04 Rockwell HTS Motor

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Development of Ultra Efficient

HTS Electric Motor Systems2006 Annual Superconductivity Peer

Review MeetingWashington, DC

July 26, 2006

Rich SchiferlRockwell Automation

Chris ReyOak Ridge National Laboratory

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1600 horsepower, 1800 rpm Motor

Demonstrated in 2001

LargestMotor

Largest2nd Gen

HTSCoil

Motor

Rockwell Automation SuperconductingMotor Development

First investigation started in1987 with EPRI fundedproject.

Worlds first demonstrationsof HTS motors from 1990through 2005

7.5 horsepower, 1800 rpm Motor

Demonstrated in 2005

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Superconducting Motor Development

Technology DriversCompared to conventional high efficiency induction

motors, HTS motors will be . . .

more efficient (half the losses) lower in life cycle costs

$50,000 per year savings for 5000 hp motor due to

efficiency improvement smaller and lighter (half the volume)

Projected ApplicationsLarge motors: greater than 1000 hp

Pumps, fans, compressors

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Benefits of HTS Motors

About 1/3 of US electrical energy is

utilized by electric motors rated at 1000 hpand above.

Energy savings potential of HTS Motors inUS alone is $1 Billion per year

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Rockwell Automation SPI Program:

Research Topics for the Development of Ultra Efficient

HTS Electric MotorsProgram includes eight critical technology research tasks in twokey areas:

Total cost of ownership reduction (first cost reduction and

efficiency improvements) Alternate HTS motor topologies

Eddy current heating in air-core rotating machinery

Alternate HTS wire application issues

Second generation HTS conductor application Variable Speed Drive integration/shielding for HTS motors

Cryogenic persistent current switch for HTS field winding

Reliability improvement On-board refrigeration systems

Composite torque tube technology advancement

Coil quench detection and protection

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Armature

Heat ExchangerMotor Frame

Magnetic Shield

Nonmagnetic ArmatureWinding Support

Copper

Armature

Winding

Drive Shaft

ConnectionBox

Inverter

Cryogenic

Transfer

Coupling

CryocoolerHTS Field

Winding

Composite Torque

Tube Extension

Cold AC Flux Shield

Warm Vacuum Jacket

Coil Support Structure

Brushless

Exciter

Physical Air Gap

Superconducting Synchronous Motor

with HTS Field Winding

Rockwell SPI Phase 3 tasks address these components

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R k ll A t ti SPI P


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Progress has been made on all 8 tasks

Quench task results will be reported on, in

detail, here

Summary progress sheets are included atthe end of this presentation in thereviewers handouts


Research Topics for the Development of Ultra

Efficient HTS Electric Motors

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Task 6: Coil Quench Detection and Protection

Issue HTS coil quench during 1000 hp motor test resulted in coil failure Reliable quench detection and protection methods must be developed for

industrial HTS motors.

FY06 Planned Accomplishments

Verify quench models at lower temperature and issue report Demonstrate quench detection / prevention system during testing at ORNL

FY06 Accomplishments / Progress Quench testing completed on 1G HTS motor coils at ORNL at 30K

Quench phenomenon was found to be similar to 77K test results fromFY05 and matched models Quench detection and prevention system defined and verified Four technical papers will be published or presented on tests and models

FY07 Planned Accomplishments Task completed in FY06 2G characterization studies will continue under Alternate HTS Wire

Technology task.

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1000 hp motor HTS coil failure

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HTS Coil Quench: Definitions

Quench:A condition under which coil

voltage/temperature are observed to beunstable (e.g. they increase without boundin spite of constant coil current). Thisoccurs because the coil cooling system isunable to keep pace with the increase in

coil heating which occurs as the coiltemperature increases.

