Oceans cover two thirds of the Earth’s surface and the energy potential of ocean waves as a renewable energy source is huge. It would therefore be a tremendous achievement if the vast mechanical energy in waves was converted into a form of energy that could be used successfully by society. For years, scientists and engineers have endeavored to exploit this renewable energy by inventing various generators designed to transform wave energy into electrical energy. Generally, this sort of generator is called a Wave Energy Converter (WEC).

In this thesis, the research is based on the WEC developed in the Lysekil Project. The Lysekil Project is led by a research group at Uppsala University and has a test site located on the west coast of Sweden. The project started in 2002. So far, more than ten prototypes of the WEC have been deployed and relevant experiments have been carried out at the test site. The WEC developed at Uppsala University can be categorized as a point absorber. It consists of a direct-drive linear generator connected to a floating buoy. The linear generator is deployed on the seabed and driven by a floating buoy to extract wave energy. The absorbed energy is converted to electricity and transmitted to a measuring station on land.

The work presented in this thesis focuses on building a linear generator model which is able to predict the performance of the Lysekil WEC. Studies are also carried out on the damping behavior of the WEC under the impact of different sea climates. The purpose is to optimize the energy absorption with a specific optimal damping coefficient. The obtained results indicate an optimal damping for the Lysekil WEC which can be used for optimizing the damping control.

Additionally, the impact two central engineering design features (the translator weight and the stroke length) are investigated. The aim is to find a reasonable structural design for the generator which balances the cost and the energy production.

The Division for Electricity of Uppsala University is developing a wave power concept. The energy of the ocean waves is harvested with wave energy converters, consisting of one buoy and one linear generator. The units are connected in a submerged substation. The mechanical design is kept as simple as possible to ensure reliability.

The submerged substation includes power electronics and different types of electrical power components. Due to the high cost of maintenance operations at sea, the reliability of electrical systems for offshore renewable energy is a major issue in the pursuit of making the electricity production economically viable. Therefore, proper thermal management is essential to avoid the components being damaged by excessive temperature increases.

The chosen cooling strategy is fully passive, and includes no fans. It has been applied in the second substation prototype with curved heatsinks mounted on the inner wall of the pressurized vessel. This strategy has been evaluated with a thermal model for the completed substation. First of all, 3D-CFD models were implemented for selected components of the electrical conversion system. The results from these submodels were used to build a lumped parameter model at the system level.

The comprehensive thermal study of the substation indicates that the rated power in the present configuration is around 170 kW. The critical components were identified. The transformers and the inverters are the limiting components for high DC-voltage and low DC-voltage respectively. The DC-voltage—an important parameter in the control strategy for the WEC—was shown to have the most significant effect on the temperature limitation.

As power diodes are the first step of conversion, they are subject to large power fluctuations. Therefore, we studied thermal cycling for these components. The results indicated that the junction undergoes repeated temperature cycles, where the amplitude increased with the square root of the absorbed power.

Finally, an array of generic heat sources was optimized. We designed an experimental setup to investigate conjugate natural convection on a vertical plate with flush-mounted heat sources. The influence of the heaters distribution was evaluated for different dissipated powers. Measurements were used for validation of a CFD model. We proposed optimal distributions for up to 36 heat sources. The cooling capacity was maximized while the used area was minimized.

The wave energy converter (WEC) concept developed at Uppsala University consists of a point absorbing buoy, directly connected to a permanent magnet linear generator. Since 2006, over a dozen full scale WECs have been deployed at the Lysekil Research Site, on the west coast of Sweden. Beyond the development of the WEC concept itself, the full scale approach enables, and requires, experimental and multidisciplinary research within several peripheral areas, such as instrumentation, offshore operations, and wave power infrastructure.

This thesis addresses technical challenges of testing, deploying and monitoring full scale WECs. It is divided accordingly into three topics: offshore measurement systems, onshore WEC testing and deployments. Each topic presents new or improved technical solutions to enable offshore wave power research.

For the offshore measurement systems, a new portable data acquisition unit was developed, together with a new sensor system to be installed inside the WEC. The developed system offers a cheap and flexible option for short term offshore measurement ventures, when or where site infrastructure is not available. The system has been developed and tested during both onshore and offshore experiments, with promising results.

