Design of a Kite Controller for Airborne Wind Energy

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Design of a Kite Controller for Airborne Wind Energy Dissertation for Masters of Science in Engineering Design of a Kite Controller for Airborne Wind Energy Matteo Milandri February 2015 University of Cape Town University of Cape Town Faculty Engineering and the Built Environment Electrical Engineering Department The copyright of this thesis vests in the author. No quotation from it or information derived from it is to be published without full acknowledgement of the source. The thesis is to be used for private study or non- commercial research purposes only. Published by the University of Cape Town (UCT) in terms of the non-exclusive license granted to UCT by the author. University of Cape Town Supervised by Samuel Ginsberg Dr. Ian de Vries Declaration I know the meaning of plagiarism and declare that all the work in the document, save for that which is properly acknowledged, is my own. Matteo F. Milandri ___________________ i Abstract Airborne wind energy is a field of technology being developed to make use of the vast, renewable wind power resource which is above the reach of traditional wind turbines, without the need for a large tower. Much analytical research has been undertaken in recent years to better understand the problem space. However, there are relatively few working systems that demonstrate their functioning and can be compared with simulations and theory. Off-grid power systems still rely heavily on diesel generators, so devices that tap renewable energy sources with similar ease of deployment and lower cost of energy would help this sector to reduce its reliance on expensive, polluting, fossil fuels. The development of these systems is often performed by teams with business interests leaving little open access content available regarding the design process of such devices or the data that they provide. A kite control pod has been designed for the remote control of a standard kitesurfing kite and a prototype has been demonstrated stably flying such a kite on a fixed length tether. This pod and kite would be tethered to a winch and as the kite flies across the wind, the lift force generated is applied to the winch which is reeled out and electrical power generated. Once fully extended, the tether would be reeled in with the kite de-powered, using some of the generated energy, stored in a battery. This system can then be used as a test bed for the further development of a compact, autonomous, airborne wind energy system for off-grid applications. ii Contents Abstract ii 1. Introduction 1 1.1. Airborne wind energy . 1 1.2. Scope of study . 2 1.2.1. Limitations . 2 1.2.2. Report overview . 3 1.3. User requirements . 3 1.3.1. Functional description . 4 1.4. Contextual considerations for AWE projects . 5 1.4.1. Energy . 5 1.4.2. Benefits of airborne wind energy . 5 1.4.3. Deployment locations and flight duration . 6 1.4.4. Regulatory considerations . 6 1.4.5. Safety . 7 1.5. Terminology . 7 2. Literature review 9 2.1. A brief history of kites . 9 2.2. Physics of wind power . 9 2.2.1. Apparent wind . 10 2.2.2. Cross-wind flight . 11 2.2.3. How electrical power is generated . 11 2.2.4. Scaling to larger systems . 12 2.3. Meteorology of wind power . 12 2.3.1. Stratification of wind . 13 2.3.2. Wind power and availability . 13 2.3.3. Saturation wind power or total power available . 14 2.4. Active airborne wind energy projects . 14 2.5. Challenges to commercialisation . 18 2.5.1. Technical challenges . 18 2.5.2. Regulatory approval . 19 2.5.3. Demonstrable safety . 19 2.5.4. Funding requirements . 19 2.5.5. Competition from other energy sources . 19 iii Contents 2.6. Kite control mechanisms/systems as found in literature . 20 2.6.1. Categorisation of AWE systems . 20 2.6.2. Launching and landing . 22 2.6.3. Sensors . 23 2.6.4. Flight software and control theory . 23 3. Specification 25 3.1. Basic operation . 25 3.1.1. Remote controlled actuation . 25 3.1.2. Launching / Landing . 26 3.1.3. Flight . 26 3.2. System features . 27 3.2.1. Actuation . 27 3.2.2. Traction force transmission . 28 3.2.3. Powering the pod . 28 3.2.4. Control input . 28 3.2.5. Feedback . 29 3.2.6. Dimensions and mass . 29 3.2.7. Mechanical integration . 29 3.2.8. Flight time . 30 3.2.9. Safety release mechanism . 30 3.2.10. Ground station data aggregation and display . 30 3.3. Environmental stresses . 31 3.3.1. Wind range . 31 3.3.2. Impact . 31 3.3.3. Sand and dust ingress . 31 3.3.4. Temperature range . 31 3.3.5. Water immunity . 31 3.3.6. System and subsystem reliability . 32 4. Design 33 4.1. Initial design exploration . 33 4.2. Mechanical structure and integration . 34 4.2.1. Baseplate strength . 34 4.2.2. Packaging and mechanical layout . 35 4.2.3. Wire harnesses . 35 4.2.4. Enclosure . 36 4.2.5. Mass budget . 36 4.3. Actuators . 37 4.3.1. Motors and winch assemblies . 37 4.3.2. Position sensors . 38 4.3.3. Motor drives and controllers . 39 4.4. Energy storage and management . 40 4.5. Embedded system architecture and microcontroller selection . 41 iv Contents 4.6. Control input . 42 4.7. Telemetry . 42 4.7.1. Link budget . 42 4.7.2. Kite to ground data . 43 4.7.3. Ground to kite data . 43 4.8. Sensors . 43 4.8.1. GPS . 43 4.8.2. Inertial motion unit . 44 4.8.3. Barometer and temperature sensors . 44 4.9. Electrical integration . 44 4.9.1. System coordination . 45 4.9.2. Power supply . 45 4.9.3. Grounding strategy . 45 4.9.4. Sources of electromagnetic interference . 45 4.9.5. Sharing the battery power supply . 45 4.10. Embedded software design . 46 4.10.1. Motor controller software . 46 4.10.2. System controller software . 46 4.11. Auxiliary systems . 47 4.11.1. Energy harvesting . 48 4.11.2. Safety release . 49 4.12. Ground station . 49 4.12.1. Display and logging of controller data . 49 4.12.2. Ground based measurements . 50 5. Implementation 51 5.1. Electronic circuit boards . 51 5.1.1. Motor drive PCB . 51 5.1.2. Inrush limiter and power distribution board . 56 5.1.3. System master controller . 56 5.1.4. Ground station circuit . 59 5.2. Electro-mechanical components . 60 5.2.1. Actuators . 60 5.2.2. Battery . 61 5.2.3. Wind power generator . 61 5.2.4. Safety release mechanism . 62 5.2.5. Wiring harnesses . 62 5.3. Mechanical aspects . 62 5.3.1. Base structure and layout . 62 5.3.2. Packaging and assembly . 63 5.3.3. Outer housing . 63 5.3.4. Attachment to the kite and tether . 65 5.4. Main controller embedded software . ..
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