A stator module for a generator of a wind turbine generator set and a manufacturing method thereof

Abstract

The present invention discloses a stator module for a generator of a wind turbine generator and a manufacturing method thereof, comprising: an iron core, a bottom of which is provided with a plurality of mortises in an annular direction; a top block disposed in the mortises; a mortise beam composed of an upper wing plate, a lower wing plate, and a web plate, the web plate having a plurality of operating holes in an axial direction, the upper wing plate having a fixing screw hole having the same number of operating holes, the upper wing plate passing through the mortise of the iron core; a fixing screw passing through the fixing screw hole from the operating hole and pressing against the top block; a pair of end plates clamping the iron core in the axial direction, the end plates having access holes having the same shape as the cross-section of the mortise beam, the ends of each mortise beam being respectively inserted into the access holes of the two end plates; a pair of side plates clamped in the annular direction on the pair of end plates; and multiple sets of ring plates extending between the mortise beam and the side plates and integrally connected to the mortise beam and the side plates. The present invention can significantly improve the structural safety and reliability and reduce the structural complexity and cost.

Description

Technical Field

[0001] The present application relates to the technical field of wind turbines, and in particular to a stator module for a generator of a wind turbine and a manufacturing method thereof. Background Art

[0002] To reduce the levelized cost of electricity (LCO) and conserve land and marine resources for wind power projects, wind turbine development is trending toward larger units. Due to the unprecedented pace of product iteration, the time required to test and verify new products is also relatively short. The industry generally believes that the safety and reliability of wind turbines are key to ensuring the high-quality development of the wind power industry in the future. As a core and critical component of wind turbines, the modular design of generators can improve product scalability, efficiency, and reliability, while reducing manufacturing, transportation, and maintenance difficulties. Therefore, modular generator design is a key technical approach for wind turbines.

[0003] The generator rotor of a large wind turbine usually includes permanent magnets. The rotor rotates relative to the armature formed by the stator winding, and the winding generates an induced current. In most configurations, especially direct-drive wind turbines, the stator is surrounded by an outer rotor. For transportation and manufacturing reasons, the stator itself is usually divided into stator modules, each of which includes a stator core with stator teeth and carrying stator windings, and its auxiliary structures. These auxiliary structures are used to ensure the strength and rigidity of the stator module and maintain the lamination pressure of the core punching, thereby ensuring its good electrical performance. Multiple stator modules (which can each cover an angular interval of 90°, 60° or less) are attached one by one to the corresponding supporting structure components to form a complete generator stator.

[0004] WO2018197057A1 discloses a support structure segment for a generator of an abandoned turbine; WO2021170306A1 discloses a support structure and segmented status for an electric machine, wind turbine and method for manufacturing a support structure; and WO2022263070A1 discloses a support structure segment for a status of an agent of a wind turbine and wind turbine. In these designs, stacked core sheets are often connected to support structure sections by bolts. When the generator is operating, the stator core will be subjected to the dynamic magnetic attraction of the huge rotor poles, so the bolts will be subjected to huge dynamic tensile forces. Due to the limited cross-sectional area of ​​the bolts, their strength and fatigue life often constitute the weak link in the safety of the entire structure. Summary of the Invention

[0005] To overcome the above problems, an embodiment of the present application provides a stator module for a generator of a wind turbine generator and a manufacturing method thereof, which can improve structural safety and reliability.

[0006] The technical solution adopted in the present invention is:

[0007] In a first aspect, a stator module for a generator of a wind turbine is provided, characterized by comprising:

[0008] An iron core, wherein a plurality of teeth are evenly distributed along the circumferential direction on the top of the iron core, a winding slot is formed between two adjacent teeth, and a plurality of tenon grooves are opened along the circumferential direction on the bottom of the iron core;

[0009] a top block, the top block being arranged in the mortise and tenon groove;

[0010] The mortise beam is composed of an upper wing plate, a lower wing plate, and a web plate. The web plate is provided with a plurality of operating holes along the axial direction. The upper wing plate is provided with a fixing screw hole having the same number as the operating holes. The fixing screw holes penetrate the upper wing plate and communicate with the operating holes. The upper wing plate passes through the mortise groove of the iron core.

[0011] The set screw is passed through the operating hole into the set screw hole and pushed against the top block;

[0012] a pair of end plates, the pair of end plates clamping the iron core in the axial direction, the end plates being provided with access holes having the same shape as the cross-section of the tenon beam, and the two ends of each tenon beam being respectively inserted into the access holes of the two end plates;

[0013] a pair of side plates, wherein the pair of side plates are clamped on the pair of end plates in the circumferential direction, and the tenon beams and the end plates, as well as the side plates and the end plates, are connected as one piece; and

[0014] A plurality of groups of ring plates extend between the tenon beams and the side plates and are connected to the tenon beams and the side plates as a whole.

