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I have a 5 kW axial flux alternator that is rated to 10 kW. At 1000 RPM the unit produces 5 kW. It produces 10 kW@1720 rpm and 15 kW@ 2000 while the amperage remains relatively consistent @16A.
During acceleration the phase frequency is accelerated too. Generally speaking, it moves from 50 Hz to 73 Hz at which point it peaks. To take advantage of the additional output power that higher RPM, a series of steps is required to 1st of all, re-stabilize the phase to 50 Hz and to subsidize the high watts back into 220 V segments. The components required to make this step and their specifications are my problem. I need to solve this phase issue. Do you have any knowledge of the solutions or know anyone who does? I would appreciate your reply to assist in this development.
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Using rectification of the alternators output current, I am achieving 1600 VDC. My goal is to invert this DC current into segments of 220 VAC output. Can you make suggestions as to how this can be done and what equipment is required? During this step down process phase control is also required. I’m looking for assistance to control this transition.
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I am looking for information about uneven loads on single phase power output from each phase of the generator. Uneven loads would be 220 VAC @ 32A maximum decreasing to inverting AC to DC for charging 12 VDC batteries. With the rise in interest of off grid power generation, these are base-level questions and processes that I would like to solve for easy implementation in a variety of configurations. Any assistance or suggestions would be greatly appreciated.
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I’m also interested in locating a technician that is skilled in BLDC motor controllers for programming load response into standard controllers, such as Fardriver. Any leads to such a person would be much appreciated.
To design this stuff from scratch is not the sort of thing that we would recommend unless you have an advanced degree in such specialized fields. These voltages and currents are highly dangerous, and beyond the scope of what we can support from an architectural design standpoint.
I would suspect that most of the issues you are dealing with are solved problems within the wind power generation market, and I would suggest looking for products from companies that specialize in producing products for such markets.
I have tried to work with the manufacturers of the (wind) generators in China but they are completely unwilling to help.
I had a zoom with a factory engineer and he denied that the unit can produce more than 5kw; (50Hz) when their spec sheet shows 10kw (68Hz) output specs. I asked if they did test to destruction and he said that they had not.
I have done 15kw trial successfully.(73Hz)
They will change the wire size of the stators only. This will improve the amps but the Hz issue remains. I feel that 73Hz to 50Hz is not a large margin and we should be able to regulate/automate a transition control method.
This is a limiting factor inside the AC system itself and it is restricting the output an independent producer can achieve.
If we solve this issue it could help many small producers to improve the output of their units.
What say you?
To reiterate what @David_1528 was stating what you are proposing is dangerous, support for which creates a liability on our end, and to be honest more complex than we can support.
From my somewhat limited knowledge of wind generation, there are two primary methods of producing a steady 50Hz or 60Hz output.
The first is to use a wind turbine that can strictly maintain a fixed rpm at the generator which natively produces the desired frequency. This would be accomplished by using a very sophisticated variable-pitch prop and/or continuously variable transmission to the generator which would then output the desired frequency. Additionally, to be connected to the grid, this would also somehow have to be synchronized with the grid’s phase as well as frequency. Otherwise, it would seriously damage the grid. As far as I know, only the giant units used by major power producers use such technology.
The second method is to first convert the voltage to DC with an active rectification system and then use an inverter to convert that back into AC at the correct phase and frequency. Both of these systems already exist commercially and one should never attempt to build one on their own, as it’s far too complex and dangerous for anyone other than experienced professionals to take on.
Regarding the output of your generators, it would not be advisable to exceed the load specified by the manufacturers of the products. At a minimum, it’s likely to shorten the life of the units, and at worst, could cause fires, etc. It’s conceivable that it could improve output in the short term, but if you have to replace the unit prematurely because it was overloaded, you’ll wipe out the savings you might have otherwise gained.
I’m assuming that the break-even time on such investments are in the multiple year range (likely 10+), so the real gain is in the number of trouble-free years of operation beyond that break-even point. Doing anything that jeopardizes the length of time your turbine remains operational without requiring expensive repair or replacement is probably not worth the risk.
