A split-type orbital rotor permanent magnet direct-drive wind turbine

Abstract

The present invention discloses a split-type orbital rotor permanent magnet direct-drive wind turbine generator. The generator has a split-type structure and includes a main shaft. A stator is provided on the front circumferential surface of the main shaft. The stator is composed of multiple identical stator units spliced ​​in sequence along the circumferential direction to form a complete ring. A rotor composed of multiple rotor units is rotatably connected to the circumferential surface of the stator. The circumferential surface of the rotor is evenly distributed with multiple blades. The outer ring of the stator unit bracket is provided with a track and an iron core coil. The rotor unit bracket is correspondingly provided with a supporting roller and a magnetic pole module. The air gap is adjusted by the size of the roller. In addition, a cooling unit is provided through the structure of the generator itself. Through structural innovation, the present invention breaks through the volume and diameter limitations of the generator, realizes a main bearing-free design, reduces the electromagnetic air gap, and ensures a uniform circumferential air gap. The overall split-type modular design is adopted, which is convenient for production and transportation, thereby achieving the goal of reducing the cost of the generator and breaking free from foreign constraints.

Description

Technical Field

[0001] The present invention belongs to the technical field of wind turbines, and in particular relates to a split-type orbital rotor permanent magnet direct-drive wind turbine. Background Art

[0002] In recent years, due to global energy shortages and growing environmental awareness, clean energy has seen significant development. Wind power generation, a major form of clean energy utilization, converts wind energy into electricity. Due to its environmentally friendly, pollution-free, clean, and renewable nature, it has rapidly grown worldwide, and its technology is becoming increasingly mature. As we all know, in wind power generation systems, the generator, as one of the core components, plays a crucial role in the system.

[0003] Because permanent magnet direct-drive wind turbines lack gearboxes and other structures, they offer the following advantages: First, they reduce transmission losses, improving power generation efficiency; second, they simplify the transmission structure, improving generator reliability; and third, they reduce the number of wind turbine components, eliminating the need for regular gearbox oil changes and reducing operating and maintenance costs. Consequently, they are widely used. However, as competition in the wind power industry intensifies, motor power, size, and diameter continue to increase. Traditional permanent magnet direct-drive generator structures face the risk of being eliminated due to the inability to further reduce costs. Direct-drive generator manufacturers urgently need to undergo technological transformation and seek new technological breakthroughs to adapt to the competitive market environment.

[0004] This is because the simplified structure of the conventional direct drive generator is as follows Figure 1 As shown, it is mainly composed of a rotating shaft A, a fixed shaft B, a main bearing C, a stator 2, and a rotor 3. The stator 2 is connected to the fixed shaft B, the rotor 3 is connected to the rotating shaft A, and the motor rotation is realized through the main bearing C. The main bearing C needs to bear the weight of the hub, the rotating shaft A, and the rotor 3, so the main bearing C needs to be a large heavy-duty bearing. However, at present, the main bearings of wind power have long been monopolized by foreign manufacturers, the cost is expensive, and it is easy to be constrained; in addition, since the air gap of the generator depends on the strength of the rotating shaft and the rotor bracket to support it, a higher strength needs to be selected in the rotating shaft design and the rotor design to ensure the stator-rotor air gap. The air gap usually selected for the direct-drive motor is 7mm, but due to the effects of gravity, external loads, etc., the air gap is uneven, which causes the motor vibration, increased noise, and increased electromagnetic loss, thereby increasing the cost of effective materials such as permanent magnets and copper; in addition, the existing direct-drive generator is an integral structure with a large volume and diameter, which makes it difficult to process and transport.

[0005] In view of this, the present inventor provides a split-type orbital rotor permanent magnet direct-drive wind turbine generator to overcome the above-mentioned defects of the prior art. Summary of the Invention

[0006] The purpose of the present invention is to overcome the shortcomings of the above-mentioned prior art and provide a split-type orbital rotor permanent magnet direct-drive wind turbine. The wind turbine breaks through the limitations of the generator volume and diameter by improving and innovating the existing structure, realizes a main bearing-free design, reduces the electromagnetic air gap, and maintains a uniform circumferential air gap. The overall modular design is adopted for easy production and transportation, thereby achieving the goal of reducing the cost of the generator and breaking free from foreign constraints.

