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DTIC ADA496205: A Megawatt Power Module for Ship Service - Supplement. Volume 2: MatLab Simulink Simulation User's Manual PDF

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Preview DTIC ADA496205: A Megawatt Power Module for Ship Service - Supplement. Volume 2: MatLab Simulink Simulation User's Manual

Form Approved REPORT DOCUMENTATION PAGE OMB No. 0704-0188 The public reporting burden for this collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing the burden, to Department of Defense, Washington Headquarters Services, Directorate for Information Operations and Reports (0704-0188), 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA 22202-4302. Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to any penalty for failing to comply with a collection of information if it does not display a currently valid OMB control number. PLEASE DO NOT RETURN YOUR FORM TO THE ABOVE ADDRESS. 1. REPORT DATE (DD-MM-YYYY) 2. REPORT TYPE 3. DATES COVERED (From - To) 26-11-2007 Final 27-03-2007 --- 30-09-2008 4. TITLE AND SUBTITLE 5a. CONTRACT NUMBER A Megawatt Power Module for Ship Service - Supplement N00014-07-C-0361 Volume 2 5b. GRANT NUMBER 5c. PROGRAM ELEMENT NUMBER 6. AUTHOR(S) 5d. PROJECT NUMBER Herbst, John D. Gattozzi, Angelo L. 5e. TASK NUMBER Hebner, Robert E. 5f. WORK UNIT NUMBER 7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) 8. PERFORMING ORGANIZATION REPORT NUMBER The University of Texas at Austin, Center for Electromechanics RF280 Volume 2 10100 Burnet Road, Bldg 133 Austin, TX 78758-4497 9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSOR/MONITOR'S ACRONYM(S) Office of Naval Research ONR 875 North Randolph Street Arlington, VA 22203-1995 11. SPONSOR/MONITOR'S REPORT NUMBER(S) 12. DISTRIBUTION/AVAILABILITY STATEMENT Approved for Public Release; Distribution is Unlimited. 13. SUPPLEMENTARY NOTES 14. ABSTRACT This report is Volume 2 of a three volume Final Report on ONR Contract N00014-07-C-0361. Activities documented in this report were performed as a supplement to ONR Grant N00014-06-01-0886. The two programs address the use of energy storage and high speed power generation to reduce fuel consumption of DDG51 Arleigh Burke class ship service generation system by improving efficiency and permitting safe operation on one gas turbine generator set. In the event of turbine failure, the energy storage unit will provide power for critical loads until a second gas turbine generator set can be brought online. Volume 2 of the Final Report is a User's Manual for the high fidelity MatLab Simulink system simulation model. Volume 1 of the Final Report documents trade studies and preliminary design of the energy storage flywheel and associated motor/generator, the final system topology, high fidelity modeling and simulation activities, and top level platform integration issues. Volume 3 of the Final Report documents projected fuel savings, a preliminary interface control matrix, a ship installation study, and a technology development plan. 15. SUBJECT TERMS 16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF 18. NUMBER 19a. NAME OF RESPONSIBLE PERSON a. REPORT b. ABSTRACT c. THIS PAGE ABSTRACT OF Herbst, John D. PAGES U U U UU 65 19b. TELEPHONE NUMBER (Include area code) 512-232-1645 Standard Form 298 (Rev. 8/98) Reset Prescribed by ANSI Std. Z39.18 Megawatt Power Module for Ship Service Supplement ONR Contract N00014-07-C-0361 Final Report Volume 2 MatLab Simulink Simulation User’s Manual Submitted by: J.D. Herbst, A.L. Gattozzi, and R.E. Hebner RF 280 Center for Electromechanics The University of Texas at Austin 1 University Station, R7000 Austin TX 78712 January 2009 Contents Introduction.....................................................................................................................1
 Model Overview..............................................................................................................3
 Program inputs and the file RunXXX.m........................................................................6
 General Inputs ........................................................................................................6
 Inputs Specific to Program Elements......................................................................6
 Rolls-Royce AE1107 turbine model.................................................................6
 Turbine Generator Model...............................................................................10
 Quad Passive Rectifier...................................................................................15
 Quad Filter......................................................................................................17
 DC Bus, Quad DC-AC Converter with Filter, and AC Bus.............................19
 Flywheel.........................................................................................................27
 Flywheel Motor/Generator Model...................................................................30
 Controlled Rectifier.........................................................................................35
 DC Filter and Measurements.........................................................................38
 Field and SCR controller................................................................................40
 Field Balancing Controller..............................................................................49
 Flywheel Recharge Controller........................................................................51
 Flywheel Recharging Variable Frequency Drives (VFD)................................53
 Various Loads................................................................................................57
 Tables Table 1. MATLAB/Simulink version and modules used for the MPM simulation..............1
 Figures Figure 1. Overall Simulink model diagram .......................................................................2
 Figure 2. The file RunXXX.m in the simulation run directory that must be run before every simulation...................................................................................4
 Figure 3. The composition of the simulation root directory - this directory should never be changed...........................................................................................4
 Figure 4. Set of basic configuration parameters used for the simulation .........................5
 Figure 5. Block representing the high fidelity turbine model.............................................7
