中国企业打造世界首创轴带永磁发电系统，引领船舶行业低碳转型
近日，江苏源上船舶电气有限公司（以下简称：源上船舶）联合湖南中车尚驱电气有限公司（以下简称：中车尚驱），共同研发的世界首款500kW船用轴带永磁全分半发电系统，已经顺利完成装船并经过试航验证。这一创新成果不仅响应了国家的“双碳”战略，更以“连接世界，造福人类”的使命，为船舶行业的绿色低碳转型提供了一种高效的能源解决方案。
源上船舶自2008年成立以来，始终扎根于江苏苏州张家港经济开发区，专注于船舶电气领域的升级改造。在“一体多翼”的品牌战略规划下，公司经过十五年的专注发展和技术探索，特别是在2017年对高压岸电设备和轴发产品的重点研发投入，以及2019年“江苏源上船舶电气有限公司”的成立，标志着公司在产品加服务的双轮驱动发展模式上的深耕细作。源上船舶作为一家以电力电子和自动控制技术为核心的高新技术企业，致力于船舶自动化控制集成的开发与设计，其团队在高压岸电和轴发系统集成项目改造方面积累了丰富的经验。
源上船舶轴带永磁全分半发电系统为既有船舶提供了一种低成本、高效率、易于安装且通用性强的绿色低碳升级改造方案。为实现不拆卸船舶螺旋桨传动轴安装轴带永磁发电机，项目团队在中车尚驱成熟的正向研发平台基础上，成功攻克了多项技术挑战，包括分半轴套的安全可靠抱紧传动轴、永磁转子的分半模块化设计、定子分半低谐波绕组设计、分半定子铁心与水冷机座的可靠连接以及低热阻传热等。在狭窄的船舱空间内，分半式永磁电机的安全、简便安装也是项目组攻克的难题之一。据统计，为解决这些问题，项目组开展进行了电磁、机械和热管理等超过100个优化迭代方案的仿真，并召开了三十多次设计和工艺方案评审会议，确保最终方案能够满足高效节能、安全可靠、经济性好、安装简便和通用性强等多重需求。
在对一艘超过5万吨的散货船进行改造后的实际测试中，与原有的辅机发电系统相比，新系统的轴带永磁分半发电能够每天节省约1.2吨轻燃油，且由于后期免维护，大大减少了发电机组的运行小时数和维护保养成本，预计两年内即可收回改造成本。这一创新性的研发成果预示着它将对整个船舶行业的绿色低碳升级改造技术产生颠覆性影响，其推广应用不仅将为船舶运输行业带来显著的经济效益，也将为全球减碳战略目标的实现提供有力支持。
"Green Revolution! Chinese Enterprises Build the World's First Shaft Permanent Magnet Power Generation System, Leading the Low Carbon Transformation of the Shipping Industry"
Recently, Jiangsu Source Marine Electrical Co., Ltd. (hereinafter referred to as Source Marine) and Hunan CRRC Shangqu Electric Co., Ltd. (hereinafter referred to as CRRC Shangqu) jointly developed the world's first 500kW marine shaft permanent magnet fully split half power generation system, which has been successfully installed onboard and verified through sea trials. This innovative achievement not only responds to the national "Double-Carbon" strategy, but also serves the mission of "connecting the world for the benefit of humanity", providing an efficient energy saving solution for the green and low-carbon transformation of the shipping industry.
Since its establishment in 2008, Source Marine has always been rooted in Zhangjiagang Economic Development Zone in Suzhou city Jiangsu province China, focusing on the upgrading and retrofitting of the marine electrical field. Under the brand strategic plan of "One Body, Multiple Wings", the company has undergone fifteen years of focused development and technological exploration, especially the key R&D investment in high-voltage AMP and shaft generator productions in 2017， and the establishment of "Jiangsu Source Marine Electrical Co., Ltd." in 2019, marking the company's deep cultivation and meticulous work in the dual wheel drive development model of productions and services. As a high-tech enterprise with power electronics and automation technology as its core, Source Marine is committed to the development and design of ship automation control integration. Its team has accumulated rich experience in the renovation of high-voltage AMP and shaft generator system integration projects.
The marine permanent magnet split half shaft generation system provides a low-cost, high-efficiency, easy-to-install and versatile green and low-carbon upgrade and renovation solution for existing ships. In order to achieve the installation of a shaft permanent magnet generator without dismantling the ship's propeller, tail shaft and intermediate shaft, the project team has successfully overcome multiple technical challenges on the basis of CRRC Shangqu's mature forward research and development platform, including the safe and reliable clamping of the split half shaft sleeve to the intermediate shaft, the modular design of the permanent magnet rotor split half, the design of the stator split half low harmonic winding, the reliable connection between the split half stator core and the water-cooled machine base, and low thermal resistance heat transfer. The safe and easy installation of split type permanent magnet motors in narrow spaces is also one of the challenges that the project team has overcome. According to statistics, in order to solve these problems, the project team conducted simulations of over 100 optimization iterations in electromagnetic, mechanical, and thermal management, and held more than 30 design and process plan review meetings to ensure that the final plan can meet multiple requirements such as high efficiency, energy conservation, safety and reliability, perfect economy, easy installation, and strong universality.
In actual testing after the retrofitting a bulk carrier over 50000 DWT, compared with the original auxiliary generator system, the new system's shaft permanent magnet split half power generation can save about 1.2 tons of light fuel oil per day. Moreover, due to maintenance free operation in the later stage, the running hours and maintenance costs of the generator sets are greatly reduced. It is expected that the retrofitting cost can be recovered within two years. This innovative R&D achievement indicates that it will have a disruptive impact on the green and low-carbon upgrading and transformation technology of the entire shipping industry. Its promotion and application will not only bring significant economic benefits to the shipping industry, but also provide strong support for the achievement of global carbon reduction strategy goals.