Fiber reinforced composite armature winding support structure for superconducting machine

Abstract

A rotary machine includes a field winding assembly and an armature winding assembly having a plurality of winding modules. Each of the plurality of winding modules includes a plurality of conductive coils and at least one armature winding support structure. The armature winding support structure includes a body and a plurality of slots defined between adjacent teeth extending radially from the body. The plurality of slots receive and support a subset of the plurality of conductive coils therein. The armature winding support structure further includes a plurality of support bars disposed within the body and a fiber reinforced composite structure secured around each of the plurality of winding modules.

Description

Technical Field

[0001] The present disclosure relates generally to superconducting machines, and more particularly to armature winding support structures for superconducting machines. Background Art

[0002] As an alternative energy source that is safe for the environment and relatively inexpensive, wind turbines have received increasing attention. With this growing interest, considerable efforts have been made to develop reliable and efficient wind turbines. Generally, a wind turbine includes a plurality of rotor blades connected to the main shaft of the turbine via a rotor hub. The rotor hub is located on the top of a tubular tower or base. Utility-grade wind turbines (i.e., wind turbines designed to provide electrical power to a utility grid) can have large rotors (e.g., 100 meters or more in diameter). The rotor blades convert wind energy into a rotational torque or force that drives a generator that is rotationally connected to the rotor.

[0003] Low reactance machines (e.g., superconducting generators) are being explored for use in wind turbine installations, particularly offshore installations. In such machines, the low reactance is a natural result of the air gap windings (discussed below), which can produce higher forces and torques in the armature windings during abnormal events (such as electrical faults in the windings or equipment connected to the windings). These higher forces and torques must be managed so that destructive movement of the winding conductors does not occur. These machines use superconducting field windings and armature coil assemblies, cooling systems, and non-magnetic teeth disposed between the coils in the armature. In a particular design, the superconducting generator includes an armature winding assembly that, unlike conventional machine (e.g., conventional non-superconducting generator) configurations, rotates within a superconducting excitation assembly that includes a cryostat with superconducting excitation coils within the cryostat.

[0004] In addition, the armature winding in a rotating electrical machine (such as a motor and a generator) typically embeds the conductor comprising the armature winding into an iron structure (such as a magnetic core), and the iron structure includes an axial slot to receive the conductor. The iron structure is configured to enhance the performance of the motor and provide mechanical support for the winding. In a motor that uses a superconducting coil in the field winding, the magnetic field in the air gap between the superconducting coil and the armature winding may be strong enough to saturate the tooth magnetic field of the core. In those cases, the portion of the magnetic core closest to the field coil is usually removed, leaving only an annular ring. The armature winding without any magnetic material can then be attached to the annular ring in the space between the ring and the field coil. In this case, the winding can be called an air gap winding.

[0005] In some cases, airgap windings can be associated with certain problems. For example, the magnetic forces that produce the braking torque on the rotor usually act on the iron teeth that contain the armature winding. However, in airgap windings, these magnetic forces act on the conductors themselves. In addition, the absence of teeth means that support for the coils must be achieved by other means. The underlying principle of designing and manufacturing reliable armature windings is to minimize or eliminate spaces in the assembly so that vibration or movement (other than thermal expansion) cannot occur. If space is available, the conductor will eventually move into that space. In addition, movement causes wear, creates more space, and failures.

[0006] In particular, there are multiple sources of motion in the armature windings that can cause winding failure, including thermal expansion, normal vibrations, and fault forces. Thermal expansion forces are applied every time the generator changes the power it produces. Higher power output corresponds to greater currents, greater losses, and higher temperatures in the windings. This increase in temperature causes the windings to expand, most notably in the axial direction. The thermal forces that drive this expansion are unavoidable but can be accurately calculated, and they are applied to the windings over periods ranging from seconds to minutes. Normal vibrations of the windings are caused by magnetic forces acting directly on the conductors, which will be an order of magnitude smaller than the thermal forces but occur at a frequency twice the electrical frequency. Fault forces occur infrequently and unexpectedly. However, when fault forces occur, their magnitude may be 100 times that of the thermal forces and may be high enough to damage the insulation on the armature conductors or move these conductors from their normal positions.