 Figure 6. Dialog box for input items of high fidelity turbine model....................................7
 Figure 7. First tier of high fidelity turbine model showing input data fed to core block................................................................................................................8
 i Figure 8. Second tier of high fidelity turbine model - lower level tiers give no additional information as the turbine model is proprietary to Rolls- Royce..............................................................................................................8
 Figure 9. Turbine RPM during initialization with constant load equal to THPLOADinit................................................................................................10
 Figure 10. Block representing the turbine generator shown between the turbine and the rectifier blocks..................................................................................11
 Figure 11. Dialog box for input items of turbine generator.............................................12
 Figure 12. First tier of turbine generator block showing the four independent PM generators (dark yellow blocks) with phase inputs (bright yellow blocks)...........................................................................................................12
 Figure 13. Second tier of turbine generator model showing the internal structure of each component PM generator.................................................................13
 Figure 14. Typical output of turbine generator into a resistive load................................14
 Figure 15. Quad passive rectifier and quad filter blocks following downstream the turbine generator block...........................................................................15
 Figure 16. Dialog box for input items of quad passive rectifier - these items are rarely changed..............................................................................................15
 Figure 17. First tier of quad passive rectifier - the individual diode rectifiers (blue) are native Simulink blocks, thus no further tiers are accessible, white blocks are for measuring currents.................................................................16
 Figure 18. Typical voltages input to the turbine generator rectifier and from it output into a resistive load............................................................................17
 Figure 19. Input dialog box of quad filter........................................................................17
 Figure 20. Structure of the quad filter.............................................................................18
 Figure 21. Diagram of individual T-type filter within the quad filter.................................18
 Figure 22. dc bus, quad dc-ac converter with filter, and ac bus - White blocks are used for measurements and bright yellow blocks are ideal breakers whose switching times are settable...............................................19
 Figure 23. Input dialog box for the quad dc-ac converter with filter................................20
 Figure 24. First level of quad dc-ac converter with filter.................................................20
 ii Figure 25. Input dialog box for one of the IGBT bridges - once determined, these rarely need to be changed............................................................................21
 Figure 26. circuit diagram of one of the output filters of the quad dc-ac converter ........21
 Figure 27. Structure of PWM controller of Figure 24......................................................22
 Figure 28. Dialog box for voltage regulator block in Figure 27 - the values shown (affecting the PI block in Figure 29) have been proven to give the best results, thus, normally they should not be changed..............................23
 Figure 29. Internal diagram of voltage regulator block shown in Figure 27 - although the PLL and the PI blocks (both bright yellow) have input dialog screens of their own, it is not necessary or advisable to change them.................................................................................................23
 Figure 30. AC bus voltage as load current is stepped up from initial no-load................25
 Figure 31. AC bus total voltage RMS (blue) and fundamental voltage only (green) as load current is stepped up from initial no-load. Blue and green traces overlap, indicating minimal harmonic contents. Total harmonic distortion (THD) is shown in red times a factor of 100 for scaling purposes. Thus, ignoring the initial settling transient (t < 0.2 s) the THD is always less than 4%. Actual simulation readouts are also shown above.................................................................................................26
 Figure 32. Detail of ac voltage waveform at the current transition point t = 0.4 s...........27
 Figure 33. One of the two flywheels in the simulation circuit with its motor/generator............................................................................................28
 Figure 34. Dialog box for flywheel data input.................................................................28
 Figure 35. First level of flywheel showing flywheel block proper (dark yellow) and blocks calculating the equivalent electrical power put into or extracted out of the flywheel. The step function block in bright yellow is the time when the power flow changes sign due to flywheel re-charging...................29
 Figure 36. Internal structure of the flywheel block proper (dark yellow in Figure 33). The calculation of the flywheel speed is done by integrating the ratio torque/inertia. The input variables from the dialog box of Figure iii 34, flywheel inertia and initial speed, are used in the bright yellow blocks shown here........................................................................................29
 Figure 37. Input dialog box for the flywheel motor/generator modeled in the rotor dq frame of reference....................................................................................31
 Figure 38. First level structure of flywheel motor/generator. The machine is modeled as a standard Simulink wound field synchronous machine (dark yellow block) with three measurement blocks (white)..........................31
 Figure 39. Pre-filled dialog box of synchronous machine shown in Figure 38 - these inputs should never be changed.........................................................32
