element analysis. Beside, the copper losses the iron losses have to be considered. For these reasons this paper presents a method to calculate iron losses in electrical machines with 3D flux path. Alternating and rotational magnetic fields are considered, as well as the influence of saturation. The computation method of iron losses is performed exemplary on a transverse flux machine. The results are compared with the measurements of the transverse flux machine on the test bench.

Loss Calculation for Electrical Machines Based on Finite Element Analysis Considering 3D Magnetic Flux

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Loss Calculation for Electrical Machines Based on Finite Element Analysis Considering 3D Magnetic Flux