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HTS Coil Quench Observations from 77K

Tests in FY05 Typically quench in superconducting coils is thought of as the

propagation of a normal zone Especially for low temperature superconductors that are perfect

conductors This is considered a true quench and has been studied extensively for

HTS wire in the literature

In HTS coils the true quench is preceded by a phenomenon that wecall pre-quench instability which has two steps1. Slow increase in coil voltage and temperature that is almost linear vs

time. This may last for hours.2. Nonlinear rise in temperature and voltage. This may last 10s of

seconds. The pre-quench instability is, by far, more important for quench

detection and protection than the true quench. Quench detection must occur here

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Typical test results: constant applied current

Note: Entire test time shown is during pre-quench instability

Measured Coil Voltage200-hp Coil 2 Quench - Liqu id Nitrogen Cooling

1000

1200

1400

1600

1800

2000

0 200 400 600 800 1000 1200

Time [sec]

CoilVoltage[mV]

Linear region

Nonlinear region

Linear Fit of Early

Data Points

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Quench Detection and Protection

30 K Testing Goals

Match cooling conditions of HTS coils in motors Conduction cooled at 30 K

Verify expected voltage versus time response of HTScoil before and during quench event

Does it match what we saw with 77 K testing?

Does it match model results?

Characterize current induced quench and temperatureinduced quench (loss of cooling)

Complete testing on 200 hp and 1000 hp motor coils

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HTS Test Coils and Coil Test Fixtures

200 hp motor coil 1000 hp motor coil

CoilsMounted in

Test Fixturesfor 30 KTesting

2 coils mounted back-to-back Single coil tested at a time

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ORNL CRADAResults

Chris Rey

Oak Ridge National Laboratory

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1000 hp Status

Task Status

Thermal cycle testing 2 (complete)

Multiple-coils 2 (complete)

Quench tests Complete

Loss of Cooling test Complete

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Experimental Apparatus

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1000 hp Test Circuit

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1000 hp 77 K Quench Test

Ic

(1 uV/cm ~ 250 mV)

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1000 hp 30 K Quench Test, 172.5 A

(Stable)Ic

( 1uV/cm ~ 250 mV)

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1000 hp 30 K Quench Test, 172.5 A

(Stable)

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1000 hp 30 K Quench Test, 175 A

(Unstable)Ic

( 1uV/cm ~ 250 mV)

(> 5000 s)

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(Unstable) (> 36 K @ non-linear onset)

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1000 hp 30 K Quench Test, 180A

(Unstable)Ic

( 1uV/cm ~ 250 mV)

(> 600 s)

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1000 hp 30 K Quench Test, 180A

(Unstable)

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1000 h 30 K Q h T t


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(Terminal Voltage)Ic

( 1uV/cm ~ 250 mV)

(Stable)

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1000 hp 30 K Loss of Cooling


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1000 hp 30 K Loss of Cooling

Test, 140 AIc( 1uV/cm ~ 250 mV)

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1000 hp 30 K Loss of Cooling Test


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1000 hp 30 K Loss of Cooling Test,

140 A(Temperature)

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200 hp Status

Task Status

Thermal cycle testing 2 (complete)

Multiple-coils 2 (complete)

Quench Test Complete

Loss of Cooling Test Complete

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200 hp Experimental


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200 hp Experimental

Apparatus

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200 hp Test Circuit

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Ic(~ 60 mV)

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200 hp 77 K Quench Test 30 A


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(Unstable)

Ic(~ 60 mV)

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Ic( 1uV/cm ~ 60 mV)

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200 hp 30 K Quench Test 92 A


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(Unstable)

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200 hp 30 K Loss of


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200 hp 30 K Loss of

Coolant Test

CurrentOff

CryocoolerOff

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Summary


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Summary Conduction cooled (30 K) vs. bath cooled (77 K) gives

qualitatively similar features but vastly different quantitativevalues

Differences between a quench and a stable condition only ~

1-2 A apart Quench characteristics qualitatively similar between Bi-2223

wire manufactured ~ 5 years apart

Large temperature rise before quench Critical current Ic is an inadequate number for characterizing

quench & stability must be modeled based upon heating &

cooling Quench current based upon fundamental non-linear physics

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Quench Modeling

Rich Schiferl

Rockwell Automation

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HTS Coil Quench Event Modeling


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HTS Coil Quench Event Modeling

Goal: Determine the coil temperaturedistribution and terminal voltage as afunction of time to provide information for

quench detection and protection methods.