 Figure 40. Details of both measurement blocks shown in Figure D33 - the artificial resistive load for the flywheel motor/generator needed for computational stability is visible in the lower block.......................................33
 Figure 41. Output of flywheel generator at input to controlled rectifier...........................34
 Figure 42. Active rectifier (blue), filter (purple), measurement block (white) and breaker (bright yellow) connecting the 3-phase output of a flywheel motor/generator to the dc bus.......................................................................35
 Figure 43. Dialog screen for the SCR controlled rectifier block......................................36
 Figure 44. First level diagram under the SCR controlled rectifier block - the SCR bridge proper is the blue block and the firing angle controller is the cyan block.....................................................................................................36
 Figure 45. Dialog box for the SCR bridge in Figure 44 - once determined, these values need rarely be changed.....................................................................37
 Figure 46. Diagram of the level beneath the firing controller block - all blocks shown here are native Simulink blocks, the pulses here generated are used to fire the SCRs in the rectifying bridge.........................................37
 Figure 47. Dialog input screen for the DC filter..............................................................39
 Figure 48. First level structure (top) and second level structure (bottom) for the dc filter..........................................................................................................39
 Figure 49. Rectified voltage output of controlled rectifier (blue) and of filter (green)..........................................................................................................40
 iv Figure 50. The flywheel control blocks: the field and SCR controller, the field balancing controller between the two flywheels, and the flywheel re- charge controller...........................................................................................41
 Figure 51. Input dialog box for the field and SCR controller block.................................41
 Figure 52. First level structure of the field and SCR controller block .............................42
 Figure 53. Second level of field and SRC controller block: voltage loop........................43
 Figure 54. Second level of field and SCR controller block: current loop........................43
 Figure 55. Voltage loop flow chart, part 1 of 2................................................................44
 Figure 56. Voltage loop flow chart, part 2 of 2................................................................45
 Figure 57. Current loop flow chart..................................................................................46
 Figure 58. Control action flow chart................................................................................47
 Figure 59. Input dialog box of field balancing controller.................................................49
 Figure 60. Structure of field balancing controller............................................................49
 Figure 61. Flow chart of field balancing controller..........................................................50
 Figure 62. Structure of flywheel recharge controller.......................................................52
 Figure 63. VFD circuit used for recharging a flywheel. The VFD is the bright light blue block. The purple rectangle within it indicates that the block has a filter incorporated within it. The VFD interfaces to the dc bus and to the HIA machine via circuit breakers (bright yellow blocks)..........................53
 Figure 64. recharging VFD dialog box............................................................................54
 Figure 65. First level structure of VFD block..................................................................54
 Figure 66. Second level of the VFD: structure of PWM controller - the shaded area is where it differs from that of the dc-ac controller (compare with Figure 27)......................................................................................................55
 Figure 67. PLL block modification (highlighted) to allow starting at an arbitrary frequency and ending at the maximum frequency........................................56
 Figure 68. Resistive loads (e.g. lighting). 0.135 Ohms were used in preliminary runs, equal to 1.5 MW each..........................................................................57
 Figure 69. Bottom: 100 HP induction motor started across the line with load torque, applied at predetermined time (e.g. positive displacement v pump), Top:200 HP induction motor started across the line with load torque applied as a ramp (soft start).............................................................58
 Figure 70. 200 HP induction motor with square law torque load (e.g. centrifugal pump) started via a variable frequency drive much like the one described in the previous section for recharging the flywheel......................58
 vi Introduction The MATLAB Simulink simulation model of the Megawatt Power Module is a deliverable under ONR contract N00014-07-C-036. This document serves as a User’s Manual for the simulation, providing descriptions of the various operator inputs and how to modify and execute the simulation. The Simulink model for the MPM was developed and run on a desktop personal computer with Microsoft XP operating system and 2.0 GHz of clock speed. The latest MATLAB/Simulink version and modules used for the MPM simulation are listed in Table 1. The overall model schematic is reported in Figure 1. Table 1. MATLAB/Simulink version and modules used for the MPM simulation MATLAB Version 7.6.0.324 (R2008a) Operating System: Microsoft Windows XP Version 5.1 (Build 2600: Service Pack 2) Java VM Version: Java 1.6.0 w/ Sun Microsystems Inc. Java HotSpot™ Client VM mixed mode MATLAB Version 7.6 (R2008a) Simulink Version 7.1 (R2008a) Control System Toolbox Version 8.1 (R2008a) Curve Fitting Toolbox Version 1.2.1 (R2008a) Real-Time Workshop Version 7.1 (R2008a) Signal Processing Blockset Version 6.7 (R2008a) Signal Processing Toolbox Version 6.9 (R2008a) SimPowerSystems Version 4.6 (R2008a) Simulink Control Design Version 2.3 (R2008a) Symbolic Math Toolbox Version 3.2.3 (R2008a) 1 Figure 1. Overall Simulink model diagram 2

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