[0015] In a second aspect, a generator stator is provided, which is formed by attaching multiple stator modules described in the first aspect one by one.

[0016] In a third aspect, a generator for a wind turbine is provided, comprising the generator stator described in the second aspect.

[0017] In a fourth aspect, a method for manufacturing a stator module of a generator for a wind turbine generator as described in the first aspect is provided, comprising the following steps:

[0018] S1, prepare the punching sheet of the iron core;

[0019] S2, preparing mortise and tenon beams;

[0020] S3, preparing end plates, side plates and top blocks;

[0021] S4. Stack the punching sheets of the iron core together and insert the top block and the upper wing plate of the tenon beam into the tenon groove of the iron core;

[0022] S5. Stack the two end plates on both ends of the iron core, and insert both ends of all the tenon beams into the access holes of the two end plates respectively;

[0023] S6. Screw the set screw from the operating hole into the set screw hole;

[0024] S7. Partially weld all mortise beams to the same end plate;

[0025] S8. Apply a superimposed load to the two end plates and maintain this load;

[0026] S9. Tighten the set screw again with a predetermined torque;

[0027] S10, welding all the tenon beams to the two end plates to connect the iron core, the tenon beams, and the end plates into a whole to obtain an assembly;

[0028] S11, unloading the superimposed load applied on the end plate;

[0029] S12, welding the side plates and the ring plates to corresponding positions of the above assembly one by one to form a stator module.

[0030] The technical solutions provided by the embodiments of the present application may have the following beneficial effects:

[0031] As can be seen from the above embodiments, the design of the stator module provided by the present invention has a simple and clear electromagnetic force transmission path. The main force transmission components on the force transmission path are the iron core, the tenon beam, and the end plate. That is, the electromagnetic force is transmitted to the tenon beam through the stator iron core, and the tenon beam is then transmitted to the two end plates. Each force transmission component and the contact or connection method between them have a high load-bearing capacity. The set screws and spacers only play a positioning role for the iron core and the tenon beam and will not bear a large load. The side plates and ring plates play an auxiliary role in limiting deformation in the circumferential direction, and the actual circumferential load they bear is also relatively small. Therefore, compared with existing designs, the present invention can greatly improve structural safety and reliability and reduce structural complexity and cost.

[0032] It should be understood that the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the present application and, together with the description, serve to explain the principles of the present application.

[0034] Figure 1 It is a schematic diagram of the overall structure of a stator module according to an exemplary embodiment.

[0035] Figure 2 It is a schematic diagram of the partial structure of a stator module according to an exemplary embodiment.

[0036] Figure 3 It is a close-up partial cross-sectional view of a stator module according to an exemplary embodiment.

[0037] Figure 4 FIG. 4 is a schematic diagram of the core structure of a stator module according to an exemplary embodiment.

[0038] Figure 5 Schematic diagram of the end plate structure of a stator module according to an exemplary embodiment.

[0039] Figure 6 FIG. 1 is a schematic diagram of a tenon beam structure of a stator module according to an exemplary embodiment.

[0040] The reference numerals in the figures are:

[0041] 1. Iron core; 11. Teeth; 12. Winding slots; 13. Mortise and tenon; 2. End plates; 21. Access holes; 22. Mounting holes; 23. Positioning holes; 3. Mortise beams; 31. Upper wing plate; 32. Lower wing plate; 33. Web plate; 34. Operating holes; 35. Set screw holes; 4. Side plates; 5. Ring plates; 6. Top block; 7. Set screws; 8. Axial direction; 9. Circumferential direction. DETAILED DESCRIPTION

[0042] Exemplary embodiments will be described in detail herein, with examples 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 embodiments consistent with the present application. Rather, they are merely examples of apparatus and methods consistent with certain aspects of the present application, as detailed in the appended claims.

[0043] The terms used in this application are for the purpose of describing specific embodiments only and are not intended to limit this application. As used in this application and the appended claims, the singular forms "a," "an," "the," and "the" are intended to include the plural forms, unless the context clearly indicates otherwise. It should also be understood that the term "and / or" as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items.

[0044] It should be understood that although the terms first, second, third, etc. may be used in this application to describe various information, such information should not be limited to these terms. These terms are only used to distinguish information of the same type from each other. For example, without departing from the scope of this application, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Depending on the context, the word "if" as used herein may be interpreted as "at the time of" or "when" or "in response to determining".

