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Despite South Africa’s ailing electrical grid, substantial renewable energy (RE) integration is planned for the country. As grid-integrated RE affects all grids differently, this study aims to develop an adaptable grid code-guided renewable power plant (RPP) control real-time simulation testbed, tailored to South African grid code requirements to study grid-integrated RE’s behaviour concerning South Africa’s unique conditions.

The testbed is designed using MATLAB’s Simulink and live script environments, to create an adaptable model where grid, RPP and RPP guiding grid codes are tailorable. This model is integrated with OPAL-RT’s RT-LAB and brought to real-time simulation using OPAL-RT’s OP4510 simulator. Voltage, frequency and short-circuit event case studies are performed through which the testbed’s abilities and performance are assessed.

Case study results show the following. The testbed accurately represents grid code voltage and frequency requirements. RPP point of connection (POC) conditions are consistently recognized and tracked, according to which the testbed then operates simulated RPPs, validating its design. Short-circuit event simulations show the simulated wind farm supports POC conditions relative to short-circuit intensity by curtailing active power in favour of reactive power, in line with local grid code requirements.

To the best of the authors’ knowledge, this is the first design of an adaptable grid code-guided RPP control testbed, tailored to South African grid code requirements in line with which RPP behavioural and grid integration studies can be performed.

Utilizing electrical discharge machining (EDM) to process micro-holes in superalloys may lead to the formation of remelting layers and micro-cracks on the machined surface. This work proposes a method of composite processing of EDM and ultrasonic vibration drilling for machining precision micro-holes in complex positions of superalloys.

A six-axis computer numerical control (CNC) machine tool was developed, whose software control system adopted a real-time control architecture that integrates electrical discharge and ultrasonic vibration drilling. Among them, the CNC system software was developed based on Windows + RTX architecture, which could process the real-time processing state received by the hardware terminal and adjust the processing state. Based on the SoC (System on Chip) technology, an architecture for a pulse generator was developed. The circuit of the pulse generator was designed and implemented. Additionally, a composite mechanical system was engineered for both drilling and EDM. Two sets of control boards were designed for the hardware terminal. One set was the EDM discharge control board, which detected the discharge state and provided the pulse waveform for turning on the transistor. The other was a relay control card based on STM32, which could meet the switch between EDM and ultrasonic vibration, and used the Modbus protocol to communicate with the machining control software.

The mechanical structure of the designed composite machine tool can effectively avoid interference between the EDM spindle and the drilling spindle. The removal rate of the remelting layer on 1.5 mm single crystal superalloys after composite processing can reach over 90%. The average processing time per millimeter was 55 s, and the measured inner surface roughness of the hole was less than 1.6 µm, which realized the  micro-hole machining without remelting layer, heat affected zone and micro-cracks in the single crystal superalloy.

The test results proved that the key techniques developed in this paper were suite for micro-hole machining of special materials.