[0007] In view of the foregoing, there is a continuing search in the art for new and improved generators, and more particularly, armature winding support structures for superconducting generators. Summary of the invention

[0008] Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

[0009] In one aspect, the present disclosure relates to a rotating machine. The rotating machine includes an excitation winding assembly and an armature winding assembly having a plurality of winding modules. Each of the plurality of winding modules includes a plurality of conductive coils and at least one armature winding support structure. The armature winding support structure includes a body and a plurality of slots defined between adjacent teeth extending radially from the body. The plurality of slots receive and support subsets of the plurality of conductive coils therein. The armature winding support structure further includes a plurality of support rods arranged within the body and a fiber-reinforced composite structure fixed around each of the plurality of winding modules.

[0010] In another aspect, the present disclosure relates to an armature winding assembly. The armature winding assembly includes a plurality of winding modules. Each of the plurality of winding modules includes a plurality of conductive coils and at least one armature winding support structure. The armature winding support structure includes a body and a plurality of slots defined between adjacent teeth extending radially from the body. The plurality of slots receive and support subsets of the plurality of conductive coils therein. The armature winding support structure further includes a plurality of support rods arranged within the body and a fiber reinforced composite structure fixed around each of the plurality of winding modules.

[0011] These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims.The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present invention and together with the description serve to explain the principles of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] A complete and enabling disclosure of the present invention, including the best mode thereof, is set forth in the specification for one of ordinary skill in the art, and the specification refers to the accompanying drawings, in which:

[0013] Figure 1 shows a perspective view of one embodiment of a wind turbine having a generator according to the present disclosure;

[0014] Figure 2 shows an interior perspective view of one embodiment of a nacelle of a wind turbine having a superconducting generator according to the present disclosure;

[0015] Figure 3 Showing a side view of a generator according to aspects of the present invention;

[0016] Figure 4 shows a front view of an embodiment of an armature winding assembly of a generator according to the present disclosure;

[0017] Figure 5 A front view showing an embodiment of a winding module of an armature winding support structure of an armature winding assembly for a generator according to the present disclosure;

[0018] Figure 6 A front view showing another embodiment of a winding module of an armature winding support structure of an armature winding assembly for a generator according to the present disclosure;

[0019] Figure 7 A front view showing an embodiment of a body of a winding module of an armature winding support structure according to the present disclosure;

[0020] Figure 8 shows a front view of another embodiment of a body of an armature winding support structure according to the present disclosure;

[0021] Fig. 9 A side view showing an embodiment of a winding module of an armature winding support structure of an armature winding assembly for a generator according to the present disclosure;

[0022] Fig.10 A front view showing an embodiment of a winding module of an armature winding support structure of an armature winding assembly for a generator according to the present disclosure, particularly showing radial forces and tangential forces acting on the winding module;

[0023] Fig.11 A front view showing another embodiment of a winding module of an armature winding support structure of an armature winding assembly for a generator according to the present disclosure, particularly showing radial forces and tangential forces acting on the winding module; and

[0024] Fig.12 A simplified view of an embodiment of the present disclosure showing the transmission of radial forces to a rotating component of a generator through various components of an armature winding support structure.

[0025] Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention. DETAILED DESCRIPTION

[0026] Reference will now be made in detail to embodiments of the present invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided in a manner that explains the present invention rather than limiting the present invention. In fact, it will be apparent to those skilled in the art that various modifications and variations may be made in the present invention without departing from the scope or spirit of the present invention. For example, a feature illustrated or described as part of one embodiment may be used together with another embodiment to produce yet another embodiment. Therefore, the present invention is intended to encompass such modifications and variations within the scope of the appended claims and their equivalents.

[0027] Unless otherwise specified herein, the terms "coupled," "fixed," "attached to," and the like refer to both direct coupling, fixing, or attachment as well as indirect coupling, fixing, or attachment via one or more intermediate members or features.

[0028] In general, the present disclosure relates to a rotating machine having an excitation winding assembly and an armature winding assembly, the armature winding assembly having a plurality of winding modules. Each of the plurality of winding modules includes a plurality of conductive coils and a plurality of armature winding support structures. Each of the armature winding support structures includes a body, a plurality of slots defined between adjacent teeth extending radially from the body, a plurality of support rods arranged within the body, and a fiber reinforced composite structure fixed around each of the plurality of winding modules. The plurality of slots receive and support a subset of the plurality of conductive coils therein.