[0045] refer to Figures 1-6 As shown, an embodiment of the present invention provides a stator module for a generator of a wind turbine, comprising: an iron core 1, a top block 6, a tenon beam 3, a set screw 7, a pair of end plates 2, a pair of side plates 4 and a plurality of ring plates 5, wherein:

[0046] The top of the iron core 1 is evenly provided with a plurality of teeth 11 along the circumferential direction 9, and a winding slot 12 is formed between two adjacent teeth 11. Windings can be wound in the winding slots 12, or concentrated windings can be installed. The bottom of the iron core 1 is provided with a plurality of tenons 13 along the circumferential direction 9. The cross-section of the tenon 13 can be dovetail-shaped, or circular, rectangular, etc.; the top block 6 is arranged in the tenon 13; this design facilitates the independent and modular manufacturing of the iron core 1 and its adjacent components such as windings, iron core support structures, etc., reducing the difficulty of manufacturing and assembly.

[0047] The tenon beam 3 is composed of an upper wing plate 31, a lower wing plate 32, and a web 33. The web 33 is provided with a plurality of operating holes 34 along the axial direction 8. The upper wing plate 31 is provided with fixing screw holes 35 having the same number as the operating holes 34. The fixing screw holes 35 penetrate the upper wing plate 31 and are connected with the operating holes 34. The upper wing plate 31 passes through the tenon groove 13 of the iron core 1. This design enables the iron core 1 to be subjected to electromagnetic tension, and the tension can be directly transmitted from the tenon groove 13 of the iron core 1 to the upper wing plate 31 of the tenon beam 3.

[0048] The set screw 7 is inserted into the set screw hole 35 from the operating hole 34, and is tightened with a certain tightening torque and pushed against the top block 6, so that the matching surfaces of the upper wing plate 31 and the tenon groove 13 are completely fitted together, and the matching surfaces of the top block 6 and the tenon groove 13 are completely fitted together; the set screw 7 is in a pre-tightened pressure state and is not subjected to tension at any time, so it does not have the problem of strength or fatigue failure.

[0049] A pair of end plates 2 clamp the iron core 1 in the axial direction 8, and an access hole 21 with the same shape as the cross-section of the tenon beam 3 is opened on the end plate 2. The two ends of each tenon beam 3 are respectively inserted into the access holes 21 of the two end plates 2, so that the iron core 1 and the tenon beam 3 can be accurately matched and installed with the end plates 2; this design can effectively ensure the assembly and manufacturing accuracy of the generator.

[0050] A pair of side plates 4 are clamped on a pair of end plates 2 in the circumferential direction 9, and the tenon beams 3 and the end plates 2, as well as the side plates 4 and the end plates 2, are connected as a whole by welding, thereby achieving good stiffness characteristics of the structure in the axial direction 8.

[0051] The plurality of ring plates 5 extend between the tenon beams 3 and the side plates 4 and are integrally connected with the tenon beams 3 and the side plates 4 , thereby enhancing the rigidity of the structure in the circumferential direction 9 .

[0052] The end plate 2 is provided with mounting holes 22 and positioning holes 23 , and a plurality of stator modules are attached one by one through the mounting holes 22 and positioning holes 23 , thereby forming a complete generator stator.

[0053] As can be seen from the above embodiments, the design of the stator module provided by the present invention has a simple and clear electromagnetic force transmission path. The main force transmission components on the force transmission path are the iron core 1, the tenon beam 3, and the end plate 2. That is, the electromagnetic force is transmitted to the tenon beam 3 through the stator iron core 1, and the tenon beam 3 is then transmitted to the two end plates 2. Each force transmission component and the contact or connection method between them have a high load-bearing capacity. The set screws 7 and the pads only play a positioning role for the iron core 1 and the tenon beam 3 and will not bear a large load. The side plates 4 and the ring plates 5 play an auxiliary role in limiting the deformation in the circumferential direction 9, and the actual circumferential load they bear is also relatively small. Therefore, compared with existing designs, the present invention can greatly improve the structural safety and reliability and reduce the structural complexity and cost.