On the topic of onshore WEC testing, the thesis presents an experimental approach for assessing the power take-off (PTO) damping of the WEC. In previous experimental studies, it has been measured via the generated electrical power, which neglects both mechanical losses and iron losses. Consequently, the full PTO force acting on the WEC has been underestimated. The thesis presents experimentally attained trends for the speed dependence of the PTO damping at different resistive loads, as measured from both generated electric power and from measurements of the buoy line force. A study was also performed on how the generator damping is affected by partial stator overlap, which varies with the translator position. In order to assess how the characterized damping behavior will affect the WEC operation at sea, two simulation case studies were performed.

Finally, the thesis presents a new WEC deployment method, which has been developed through several deployment trials. By using only a tugboat, a WEC unit is transported and deployed, together with its buoy, in less than half a day. The procedure has proven to be faster, cheaper and safer than the previously used methods.

The main focus of this thesis is on the power electronic converter system challenges associated with the grid integration of variable-renewable-energy (VRE) sources like wave, marine current, tidal, wind, solar etc. Wave energy conversion with grid integration is used as the key reference, considering its high energy potential to support the future clean energy requirements and due the availability of a test facility at Uppsala University. The emphasis is on the DC-link power conditioning and grid coupling of direct driven wave energy converters (DDWECs). The DDWEC reflects the random nature of its input energy to its output voltage wave shape. Thereby, it demands for intelligent power conversion techniques to facilitate the grid connection.

One option is to improve and adapt an already existing, simple and reliable multilevel power converter technology, using smart control strategies. The proposed WECs to grid interconnection system consists of uncontrolled three-phase rectifiers, three-level boost converter(TLBC) or three-level buck-boost converter (TLBBC) and a three-level neutral point clamped (TLNPC) inverter. A new method for pulse delay control for the active balancing of DC-link capacitor voltages by using TLBC/TLBBC is presented. Duty-ratio and pulse delay control methods are combined for obtaining better voltage regulation at the DC-link and for achieving higher controllability range. The classic voltage balancing problem of the NPC inverter input, is solved efficiently using the above technique. A synchronous current compensator is used for the NPC inverter based grid coupling. Various results from both simulation and hardware testing show that the required power conditioning and power flow control can be obtained from the proposed multilevel multistage converter system.

The entire control strategies are implemented in Xilinx Virtex 5 FPGA, inside National Instruments’ CompactRIO system using LabVIEW. A contour based dead-time harmonic analysis method for TLNPC and the possibilities of having various interconnection strategies of WEC-rectifier units to complement the power converter efforts for stabilizing the DC-link, are also presented. An advanced future AC2AC direct power converter system based on Modular multilevel converter (MMC) structure developed at Siemens AG is presented briefly to demonstrate the future trends in this area.

A research project on renewable energy conversion from ocean waves to electricity was started at the Division of Electricity at Uppsala University (UU) in 2001. The Wave Energy Converter (WEC) unit developed in this project is intended to be used in large offshore WEC farms and has therefore been designed with large-scale production in mind. The concept has now also been commercialized by the spin-off company Seabased Industry AB.

An essential part of the UU WEC is the linear direct-drive generator. This thesis presents the pilot work on developing robotized production methods for this special electric machine. The generator design is here investigated and four different backbreaking, monotone, potentially hazardous and time consuming manual production tasks are selected for automation. A robot cell with special automation equipment is then developed and constructed for each task. Simplicity, reliability and flexibility are prioritized and older model pre-owned industrial robots are used throughout the work. The robot cells are evaluated both analytically and experimentally, with focus on full scale experiments. It is likely that the developed production methods can be applied also for other similar electric machines.

The main focus in the thesis is on robotized stator cable winding. The here presented robot cell is, to the knowledge of the author, the first fully automated stator cable winding setup. Fully automated winding with high and consistent quality and high flexibility is demonstrated. Significant potential cost savings compared to manual winding are also indicated. The robot cell is well prepared for production, but further work is required to improve its reliability.

The other three developed robot cells are used for stator stacking, surface mounting of permanent magnets on translators and machining of rubber discs. All robot cell concepts are experimentally validated and considerable potential cost savings compared to manual production are indicated. Further work is however required with regards to autonomy and reliability.

Finally, the thesis presents a pedagogical development work connected to the research on robotized production methods. A first cycle course on automation and robot engineering is here completely reworked, as it is structured around three real-world group project tasks. The new course is evaluated from the examination results, the students’ course evaluations and the feedback from the teachers during six years. The students greatly appreciated the new course. It is indicated that the developed teaching approach is effective in teaching both classical and modern engineering skills.