Include the following capabilities:

Current induced quench Loss of cooling induced quench Impact of localized defects in the coil

Current sharing between HTS and normalconducting stabilizer Applicable to any HTS conductors and coil designs

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Quench Modeling Results


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Quench Modeling Results

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200 hp coil test data Voltage vs Time

Coil vo ltage - 1000 hp Motor Coil - Simulated Results

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50

60

70

80

90

100

100 400 700 1000 1300 1600 1900 2200 2500 2800 3100 3400

Time,sec

Volltage(mV)

200-hp Coil 2 Quench - Liquid Nitro gen Cooling

1000

1200

1400

1600

1800

2000

0 200 400 600 800 1000 1200

Time [sec]

CoilVoltage[mV]

1000 hp coil simulation data Voltage vs Time

Linear region

Nonlinear regionTest Data Model Data

Model mimics test phenomenon quite well

HTS Coil Quench Event Modeling Method


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HTS Coil Quench Event Modeling Method

Input HTS wire characteristicsVoltage drop as a function of current, temperature,

magnetic field, magnetic field direction in the HTS

Solve the static magnetic field problem for theHTS coil to obtain magnetic field distributionthroughout the coil

Solve the transient thermal problem for a givenapplied current to obtain voltage and temperature

distribution throughout the HTS coil

Post process to obtain temperature and voltage vstime

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HTS Coil Quench Observations from


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HTS Coil Quench Observations from

Modeling Pre-quench instability is followed by the true quench. During the true quench, normal zone propagation

concepts can be applied

Both pre-quench and true quench periods are included inour quench models The same model is used

Quench detection must occur during the pre-quenchinstability region

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HTS Coil Quench Modeling Wire

Ch t i ti


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Characterization

Quench modeling requires mathematicalrelationships between coil voltage and current,temperature, magnetic field, and magnetic fielddirection.

If these relationships are simple enough, they

allow for model implementation and some closedform expressions for coil response during aquench.

The reduced temperature model has beendeveloped to simplify HTS wire characteristicrepresentation.

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Reduced Temperature Model for HTS

Conductor


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Conductor

Collapses multiple curves tosingle curve Works with 1G and 2G HTS

conductors Offers opportunity for dramatic

reduction in test data to fullycharacterize HTS wire

Critical Current Master Curve.

Focal curve is 0.1 T parallel field, focal critical current 125 amp.

0

50

100

150

200

250

300

350

0 20 40 60 80 100 120

Temperature, K

CriticalCurrent,amp

0.1 T, parallel

0.3 T, parallel

0.5 T, parallel

1 T, parallel

2 T, parallel

3 T, parallel

4 T, parallel

5 T, parallel

0 T

0.05 T, perpendicular


0.2 T, prependicular

0.3 T, prependicular



1 T, perpendicular

2 T, perpendicular

3 T, perpendicular

4 T, perpendicular

5 T, perpendicular

115 amp AmAC Critical current infuenced by

parallel and perpendicular magnetic fields

0

50

100

150

200

250

300

350

20 30 40 50 60 70 80 90 100 110

Temperature, deg.K

Criticalcurrent,

amp.

0 tesla

0.05 Tesla, perp

0.1 Tesla, perp.

0.2 tesla, perp.

0.3 tesla, perp.

0.4 Tesla,perp.

0.5 Tesla, perp.

1 Tesla, prep.

2 Tesla, perp.

3 tesla, perp.

4 Tesla, perp.

5 tesla, perp.

0.1 tesla, parallel

0.3 tesla, parallel

0.5 tesla, parallel

1 tesla, parallel

2 tesla, parallel

3 tesla, parallel

4 tesla, parallel

5 tesla, Parallel

Details are described in

upcoming technicalpaper

Data fromORNL

Reduced

TemperatureRepresentation

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HTS Coil Quench Technical Papers


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HTS Coil Quench Technical Papers

S. Umans & B. Shoykhet, "Quench in High-TemperatureSuperconducting Motor Field Coils: Experimental Results , IEEE,IEMDC Conference, May 2005 IEEE IAS Transactions, July 2006.