[0054] This embodiment further provides a method for manufacturing a stator module of a generator for a wind turbine generator, comprising the following steps:

[0055] S1, preparing the punching sheets of the iron core 1;

[0056] S2, prepare the tenon beam 3, which can be obtained by secondary machining of appropriate profiles if possible;

[0057] S3. Prepare the end plate 2, side plate 4, top block 6 and other components. The set screw 7 can be a standard part, such as the GB / T 85-1988 square head long cylindrical point set screw;

[0058] S4. Stack the punching sheets of the iron core 1 together, and insert the top block 6 and the upper wing plate 31 of the tenon beam 3 into the tenon groove 13 of the iron core 1;

[0059] S5. Lay the two end plates 2 on both ends of the iron core 1, and insert both ends of all the tenon beams 3 into the access holes 21 of the two end plates 2 respectively;

[0060] S6. Screw the set screw 7 from the operating hole 34 into the set screw hole 35, and use a torque wrench to tighten the set screw 7 with a small torque, for example, 10% of the standard tightening torque;

[0061] S7. Spot weld all the tenon beams 3 to the same end plate 2 so that the tenon beams 3 cannot move in the access holes 21 of the end plate 2;

[0062] S8. Apply a superimposed load to the two end plates 2 and maintain this load;

[0063] S9. Tighten the set screw 7 again with an appropriate torque using the torque wrench, for example, tightening the set screw 7 with a torque of 50% of the standard tightening torque;

[0064] S10, welding all the tenon beams 3 to the two end plates 2 to connect the iron core 1, the tenon beams 3, and the end plates 2 into a whole;

[0065] S11, unloading the superimposed load applied on the end plate 2;

[0066] S12, welding the side plates 4 and the ring plates 5 to corresponding positions of the above-mentioned assembly one by one, and finally forming a stator module.

[0067] Those skilled in the art will readily appreciate other embodiments of the present application after considering the specification and practicing the contents disclosed herein. This application is intended to cover any variations, uses, or adaptations of the present application that follow the general principles of the present application and include common knowledge or customary techniques in the art not disclosed herein. The description and examples are to be considered merely as exemplary, and the true scope and spirit of the present application are indicated by the claims.

[0068] It should be understood that the present application is not limited to the exact structures described above and shown in the drawings, and that various modifications and changes may be made without departing from the scope thereof. The scope of the present application is limited only by the appended claims.

Claims

1. A stator module for a generator of a wind turbine, characterized in that: include: An iron core, wherein a plurality of teeth are evenly distributed along the circumferential direction on the top of the iron core, a winding slot is formed between two adjacent teeth, and a plurality of tenon grooves are opened along the circumferential direction on the bottom of the iron core; a top block, the top block being arranged in the mortise and tenon groove; The mortise beam is composed of an upper wing plate, a lower wing plate, and a web plate. The web plate is provided with a plurality of operating holes along the axial direction. The upper wing plate is provided with a fixing screw hole having the same number as the operating holes. The fixing screw holes penetrate the upper wing plate and communicate with the operating holes. The upper wing plate passes through the mortise groove of the iron core. The set screw is passed through the operating hole into the set screw hole and pushed against the top block; a pair of end plates, the pair of end plates clamping the iron core in the axial direction, the end plates being provided with access holes having the same shape as the cross-section of the tenon beam, and the two ends of each tenon beam being respectively inserted into the access holes of the two end plates; a pair of side plates, wherein the pair of side plates are clamped on the pair of end plates in the circumferential direction, and the tenon beams and the end plates, as well as the side plates and the end plates, are connected as one piece; and A plurality of groups of ring plates extend between the tenon beams and the side plates and are connected to the tenon beams and the side plates as a whole.

2. The stator module of a generator for a wind turbine according to claim 1, characterized in that: The end plate is provided with mounting holes and positioning holes, and a plurality of stator modules are attached one by one through the mounting holes and positioning holes, thereby forming a complete generator stator.

3. The stator module of a generator for a wind turbine according to claim 1, characterized in that: The cross section of the tongue and groove is dovetail-shaped, circular or rectangular.

4. A generator stator, characterized in that: The stator module is formed by attaching a plurality of stator modules according to claim 2 one by one.

5. A generator for a wind turbine generator, comprising the generator stator according to claim 3.

6. A method for manufacturing a stator module of a generator for a wind turbine according to any one of claims 1 to 3, characterized in that: The steps include: S1, prepare the punching sheet of the iron core; S2, preparing mortise and tenon beams; S3, preparing end plates, side plates and top blocks; S4. Stack the punching sheets of the iron core together and insert the top block and the upper wing plate of the tenon beam into the tenon groove of the iron core; S5. Stack the two end plates on both ends of the iron core, and insert both ends of all the tenon beams into the access holes of the two end plates respectively; S6. Screw the set screw from the operating hole into the set screw hole; S7. Partially weld all mortise beams to the same end plate; S8. Apply a superimposed load to the two end plates and maintain this load; S9. Tighten the set screw again with a predetermined torque; S10, welding all the tenon beams to the two end plates to connect the iron core, the tenon beams, and the end plates into a whole to obtain an assembly; S11, unloading the superimposed load applied on the end plate; S12, welding the side plates and the ring plates to corresponding positions of the above assembly one by one to form a stator module.

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