[0029] Therefore, in one embodiment, the armature winding assembly is arranged to produce, for example, alternating north and south magnetic poles on the surface of the rotatable component. In one embodiment, each pair of north and south poles (referred to herein as winding modules) may include a magnetic core typically made of thin iron laminations and held compressed by a number of axial compression studs. In addition, the winding module includes a group of conductive coils connected in a manner to produce a north-south magnetic effect, electrical insulation around those conductive coils, cooling channels and / or filler materials. In addition, in one embodiment, the winding module may include coil wedge teeth, a non-metallic coil cover structure that protrudes inwardly between the coils for the full effective length range of the winding, and a fiber-reinforced composite tape to accommodate module components.

[0030] Therefore, the present disclosure provides many advantages that are not present in the prior art. For example, with the appropriate construction of the conductive coils, axial wedges, cooling channels and / or full-length radial teeth, any space within the winding module that would allow the conductive coils to move can be eliminated. In addition, given that some embodiments of the present disclosure may be very large compared to conventional generators with similar electrical ratings, it is necessary to expect small deflections of large structures, or accumulation of small changes in component size (which may lead to excessive gaps within the winding). As an example, for the same power and torque, the slower the generator rotates, the larger the generator must be. As an example, a high-speed (e.g., 3600rpm) generator typically has a rotor diameter of about 0.3 meters to about 1.2 meters. Anything will have excessive mechanical stress. Therefore, a wind turbine with a lower speed (such as about 8rpm) has a generator rotor diameter of about 5-10 meters, an order of magnitude larger than a conventional generator. However, the band of the present disclosure placed only around the two poles of the winding assembly more effectively limits the gaps that might otherwise accumulate. Therefore, in one embodiment, the band placed around the portion of the winding module can ensure that the tight packing remains in place, resulting in effective and reliable support for the armature coil. Furthermore, the use of fiber reinforced composite tape is cost effective, and the process of manufacturing the winding modules can be automated to achieve uniform application of the fiber reinforced composite tape to ensure a reliable product.

[0031] In further embodiments, when the generator assembly is mounted on top of the wind turbine, individual winding modules can be removed from the rotating component for maintenance and / or replacement. Specifically, in one embodiment, the present disclosure is directed to a winding module in which the entire contents of the module (e.g., iron laminations, conductive coils, cooling channels, non-metallic supports, etc.) are fully contained within the module. This containment facilitates removal of the winding module from the rotating component for maintenance and / or replacement.

[0032] With reference to the accompanying drawings, Figure 1A perspective view of a wind turbine 10 is shown. As mentioned, the present disclosure is directed to a generator that is particularly suitable for use with a wind turbine 10, although not limited to such use. Figure 1 An "onshore" (land-based) wind turbine 10 installation is depicted, but it will be appreciated that the present invention is not limited to onshore wind turbines, and is equally applicable to "offshore" (water-based) wind turbine installations.

[0033] Although a superconducting generator is depicted in the figures and described herein, it should be understood that the present invention is not limited to superconducting generators and is applicable to any generator configuration having a rotating member. For example, the generator can be configured so that the armature winding assembly rotates around a stationary excitation assembly. In an alternative generator configuration, the excitation assembly can rotate around a stationary armature winding assembly. In yet another alternative generator configuration, the generator can include a rotating permanent magnetic field having a less expensive permanent magnetic material.

[0034] Still refer to Figure 1 , wind turbine 10 includes a tower 12 extending from a support surface 14, a nacelle 16 mounted on tower 12, and a rotor 18 coupled to nacelle 16. Rotor 18 includes a rotatable hub 20 and at least one rotor blade 22 coupled to hub 20 and extending outwardly from hub 20. For example, in the illustrated embodiment, rotor 18 includes three rotor blades 22. However, in alternative embodiments, rotor 18 may include more or less than three rotor blades 22. The individual rotor blades 22 may be spaced apart around hub 20 to facilitate rotation of rotor 18, thereby enabling kinetic energy to be converted from wind into usable mechanical energy, and subsequently into electrical energy. For example, hub 20 may be rotatably coupled to a generator (not shown) located within nacelle 16 to allow electrical energy to be generated.