[0007] The purpose of the present invention is to solve the problem through the following technical solutions:

[0008] A split-type orbital rotor permanent magnet direct-drive wind turbine generator, the generator having a split-type structure, comprising a main shaft, a stator fixedly connected to the front circumferential surface of the main shaft, the stator being composed of a plurality of identical stator units sequentially spliced ​​along the circumferential direction to form a complete ring, a rotor composed of a plurality of rotor units being rotatably connected to the circumferential surface of the stator, a plurality of blades being arranged on the circumferential surface of the rotor, and the central angles between adjacent blades being the same;

[0009] The stator unit includes a stator bracket with a fan-shaped structure. The stator bracket is detachably connected to the main shaft through a stator inner flange provided on its inner ring. A complete set of U, V, and W three-phase stator core coils are fixedly provided on the outer ring of the stator bracket. Two tracks are provided on the outer ring of the stator bracket along the circumferential direction. The two tracks are respectively located on both sides of the stator core coil.

[0010] The rotor unit includes an arc-shaped rotor bracket, the interior of which is detachably connected to a magnetic pole module and a plurality of supporting rollers. The supporting rollers are symmetrically arranged on both sides of the magnetic pole module and cooperate with two tracks on the outer ring of the stator bracket.

[0011] Furthermore, the rotor is equally divided into a number of identical rotor units along the circumferential direction, and adjacent rotor units are detachably connected to each other, so as to separately install and disassemble each rotor unit in the rotor.

[0012] Furthermore, each rotor bracket is provided with radially raised folding edges on both sides, and a plurality of through holes are opened on the folding edges. Any two adjacent rotor units are connected by the folding edges and fasteners of the rotor bracket, and all the rotor units are spliced ​​to form a complete circle.

[0013] Furthermore, the rotor consists of eight rotor units.

[0014] Furthermore, the magnetic pole module adopts a stepped skew pole design.

[0015] Furthermore, the stator bracket is a cavity structure for weight reduction and heat dissipation.

[0016] Furthermore, the air gap between the stator and the rotor is adjusted by supporting rollers.

[0017] Furthermore, the air gap between the stator and the rotor is generally set to 2-4 mm.

[0018] Furthermore, the generator also includes a cooling unit, which utilizes the pressure difference between the inside and outside of the generator to absorb natural wind to cool it.

[0019] Furthermore, the cooling unit comprises:

[0020] A first air guide cover is provided at the end of the main shaft, located at the front end of the stator and covering the inner ring of the stator. The first air guide cover is circular and has a convex structure in the middle;

[0021] A second air guide cover is fixedly arranged at the front end of the rotor, wherein the second air guide cover is a circular ring structure with a conical surface and rotates with the rotor;

[0022] A radial ventilation duct is provided inside the stator bracket, and an opening is provided at the front end of the stator bracket, which is connected to the radial ventilation duct. The opening is located between the first air deflector and the second air deflector. A first filter is installed on the opening. A second filter is installed at the edge of the outer ring of the rear end of the stator bracket. The second filter is provided between the stator bracket and the rotor bracket.