S. Umans, B. Shoykhet, J. Zevchek, C.Rey and R. Duckworth, "Quenchin High-Temperature Superconducting Motor Field Coils:Experimental Results at 30 K , Invited paper for the IEEE AppliedSuperconductivity Conference, August, 2006.

B.A.Shoykhet, S.D.Umans, Quench in High-TemperatureSuperconducting Motor Field Coils: Reduced-TemperatureModeling of HTS Tapes , IEEE Applied Superconductivity Conference,August 2006

B.A.Shoykhet, S.D.Umans, Quench in High-TemperatureSuperconducting Motor Field Coils: Computer Simulations andComparison with Experiments , IEEE Applied SuperconductivityConference, August 2006.

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Future ORNL CRADA Work


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Future ORNL CRADA Work

Second Generation Wire wire characterization tests

2G wire joints characterization performance vs. strain

2G HTS coil performance before and after

winding highly instrumented coil

winding mandrel topology and material investigation

Quench testing of 2G HTS rotor coil at 30 K

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Conclusions: Coil Quench Detection


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and Protection The quench phenomenon on HTS coils is now wellunderstood

Test results at 77 K and 30 K show similar characteristics

Time is available to detect the onset of a quench and preventdamage coils

A comprehensive quench model has been developed Utilizes wire characteristic (voltage) data over range of

temperatures, magnetic fields, and currents Simply represented using the reduced temperature method The quench model matches the observed quench phenomenon

from test A simplified model has been developed that predicts quench

current quite accurately A useful tool for use in coil design calculation iterations for HTS

machines

Model has been applied to 2G coils with success

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Conclusions: Coil Quench


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Detection and Protection

1000 hp motor coil that

failed was flawedFailure occurred at a

joint

This was a mechanicalfailure and not relatedto quench at all

No other tested coil had

this type of quench orfailure response Failed HTS Coilfrom 1000 hp

Motor

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Total cost of ownership reduction (first cost reduction andefficiency improvements)

Alternate HTS motor topologies Eddy current heating in air-core rotating machinery

Alternate HTS wire application issues Second generation HTS conductor application

Variable Speed Drive integration/shielding for HTS motors Cryogenic persistent current switch for HTS field winding

Reliabili ty improvement

On-board refrigeration systems Composite torque tube technology advancement


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Research Integration


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Research Integration National Institute of Standards and Technology (NIST)

Rotating (pulse tube based) cryocooler model development

SuperPower, Inc. Second generation HTS coil development and wire

characterization

Oak Ridge National Labs CRADA HTS coil quench testing and wire characterization data

FY06 results reported here FY07 plans concentrate on 2G wire, joint, and coil characterizationtesting as previously reported

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Total cost of ownership reduction (first cost reduction andefficiency improvements)

Alternate HTS motor topologies Eddy current heating in air-core rotating machinery

Alternate HTS wire application issues Second generation HTS conductor application

Variable Speed Drive integration/shielding for HTS motors Cryogenic persistent current switch for HTS field winding

Reliability improvement

On-board refrigeration systems Composite torque tube technology advancement


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Example from Appendix: Task Summary


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Task 1: Alternate HTS Motor Topologies

Issue Other motor topologies may offer improved performance over

HTS synchronous motors

Permanent magnet, induced flux, axial gap, all HTS, topologies should be investigated

FY06 Planned Accomplishments Complete design trade-off studies of permanent magnet (PM) vs

HTS content and issue report FY06 Accomplishments / Progress

Parametric design study of PM vs HTS motor conducted Preliminary results show PM motor is between conventional motor

and HTS motor in size and performance. FY07 Planned Accomplishments

Continue trade-off studies of PM vs HTS with various ratios

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Conclusions Ultra-Efficient HTS Motors


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Project tasks address key technologies for commerciallyviable HTS motors for industrial applications

Substantial progress made in HTS coil quench modeling and test characterization

ORNL CRADA has been instrumental

Sharing of research task data

Five technical papers presented or published in FY06

2G performance and cost targets Progress is being made on all tasks toward the future of

HTS industrial motors with 2nd Generation HTS field coils

Half the losses of conventional motors Project will be completed at the end of FY07 within

original budget.

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04 Rockwell HTS Motor