[0035] Reference now Figure 2 , shows an interior perspective view of an embodiment of a nacelle 16 according to the present disclosure, housing a superconducting generator 23 therein. Further, as shown, a support tube 40 is directly connected to the hub 20 and supports an armature winding assembly 24. Thus, the armature winding assembly 24 is considered a rotating member of the generator 23, having a rotating first electromagnetic member configuration in the form of a conductive coil 27 (with end turns 28) that rotates around a stationary excitation assembly 26 having a second electromagnetic member configuration, such as a superconducting excitation winding assembly 26.

[0036] The stationary excitation assembly 26 includes a superconducting coil 63, which can be a set of wires formed into a racetrack shape. As used herein, a "racetrack" shape generally refers to a two-dimensional shape consisting of a rectangle or a square, which has a semicircular shape at a pair of opposite ends. Therefore, in some embodiments, the superconducting coil 63 is constrained to maintain a racetrack shape. In addition, as shown, each superconducting coil 63 is supported in a recess / channel 83 in a shell 71, which can be cooled to a cryogenic temperature by a helium bath or by other methods known in the field of cryogenic engineering. Therefore, the shell 71 can be supported in a cryostat housing 56 fixed to the base tube 44. Therefore, as shown in the illustrated embodiment, the mounting member 47 can support the base tube 44 within the nacelle 16.

[0037] Still refer to Figure 2 , the superconducting coils 63 may be arranged side by side in an annular array extending around the shell 71. For example, in one embodiment, thirty-six (36) coils may form an annular field winding array that serves as the stator field winding for the generator 23. Furthermore, in one embodiment, the superconducting coils 63 may each be formed of (NbTi or other superconducting) wire that is wound in a spiral around a racetrack form that may include a cooling conduit for helium.

[0038] In additional embodiments, the cryogen recondensers 60, 64 may be housed in the nacelle 16, provided that the cryogen coolant in the recondensers 60, 64 is at least partially elevated above the superconducting field windings to provide a gravity supply of cryogen to the windings. Alternatively, the recondensers 60, 64 may be mounted on top of the nacelle 16.

[0039] Reference now Figure 3 , shows a cross-section of an embodiment of a superconducting generator 23, wherein an annular rotating armature winding assembly 24 ("armature 24") is radially located inside a stationary excitation assembly 26. Specifically, as shown, the armature 24 is essentially an inner annular ring configuration ( Figure 4 ), which rotates within a stationary excitation assembly 26. The armature 24 includes conductive coils 27, such as coils or bars, arranged longitudinally along the length of the armature 24 and on the inner cylindrical surface of the armature 24. The conductive coils 27 may be interconnected at their opposite ends by conductive end turns 28. The end turn connections 28 between the longitudinal conductive coils 27 depend on their number and arrangement, as well as the electrical phase generated in the conductive coils 27. The inner cylindrical surface of the armature winding is separated from the outer surface of the stationary excitation assembly 26 by a narrow air gap (e.g., about 10-25 mm).

[0040] Thus, in one embodiment, the armature 24 may be configured to be coupled to a generator rotor 25 (eg, a rotating electromagnetic component configuration (eg, conductive coils 27 and end turns 28) Figure 4) rotates together, and the stationary excitation assembly 26 can be constructed with a stationary electromagnetic component configuration (superconducting coil 63 ( Figure 2 ))'s stationary component.

[0041] Generally speaking Figure 3-8 The armature 24 includes a cylindrical yoke or body 30 (referred to herein as the "body") that supports the conductive coil 27. Specifically, the conductive coil 27 is contained in the slot 110 ( Figure 5-6 ), the slots 110 are defined between adjacent teeth 106 extending radially from the body 30. The body 30 and the teeth 106 can be a layered laminated structure. For example, in one embodiment, the layered structure of the body 30 can include a magnetic steel sheet (e.g., about 0.5 mm thick) for generally recognized electromagnetic purposes. In addition, in one embodiment, the teeth 106 can include a fiberglass layer or other suitable non-metallic material structure molded to form the shape. The inner surface of the body 30 is fixed to a cylindrical housing 29 that rotates with the armature 24. The housing 29 is assembled to a circular disk 34 that supports the housing 29 and the armature 24.