[0023] Under the action of the first air guide cover and the second air guide cover, the cooling unit rotates the cold air through the first filter into the internal cavity of the stator bracket, cools the stator core coil through the radial ventilation duct, and then passes through the air gap and is discharged from the second filter for circulating cooling of the generator.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] 1. The present invention provides a split-type orbital rotor permanent magnet direct-drive wind turbine. The overall structure of the generator adopts a modular design, dividing the stator and rotor into several identical units, that is, splitting the existing complete stator and rotor structure into multiple relatively small stator units and rotor units, thereby reducing the production difficulty and manufacturing cost, and solving the problem of large volume and diameter of direct-drive wind turbines and difficulty in transportation. In addition, since each unit structure is relatively independent, when a unit fails, there is no need to lower the entire generator for maintenance. Only the failed unit needs to be replaced and the generator can continue to operate, which reduces the maintenance difficulty and maintenance cost. In particular, the present invention, through structural innovation, enables the stator and the rotor to be connected through the track of the stator outer ring and the support rollers on the rotor, thereby realizing a bearingless design and getting rid of the dependence on foreign wind power main bearings. The air gap between the stator and the rotor can be adjusted by rollers of different diameters, so that the air gap value of the generator can be reduced from the existing 7mm to about 3mm. Under the same power, the smaller the air gap, the smaller the amount of effective materials such as permanent magnets, copper, and punching sheets used in the generator. In addition, since the rotor is supported by support rollers at both ends, a lightweight design can be performed, the strength of the rotor bracket is reduced, and the overall cost of the generator is further reduced.

[0026] 2. The present invention provides a split-type orbital rotor permanent magnet direct-drive wind turbine generator. The stator bracket of the generator adopts a cavity structure, which has the following two advantages: on the one hand, it helps to dissipate heat from the stator core coil; on the other hand, it reduces the overall weight of the generator and reduces the requirements for the generator tower and base.

[0027] 3. The present invention provides a split-type orbital rotor permanent magnet direct-drive wind turbine generator. The generator is structurally designed to have a cooling unit. When the generator is working, the stator core coil inside the generator will heat up, causing the temperature of the internal cavity of the generator to be higher than the external temperature. In this way, the pressure inside the generator is higher than the external pressure. In addition, the first air guide cover and the second air guide cover at the front end of the generator work together to make the external cold air (natural wind) be sucked into the internal cavity of the generator and cool the stator core coil along the radial ventilation duct of the stator bracket, and then pass through the air gap and be discharged from the second filter to achieve cooling of the generator. This cooling method is natural air cooling, which eliminates the need for a complex cooling system compared to traditional generators. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The accompanying drawings are incorporated in and constitute a part of this specification and, together with the description, serve to explain the principles of the invention.

[0029] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, for ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative labor.

[0030] Figure 1 This is a simplified structural diagram of a traditional permanent magnet direct drive generator;

[0031] Figure 2 This is a schematic diagram of the overall (front end) structure of the generator of the present invention;

[0032] Figure 3 This is a rear view of the overall (rear end) structure of the generator of the present invention;

[0033] Figure 4 yes Figure 3 AA section view in;

[0034] Figure 5 Schematic diagram of the stator support structure of the present invention;

[0035] Figure 6 This is a schematic diagram of the structure of the present invention after one rotor unit is removed;

[0036] Figure 7 This is a schematic diagram of the rotor structure after the stator is removed (the track is retained);

[0037] Figure 8 It is a schematic diagram of the wind direction flow of the generator cooling unit of the present invention.

[0038] Among them: 1 is the main shaft; 2 is the stator; 3 is the rotor; 4 is the cooling unit; 21 is the stator bracket; 22 is the stator core coil; 31 is the rotor bracket; 32 is the pole module; 33 is the supporting roller; 41 is the first air deflector; 42 is the second air deflector; 43 is the radial ventilation duct; 44 is the first filter; 45 is the second filter; 211 is the stator inner flange; 212 is the track; A is the rotating shaft; B is the fixed shaft; C is the main bearing. DETAILED DESCRIPTION

[0039] Exemplary embodiments will be described in detail herein, examples of which are illustrated in the accompanying drawings. In the following description, when referring to the drawings, identical numerals in different figures represent identical or similar elements unless otherwise indicated. The embodiments described in the following exemplary embodiments are not intended to represent all possible embodiments consistent with the present invention. Rather, they are merely examples of arrangements consistent with certain aspects of the present invention as detailed in the appended claims.

[0040] In order to enable those skilled in the art to better understand the technical solutions of the present invention, the present invention is described in further detail below with reference to the accompanying drawings and embodiments.

