ANSYS > Case Studies > Optimizing Power Generation with ANSYS Emag at Kato Engineering

Optimizing Power Generation with ANSYS Emag at Kato Engineering

Technology Category

Sensors - Voltage Sensors

Applicable Industries

Electrical Grids
Telecommunications

Applicable Functions

Product Research & Development
Quality Assurance

Use Cases

Manufacturing System Automation

Services

Testing & Certification

About The Customer

Kato Engineering is a division of Emerson Industrial Automation's Leroy Somer North America. The company, founded in 1926, designs and manufactures a complete line of precision-engineered, high-quality AC generators, motor-generator sets, and controls for prime, standby, and peak-shaving power generation. Kato Engineering employs about 325 people in its design and manufacturing facility in North Mankato, Minnesota. The company's generators are used worldwide in various industries, including oil, gas, coal, copper, iron ore, and lumber extraction. They also power ships, freighters, locomotives, aircraft, and mass transit systems. In addition, Kato generators are relied upon in places where dependable, controllable electric power is needed, such as hospitals, computer centers, and telecommunications stations.

The Challenge

Kato Engineering, a company that designs and manufactures a complete line of precision-engineered, high-quality AC generators, motor-generator sets, and controls for prime, standby, and peak-shaving power generation, faced a significant challenge. The subtransient reactance of an electrical generator, which is the generator internal impedance element that is effective during the first few cycles of a transient load event, was difficult to predict. This reactance is typically determined through factory testing of new generator designs after the design process is finished. This method was not only time-consuming but also inefficient as it delayed the identification of potential issues until after the design process was completed.

The Solution

To address this challenge, Kato Engineering turned to ANSYS Emag. This software was used to predict the subtransient reactance using two-dimensional transient circuit-coupled electromagnetic analysis. This allowed for the early prediction of the subtransient reactance, thereby eliminating the need for post-design factory testing. In addition to this, other key generator characteristics such as the open-circuit saturation curve and output voltage signal harmonic distortion were evaluated. Custom macros using the ANSYS Parametric Design Language (APDL) were developed to model the four-pole generator. This solution allowed Kato Engineering to understand the key generator characteristics at an early stage in the design process before physical prototypes were created.

Operational Impact

The use of ANSYS Emag software has significantly improved Kato Engineering's generator design process. By enabling the prediction of the subtransient reactance and other key generator characteristics at an early stage in the design process, the company has been able to speed up new generator development. This has also reduced the need for post-design factory testing, thereby saving time and resources. Furthermore, the use of custom macros using the ANSYS Parametric Design Language (APDL) for modeling the four-pole generator has enhanced the accuracy and efficiency of the design process.