[0042] The circular disk 34 is fixed to a rotating cylindrical support tube 40. On the outer surface of the support tube 40, a slip ring assembly 41 is provided with contacts for each phase of the AC power generated by the generator 23. The slip ring 41 is electrically coupled to the conductive coil 27 of the rotating armature 24 and rotates with the support tube 40. Stationary connections such as carbon brushes (not shown) conduct electricity from the slip ring 41 and the armature 24 to the wire conductors, which extend to the electronic power converter and step-up transformer, and then down the tower and connected to the power utility grid, plant or other electrical power load.

[0043] A pair of annular bearings 42 are disposed toward opposite ends of the support tube 40 and rotatably support the support tube 40 on a stationary base tube 44 that is attached to a mount 47 that is supported by the floor of the nacelle 16 .

[0044] The cryostat housing 56 isolates the superconducting coils so that they can be cooled to near absolute zero, for example, to 10 Kelvin (K), and preferably to 4K. To cool the windings, the cryostat housing 56 may include one or more insulating conduits 58 to receive liquid helium (He) or other similar cryogenic liquids (referred to as cryogen). A conventional two-stage recondenser 60 is mounted in an upper region of the nacelle 16, on top of the nacelle 16 or on top of the tower 12 and above the field windings to provide cryogen, such as liquid helium, using a gravity feed. A second recondenser 64 provides a second cooling liquid, such as liquid nitrogen or neon, to the inner heat shield of the cryostat housing 56 via a conduit 66.

[0045] Reference now Figure 4-12, showing various components of an embodiment of a fiber reinforced composite armature winding support 100 for an armature winding assembly 24 according to aspects of the present disclosure. Specifically, as Figure 4 , a front view of an embodiment of an armature winding assembly 24 of a generator 23 according to the present disclosure is shown. More specifically, as shown, the generator 23 includes a non-rotating member that supports an excitation winding assembly, such as a stationary excitation assembly 26, and a rotatable member, such as a generator rotor 25 on which the armature winding assembly 24 is mounted, the rotatable member being oriented to rotate relative to the stationary excitation assembly 26 during operation of the generator 23. Thus, in certain embodiments, for example, the armature winding assembly 24 is fixedly coupled to the generator rotor 25 so as to rotate therewith during operation of the generator 23.

[0046] As mentioned, the armature winding assembly 24 includes a plurality of conductive coils 27. More specifically, as shown in FIG. Figure 4-6 As shown in FIG. 1 , the armature winding assembly 24 has a plurality of winding modules 102. Each of the plurality of winding modules 102 includes a plurality of conductive coils 27 and at least one armature winding support structure 103. More specifically, as Figure 4 , a plurality of winding modules 102 are arranged circumferentially around a rotatable member, ie, a generator rotor 25. In certain embodiments, for example, each of the plurality of winding modules 102 may extend about 10 degrees to about 20 degrees of the circumference of the armature winding assembly 24, such as about 18 degrees.

[0047] Special References Figure 5 and 6 , two axial cross-sections of one of the winding modules 102 are shown. For clarity, Figure 5 and 6 A winding module 102 having six conductive coils 27 is shown, however, it should be understood that the winding module 102 described herein may include any suitable number of conductive coils 27, such as 24 or more. Figure 5 shows a cross section in which a module component is comprised of a fiber reinforced composite tape 114 as described herein without being attached to a generator rotor 25, whereas Figure 6 Different cross sections are shown at the point where the winding module 102 is fixed to the generator rotor 25 , for example via a dovetail connection 128 .

[0048] like Figure 5-8 As shown generally in FIG. 1 , the armature winding support structure 103 includes a body 104 which may be formed of one or more iron laminations. Figure 5 1 shows a front view of an embodiment of a winding module 102 having a body 104 with a first iron lamination configuration, and Figure 6A front view of another embodiment of a winding module 102 having a body 104 with different second iron laminations is shown. Specifically, Figure 7 The main body 104 shown in FIG. 1 has a support structure 126 radially disposed between the main body 104 and the generator rotor 25, and Figure 8 The support structure 126 is absent and is used in the area around which the fiber reinforced composite tape 114 described herein is wrapped.

[0049] In addition, as shown, the armature winding support structure 103 includes a plurality of notches 110 defined between adjacent teeth 106 extending radially from the body 104. For example, as shown, the adjacent teeth 106 may include a plurality of wedge-shaped teeth disposed in a plurality of recesses 120 ( Figure 7-8 ) to provide lateral (tangential) support for the conductive coils 27. In such an embodiment, as shown, the plurality of slots 110 receive and support a subset of the plurality of conductive coils 27 therein.