[0041] See also Figures 1 to 8 As shown, the present invention provides a split-type orbital rotor permanent magnet direct-drive wind turbine generator. The generator has a split-type structure and includes a main shaft 1. A stator 2 is fixedly connected to the front circumferential surface of the main shaft 1. The stator 2 is composed of multiple identical stator units spliced ​​in sequence along the circumferential direction to form a complete ring. A rotor 3 composed of multiple rotor units is rotatably connected to the circumferential surface of the stator 2. The circumferential surface of the rotor 3 is provided with multiple blades, and the central angles between adjacent blades are the same. The blades drive the rotor 3 to rotate around the circumference of the stator 2 to generate electricity. In the embodiment of the present invention, the stator 2 and rotor 3 both adopt a modular design. That is, the traditional integral structure of the stator 2 and rotor 3 is split into multiple relatively independent and smaller stator units and rotor units in a split-type manner. The specific number of petals after splitting depends on the volume, diameter, and weight of the target stator and rotor as a whole. The present invention can achieve the goal of breaking the whole into parts through the split-type structure, thereby reducing the production difficulty and manufacturing cost of the stator 2 and rotor 3, while solving the problem of the traditional direct-drive wind turbine being too large in size and diameter and difficult to transport.

[0042] The stator unit of the present invention includes a stator bracket 21 in a fan-shaped structure, preferably, as shown in FIG. Figure 5 As shown, the stator bracket 21 selected in this embodiment has a cavity structure for weight reduction and heat dissipation. The stator bracket 21 is detachably connected to the main shaft 1 via a stator inner flange 211 provided on its inner ring. A complete set of U, V, and W three-phase stator core coils 22 are fixedly provided on the outer ring of the stator bracket 21. Two tracks 212 are provided on the outer ring of the stator bracket 21 along the circumferential direction. The two tracks 212 are respectively located on both sides of the stator core coil 22. The tracks 212 and the stator bracket 21 are an integrally formed structure to ensure strength. The outermost sides of the tracks 212 are provided with raised ribs to prevent the rollers installed on the tracks from detaching from the stator bracket.

[0043] Since the embodiment of the present invention is provided with complete U, V, and W three-phase stator core coils 22 on each stator unit, each split stator unit can work independently. Therefore, when any one of the stator units fails, the remaining stator units of the generator can still work normally, and only the power generation is reduced. Therefore, there is no need to shut down the generator immediately for maintenance. It is only necessary to replace the faulty stator unit at an appropriate time, thereby increasing the fault tolerance and reliability of the generator.

[0044] Correspondingly, the rotor unit of the present invention includes an arc-shaped rotor bracket 31, and the interior of the rotor bracket 31 is detachably connected to a magnetic pole module 32 and a plurality of support rollers 33. The support rollers 33 are symmetrically arranged on both sides of the magnetic pole module 32. As shown in the drawings of the present invention, 2 to 3 support rollers are evenly distributed on one side, and cooperate with the two tracks 212 on the outer ring of the stator bracket 21. The rotor bracket 31 is set on the track 212 of the stator bracket 21 through the support rollers 33 at both ends. Therefore, the air gap between the stator 2 and the rotor 3 can be adjusted by the roller diameter of the support roller 33. The air gap is generally set to 2 to 4 mm. Since the rotor 3 adopts a two-end support structure, a lightweight design can be performed, reducing the strength and cost of the rotor bracket 31. In addition, the assembly of the split rotor 3 of the present invention eliminates the overall set compared to the traditional assembly, reduces the risk of adsorption between the stator and rotor, eliminates safety hazards, and simplifies the assembly process of the generator.

[0045] Preferably, in the embodiment of the present invention, the magnetic pole module 32 is connected to the rotor bracket 31 through a bolt assembly, and the magnetic pole module 32 adopts a stepped skew pole design for the purpose of reducing vibration and noise and improving the performance of the permanent magnet generator.

[0046] Through the above settings, the present invention can reduce the air gap value of the generator from 7mm to about 3mm. According to generator design experience, the smaller the air gap, the smaller the amount of effective materials such as permanent magnets, copper, and punching sheets of the motor for the same power, and the roller can keep the circumferential air gap uniform. Therefore, the three-phase output voltage and current balance of the generator can be optimized, the unilateral magnetic pull can be reduced, etc., thereby improving the power generation efficiency and reducing the power generation cost.

