Ultra-Compact Electrical Machines for Wind Energy DE-FOA : Demo Machine C. L. Goodzeit and M. J. Ball May 1, 2014 General List of Tasks by Performance Period (stage) and Institution General List of Tasks by Performance Period (stage) and Institution 5/1/2014 V11 Project is 18 months total, with 3 stages of 6 months each. Participating Institutions are Fermilab (FNAL) as principal, for ~60% of effort Brookhaven (BNL) for ~32% of effort Florida Institute of Technology (FIT) for ~8% of effort Project is 18 months total, with 3 stages of 6 months each. Participating Institutions are Fermilab (FNAL) as principal, for ~60% of effort Brookhaven (BNL) for ~32% of effort Florida Institute of Technology (FIT) for ~8% of effort

FNAL Stage 1: Order SC / cable and parts for the field coils. Prepare engineering drawings for the field coil assembly and demo device. Start the winding and vacuum impregnation of the field coils. Prepare progress report. BNL Stage 1: Order SC / cable for the inner and outer armature coils. Order temperature sensors and required instrumentation for data acquisition. Prepare engineering drawings for winding the inner & outer armature coils (to include temperature sensors. ) Program the direct wire machine for winding the armature coils. Prepare progress report. FIT Stage 1: studies and planning listed on next slide FNAL Stage 1: Order SC / cable and parts for the field coils. Prepare engineering drawings for the field coil assembly and demo device. Start the winding and vacuum impregnation of the field coils. Prepare progress report. BNL Stage 1: Order SC / cable for the inner and outer armature coils. Order temperature sensors and required instrumentation for data acquisition. Prepare engineering drawings for winding the inner & outer armature coils (to include temperature sensors. ) Program the direct wire machine for winding the armature coils. Prepare progress report. FIT Stage 1: studies and planning listed on next slide 5/1/2014 V12

FIT Stage 1: (months 1-6) a. Create finite element models of demonstration machine for electromagnetic, mechanical and thermal analysis. b. Electromagnetic study: magnetic field, coil inductances, Lorentz forces on coils, flux linkages, generated power. c. Initial thermal model study: Using empirical values of the expected energy deposition due to AC losses in the specified armature conductor at various frequencies, compute temperature profiles in armature coils. d. Test plan: Develop the portion of the test plan required to obtain the temperature gradient data from the testing at the FNAL VMTF and processing the data. d. Test equipment: Establish requirements and specify equipment for mechanical drive required for testing the generator at various rotational speeds. Develop circuitry to measure and absorb output power from generator test. Include requirements for mounting the test equipment on the top plate of the VMTF at FNAL. e. Coordinate efforts with Goodzeit and Ball as required for demonstration machine design, temperature dependent materials properties, initial energy deposition estimates and documentation. f. Prepare Progress Report. FIT Stage 1: (months 1-6) a. Create finite element models of demonstration machine for electromagnetic, mechanical and thermal analysis. b. Electromagnetic study: magnetic field, coil inductances, Lorentz forces on coils, flux linkages, generated power. c. Initial thermal model study: Using empirical values of the expected energy deposition due to AC losses in the specified armature conductor at various frequencies, compute temperature profiles in armature coils. d. Test plan: Develop the portion of the test plan required to obtain the temperature gradient data from the testing at the FNAL VMTF and processing the data. d. Test equipment: Establish requirements and specify equipment for mechanical drive required for testing the generator at various rotational speeds. Develop circuitry to measure and absorb output power from generator test. Include requirements for mounting the test equipment on the top plate of the VMTF at FNAL. e. Coordinate efforts with Goodzeit and Ball as required for demonstration machine design, temperature dependent materials properties, initial energy deposition estimates and documentation. f. Prepare Progress Report. 5/1/2014 V13

FNAL Stage 2: (months 7-12) Complete the winding and vacuum impregnation of the field coils. Assemble field coils onto strong back fixture. Test field coil assembly for quench properties, transfer function, inductance. Fabricate components for demo device. Design and fabricate components for test stand. Start assembly of the demo device. Liaison with FIT re device test equipment. Prepare progress report. BNL Stage 2: (months 7-12) Wind the inner and outer armature coils. Test armature coils for quench properties, transfer function, inductance. Test armature coils for performance of temperature sensors. Ship completed armatures to FNAL. Prepare progress report. FNAL Stage 2: (months 7-12) Complete the winding and vacuum impregnation of the field coils. Assemble field coils onto strong back fixture. Test field coil assembly for quench properties, transfer function, inductance. Fabricate components for demo device. Design and fabricate components for test stand. Start assembly of the demo device. Liaison with FIT re device test equipment. Prepare progress report. BNL Stage 2: (months 7-12) Wind the inner and outer armature coils. Test armature coils for quench properties, transfer function, inductance. Test armature coils for performance of temperature sensors. Ship completed armatures to FNAL. Prepare progress report. 5/1/2014 V14

FIT Stage 2: (months 7-12) a. Thermal model study: Complete temperature profile studies. Prepare analytical models to compute the energy deposition in a unit volume of the armature coils from temperature sensor data at the specific locations in the armature coils. This will be used to compare the predicted and measured results. b. Participate in testing the armature coils at BNL for involvement in data acquisition and processing data of the temperature sensors. c. Complete the fabricating and in house testing of the generator test equipment and deliver to FNAL. d. Coordinate efforts with Goodzeit and Ball for technical support and documentation services. e. Prepare progress report. FIT Stage 2: (months 7-12) a. Thermal model study: Complete temperature profile studies. Prepare analytical models to compute the energy deposition in a unit volume of the armature coils from temperature sensor data at the specific locations in the armature coils. This will be used to compare the predicted and measured results. b. Participate in testing the armature coils at BNL for involvement in data acquisition and processing data of the temperature sensors. c. Complete the fabricating and in house testing of the generator test equipment and deliver to FNAL. d. Coordinate efforts with Goodzeit and Ball for technical support and documentation services. e. Prepare progress report. 5/1/2014 V15

FNAL Stage 3: (months 13-18) Complete assembly of the demo device. Set up demo device in vertical test facility dewar. Perform designated test plan, with FIT assistance. Implement market/commercialization plan Prepare progress report. Prepare final project report. BNL Stage 3: (months 13-18) Participate in demo device tests at FNAL. Prepare progress report. FNAL Stage 3: (months 13-18) Complete assembly of the demo device. Set up demo device in vertical test facility dewar. Perform designated test plan, with FIT assistance. Implement market/commercialization plan Prepare progress report. Prepare final project report. BNL Stage 3: (months 13-18) Participate in demo device tests at FNAL. Prepare progress report. 5/1/2014 V16 FIT Stage 3: (months 13-18) a. Generator testing: Participate in the testing program at FNAL for the acquisition and processing of the temperature sensor data using the supplied equipment according to the developed test plan. b. Data processing and analysis: Combine analytical and measured test results in a final report form with conclusions relating to the results of this research. c. Coordinate efforts with Goodzeit and Ball for technical support and documentation services. FIT Stage 3: (months 13-18) a. Generator testing: Participate in the testing program at FNAL for the acquisition and processing of the temperature sensor data using the supplied equipment according to the developed test plan. b. Data processing and analysis: Combine analytical and measured test results in a final report form with conclusions relating to the results of this research. c. Coordinate efforts with Goodzeit and Ball for technical support and documentation services.