[0050] Furthermore, in one embodiment, Figure 5-6 9-10, each winding module 102 may include a coil cover structure 124 that extends around a plurality of conductive coils 27 within the fiber reinforced composite structure 112. Thus, in one embodiment, the conductive coils 27 may be placed on the outer surface of the body 104 between the teeth 106. In another embodiment, the coil cover structure 124 may include a plurality of full-length non-metallic coil caps that may be inserted over and between radially outer portions of the conductive coils 27. Thus, in one embodiment, the coil cover structure 124 may be molded or machined from a suitable material with a circumference spanning two or more conductive coils 27. Thus, the coil caps may be distinguished from the wedge-shaped teeth 106, which only occupy a single space between the conductive coils 27.

[0051] In addition, if Figure 5 , 9 10, each winding module 102 includes a fiber reinforced composite structure 112 fixed around each of the plurality of winding modules 102. For example, in one embodiment, as shown, the fiber reinforced composite structure 112 may include one or more fiber reinforced composite tapes 114, such as a plurality of fiber reinforced composite tapes 114, such as Fig. 9 Therefore, if Fig. 9 , the fiber reinforced composite tape 114 may be wrapped around each body 104 and a subset of the plurality of conductive coils 27 and cured thereon to form one of the winding modules 102. In particular, Fig. 9A side view of one of the winding modules 102 is shown, with several tape sections interleaved with sections for attachment to the generator rotor 25. In this way, the length section supported by the fiber reinforced composite tape 114 and the length section attached to the generator 25 can be determined so that all mechanical forces are properly accounted for.

[0052] In certain embodiments, the fiber reinforced composite tape 114 may be composed of, for example, glass fiber or carbon fiber. In such embodiments, the fiber reinforced composite tape 114 does not prevent thermally induced axial expansion. Instead, the fiber reinforced composite tape 114 may function unrestrained and limit radial and tangential motion of the conductive coil 27. Thus, in one embodiment, the forces driving the motion will be load torque, normal operating vibrations, and / or fault forces.

[0053] In additional embodiments, as shown, each winding module 102 includes a plurality of support rods 108 disposed within the body 104. In such embodiments, the support rods 108 may be constructed of, for example, a metal or metal alloy. Thus, in one embodiment, the support rods 108 may include a set of full-length axial members ("key rods") located on the radially inner portion of the winding module 102 to axially transfer forces acting on the banded portions of the module 102 to those portions attached to the generator rotor 25.

[0054] In a further embodiment, Figure 5-6 As shown in FIGS. 9-10 , the armature winding support structure 103 may further include one or more axially extending studs 116 for providing compression to the corresponding winding module 102. Figure 7 and 8 As shown in FIG. 1 , the body 104 of the armature winding support structure 103 may include one or more through holes 122 for receiving the studs 116 extending in the axial direction.

[0055] Furthermore, in one embodiment, Figure 5-6 9-10, each winding module 102 may further include one or more cooling channels 118 disposed between each conductive coil 27. In such an embodiment, the cooling channels are configured to remove heat from the conductive coil 27.

[0056] Special References Fig.10 and 11 , showing the Figure 5 and 6 The tangential force F on the winding module 102 θ and radial force F RThese forces are substantially uniform over the effective axial length of the winding module 102, such that forces are applied to both the belted sections and the non-belted sections. Thus, in one embodiment, the wedge teeth 106 and the non-metallic coil cover structure 124 are configured to transfer forces from the non-belted sections to the adjacent belted sections.

[0057] In addition, and with reference Fig.12 , a set of example free body diagrams show how radial forces on the winding modules 102 described herein are ultimately transferred to the generator rotor 25. Specifically, as shown, the various arrows illustrate radial forces between the conductive coils 27, the support rods 108, and the body 104 of one of the winding modules 102.

[0058] In addition, those skilled in the art will recognize the interchangeability of various features from different embodiments. Similarly, those of ordinary skill in the art can mix and match the various method steps and features described, as well as other known equivalents of each such method and feature, to build additional systems and techniques according to the principles of the present disclosure. Of course, it should be understood that not necessarily all of such purposes or advantages described above can be achieved according to any particular embodiment. Thus, for example, those skilled in the art will recognize that the systems and techniques described herein can be embodied or performed in a manner that achieves or optimizes one advantage or a group of advantages as taught herein, without necessarily achieving other purposes or advantages as may be taught or suggested herein.