[0047] The stator 2 and rotor 3 of the present invention are both equally divided into a plurality of corresponding units along the circumferential direction. The number of equal divisions can be set according to actual conditions. The purpose of the equal division is, firstly, to facilitate processing and transportation, and secondly, to improve the interchangeability between the units and facilitate subsequent assembly. Since the purpose of splitting the stator 2 and rotor 3 into multiple units is the same, this embodiment uses the rotor 3 as an example for description. Specifically, as shown in the accompanying drawings of the present invention, the rotor 3 is divided into eight rotor units of the same structure, and adjacent rotor units are provided with a detachable connection structure. In this way, when a rotor unit fails, there is no need to lower the entire generator for maintenance. Only the failed rotor unit needs to be replaced for continued operation, which reduces the difficulty of maintenance.

[0048] Specifically, each rotor bracket 31 may be provided with radially raised hems on both the left and right sides, each with a plurality of through-holes. Any two adjacent rotor units are connected via the hems and fasteners of the rotor bracket 31, and all rotor units are joined to form a complete circle. The connection structure between the rotor units may also employ other methods, as long as they enable a detachable connection, and will not be described in detail here.

[0049] The present invention also includes a cooling unit 4, which uses the pressure difference between the inside and outside of the generator to absorb natural wind to cool the generator itself. The cooling unit 4 includes a first air guide hood 41, a second air guide hood 42, a radial ventilation duct 43, a first filter 44 and a second filter 45. Specifically, the first air guide hood 41 is set at the end of the main shaft 1, and is located at the front end of the stator 2 and covers the inner ring of the stator 2. The first air guide hood 41 is circular and has a convex structure in the middle; the second air guide hood 42 is fixedly set at the front end of the rotor 3. The second air guide hood 42 is a circular ring structure with a conical surface, and the diameter of the conical surface gradually decreases from the front end to the rear section; the radial ventilation duct 43 is located at Inside the stator bracket 3, a radial ventilation duct 43 penetrates the stator core coil 22, and an opening that penetrates the radial ventilation duct 43 is provided at the front end of the stator bracket 21. The opening is located between the first air deflector 41 and the second air deflector 42. A first filter screen 44 is installed on the opening, and a second filter screen 45 is installed at the edge of the outer ring of the rear end of the stator bracket 21. The second filter screen 45 is located between the stator bracket 21 and the rotor bracket 31, and together with the rotor bracket 3 and the stator bracket 2, forms the internal cavity of the motor. Through the above settings, when the generator is working, the stator core coil 22 inside the generator will heat up, causing the temperature of the internal cavity of the generator to be greater than the external (air) temperature, so that the pressure inside the generator is greater than the external pressure. In addition, the first air deflector 41 and the second air deflector 42 at the front end of the generator work together to allow the external cold air (natural wind) to pass through the first filter 44 into the internal cavity of the generator, and cool the stator core coil 22 along the radial ventilation duct 43 of the stator bracket 21, and then pass through the air gap and be discharged from the second filter 45 to achieve cooling of the generator. This cooling method is natural air cooling, which eliminates the need for a complex cooling system compared to traditional generators.

[0050] The foregoing description is intended only to provide specific embodiments of the present invention, which will enable those skilled in the art to understand and implement the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention.

[0051] It should be understood that the present invention is not limited to the above description and that various modifications and changes may be made without departing from the scope thereof. The scope of the present invention is limited only by the appended claims.