[0059] Further aspects of the invention are provided by the subject matter of the following clauses: Clause 1. A rotating machine comprising: Field winding assembly; An armature winding assembly comprising a plurality of winding modules, each of the plurality of winding modules comprising a plurality of conductive coils and at least one armature winding support structure, the at least one armature winding support structure comprising: main body; A plurality of notches are defined between adjacent teeth extending radially from the body, the plurality of notches being a slot receiving and supporting a subset of the plurality of conductive coils therein; a plurality of support rods disposed within the body; and A fiber-reinforced composite structure is secured around each of the plurality of winding modules. Clause 2. A rotating machine as described in clause 1, wherein the body is formed from one or more magnetic laminations. Clause 3. A rotating machine according to any of the preceding clauses, wherein the plurality of support rods are made of metal or a metal alloy, and one or more of the plurality of support rods extend the entire axial length of one of the plurality of winding modules so as to transmit forces acting on the fiber reinforced composite structure axially to a rotatable member of the rotating machine. Clause 4. A rotating machine according to any one of the preceding clauses, wherein the fiber reinforced composite structure comprises one or more fiber reinforced composite tapes. Clause 5. The rotating machine of clause 4, wherein the one or more fiber-reinforced composite tapes are comprised of at least one of: glass fibers, synthetic fibers, polymer fibers, wood fibers, ceramic fibers, metal fibers, carbon fibers, or combinations thereof. Clause 6. A rotary machine as recited in any preceding clause, wherein a fiber reinforced composite structure is wound around the body and a subset of the plurality of electrically conductive coils and cured thereon to form one of the plurality of winding modules. Clause 7. The rotary machine of any of the preceding clauses, wherein each of the plurality of winding modules further comprises one or more axially extending studs for providing compression to the respective winding module. Clause 8. The rotary machine of any of the preceding clauses, wherein each of the plurality of winding modules further comprises one or more cooling channels disposed adjacent to or within the plurality of conductive coils. Clause 9. A rotary machine as recited in any one of the preceding clauses, wherein adjacent teeth comprise a plurality of wedge-shaped teeth disposed within a plurality of recesses formed in the body. Clause 10. The rotary machine of Clause 9, further comprising a coil cover structure extending around the plurality of electrically conductive coils within the fiber reinforced composite structure. Clause 11. The rotary machine of any of the preceding clauses, wherein each of the plurality of winding modules extends from about 10 degrees to about 20 degrees of the circumference of the armature winding assembly. Clause 12. A rotary machine as recited in any one of the preceding clauses, wherein at least one of the field winding assembly and the armature winding assembly is a superconducting winding assembly having superconducting coils. Clause 13. An armature winding assembly comprising: A plurality of winding modules, each of the plurality of winding modules comprising a plurality of conductive coils and at least one armature winding support structure, the at least one armature winding support structure comprising: main body; A plurality of notches are defined between adjacent teeth extending radially from the body, the plurality of notches being a slot receiving and supporting a subset of the plurality of conductive coils therein; a plurality of support rods disposed within the body; and A fiber-reinforced composite structure is secured around each of the plurality of winding modules. Clause 14. The armature winding assembly of Clause 13, wherein the body is comprised of one or more magnetic laminations. Clause 15. An armature winding assembly according to clauses 13 to 14, wherein the plurality of support rods are formed of metal or a metal alloy, and one or more of the plurality of support rods extend the entire axial length of one of the plurality of winding modules so as to axially transmit forces acting on the fiber reinforced composite structure to a rotatable member of a rotating machine. Clause 16. An armature winding assembly according to clauses 13 to 15, wherein the fiber-reinforced composite structure comprises one or more fiber-reinforced composite tapes, wherein the one or more fiber-reinforced composite tapes are composed of at least one of the following: glass fibers, synthetic fibers, polymer fibers, wood fibers, ceramic fibers, metal fibers, carbon fibers, or combinations thereof. Clause 17. The armature winding assembly of clauses 13 to 16, wherein a fiber reinforced composite structure is wound around the body and a subset of the plurality of coils and cured thereon to form one of the plurality of winding modules. Clause 18. The armature winding assembly of clauses 13 to 17, wherein each of the plurality of winding modules further comprises one or more axially extending studs for providing compression to the corresponding winding module. Clause 19. The armature winding assembly of clauses 13 to 18, wherein adjacent teeth comprise a plurality of wedge-shaped teeth arranged within a plurality of recesses formed in the body, and wherein the armature winding support structure further comprises a coil cover structure extending around the plurality of coils within the fiber reinforced composite structure. Clause 20. The armature winding assembly of clauses 13 to 19, wherein each of the plurality of winding modules extends from about 10 degrees to about 20 degrees of a circumference of the armature winding assembly.