Claims

1. A split-type orbital rotor permanent magnet direct-drive wind turbine, characterized in that: The generator is a split-petal structure, comprising a main shaft (1), a stator (2) fixedly connected to the front circumferential surface of the main shaft (1), the stator (2) being composed of a plurality of identical stator units sequentially spliced ​​in the circumferential direction to form a complete ring, a rotor (3) composed of a plurality of rotor units being rotatably connected to the circumferential surface of the stator (2), a plurality of blades being arranged on the circumferential surface of the rotor (3), and the central angles between adjacent blades being the same; The stator unit comprises a stator support (21) with a fan-shaped structure, the stator support (21) is detachably connected to the main shaft (1) via a stator inner flange (211) provided on its inner ring, a complete U, V, and W three-phase stator core coil (22) is fixedly provided on the outer ring of the stator support (21), and two tracks (212) are provided on the outer ring of the stator support (21) along the circumferential direction, and the two tracks (212) are respectively located on both sides of the stator core coil (22); The rotor unit comprises an arc-shaped rotor support (31), the interior of the rotor support (31) is detachably connected to a magnetic pole module (32) and a plurality of supporting rollers (33), the supporting rollers (33) are symmetrically arranged on both sides of the magnetic pole module (32), and are matched with two tracks (212) on the outer ring of the stator support (21).

2. A split-type orbital rotor permanent magnet direct-drive wind turbine according to claim 1, characterized in that: The rotor (3) is equally divided into a plurality of identical rotor units along the circumferential direction, and adjacent rotor units are detachably connected, so as to be used for individually installing and disassembling each rotor unit in the rotor (3).

3. A split-type orbital rotor permanent magnet direct-drive wind turbine according to claim 2, characterized in that: Each rotor bracket (31) is provided with radially raised folded edges on both the left and right sides, and a plurality of through holes are provided on the folded edges. Any two adjacent rotor units are connected through the folded edges and fasteners of the rotor bracket (31), and all the rotor units are spliced ​​together to form a complete circle.

4. A split-type orbital rotor permanent magnet direct-drive wind turbine according to claim 1, characterized in that: The rotor (3) consists of eight rotor units.

5. The split-type orbital rotor permanent magnet direct-drive wind turbine according to claim 1, characterized in that: The magnetic pole module (32) adopts a stepped oblique pole design.

6. A split-type orbital rotor permanent magnet direct-drive wind turbine according to claim 1, characterized in that: The stator bracket (21) is a cavity structure, which is used for weight reduction and heat dissipation.

7. The split-type orbital rotor permanent magnet direct-drive wind turbine according to claim 1, characterized in that: The air gap between the stator (2) and the rotor (3) is adjusted by a supporting roller (33).

8. A split-type orbital rotor permanent magnet direct-drive wind turbine according to claim 7, characterized in that: The air gap between the stator (2) and the rotor (3) is generally set to 2 to 4 mm.

9. A split-type orbital rotor permanent magnet direct-drive wind turbine according to any one of claims 1 to 8, characterized in that: The generator further comprises a cooling unit (4), which utilizes the pressure difference between the inside and outside of the generator to absorb natural wind to cool it.

10. A split-type orbital rotor permanent magnet direct-drive wind turbine according to claim 9, characterized in that: The cooling unit (4) comprises: A first air guide cover (41) is provided at the end of the main shaft (1), is located at the front end of the stator (2), and covers the inner ring of the stator (2), wherein the first air guide cover (41) is circular and has a convex structure in the middle; a second air guide cover (42) fixedly arranged at the front end of the rotor (3), wherein the second air guide cover (42) is a circular ring structure with a conical surface, and the second air guide cover (42) rotates along with the rotor (3); A radial ventilation duct (43) is provided inside the stator support (21), and an opening communicating with the radial ventilation duct (43) is provided at the front end of the stator support (21), the opening being located between the first air guide cover (41) and the second air guide cover (42), a first filter screen (44) being installed on the opening, a second filter screen (45) being installed at the outer edge of the rear end of the stator support (21), and the second filter screen (45) being provided between the stator support (21) and the rotor support (31); The cooling unit (4) rotates cold air into the internal cavity of the stator bracket (21) through the first filter (44) under the action of the first air guide cover (41) and the second air guide cover (42), and cools the stator core coil (22) through the radial ventilation duct (43), and then passes through the air gap and is discharged from the second filter (45) for circulating cooling of the generator.

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