[0060] This written description uses examples to disclose the invention, including the best mode, and also to enable those skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that do not differ substantially from the literal language of the claims.

Claims

1. A rotating machine comprising: Field winding assembly; An armature winding assembly comprising a plurality of winding modules, each of the plurality of winding modules comprising a plurality of conductive coils and at least one armature winding support structure, the at least one armature winding support structure comprising: main body; a plurality of slots defined between adjacent teeth extending radially from the body, the plurality of slots receiving and supporting a subset of the plurality of conductive coils therein; a plurality of support rods disposed within the body; and A fiber reinforced composite structure is fixed around each of the plurality of winding modules.

2. The rotary machine according to claim 1, wherein: The body is formed from one or more magnetic stacks.

3. The rotary machine according to claim 1, wherein: The plurality of support rods are made of metal or metal alloy, and one or more of the plurality of support rods extend the entire axial length of one of the plurality of winding modules so as to axially transmit forces acting on the fiber reinforced composite structure to a rotatable member of the rotary machine.

4. The rotary machine according to claim 1, wherein: The fiber reinforced composite structure includes one or more fiber reinforced composite tapes.

5. The rotary machine according to claim 4, wherein: The one or more fiber-reinforced composite tapes are comprised of at least one of glass fibers, synthetic fibers, polymer fibers, wood fibers, ceramic fibers, metal fibers, carbon fibers, or combinations thereof.

6. The rotary machine according to claim 1, wherein: The fiber reinforced composite structure is wrapped around the body and the subset of the plurality of conductive coils and cured thereon to form one of the plurality of winding modules.

7. The rotary machine according to claim 1, wherein: Each of the plurality of winding modules further includes one or more axially extending studs for providing compression to the corresponding winding module.

8. The rotary machine according to claim 1, wherein: Each of the plurality of winding modules further includes one or more cooling channels disposed adjacent to or within the plurality of conductive coils.

9. The rotary machine according to claim 1, wherein: The adjacent teeth include a plurality of wedge-shaped teeth disposed within a plurality of recesses formed in the body.

10. The rotary machine of claim 9, further comprising a coil cover structure extending around the plurality of electrically conductive coils within the fiber reinforced composite structure.

11. The rotary machine according to claim 1, wherein: Each of the plurality of winding modules extends from about 10 degrees to about 20 degrees of the circumference of the armature winding assembly.

12. The rotary machine according to claim 1, wherein: At least one of the field winding assembly and the armature winding assembly is a superconducting winding assembly having a superconducting coil.

13. An armature winding assembly, comprising: A plurality of winding modules, each of the plurality of winding modules comprising a plurality of conductive coils and at least one armature winding support structure, the at least one armature winding support structure comprising: main body; a plurality of slots defined between adjacent teeth extending radially from the body, the plurality of slots receiving and supporting a subset of the plurality of conductive coils therein; a plurality of support rods disposed within the body; and A fiber reinforced composite structure is fixed around each of the plurality of winding modules.

14. The armature winding assembly according to claim 13, wherein: The body is formed from one or more magnetic stacks.

15. The armature winding assembly according to claim 13, wherein: The plurality of support rods are made of metal or metal alloy, and one or more of the plurality of support rods extend the entire axial length of one of the plurality of winding modules so as to axially transmit forces acting on the fiber reinforced composite structure to a rotatable member of the rotary machine.

16. The armature winding assembly according to claim 13, wherein: The fiber-reinforced composite structure includes one or more fiber-reinforced composite tapes, wherein the one or more fiber-reinforced composite tapes are composed of at least one of the following: glass fibers, synthetic fibers, polymer fibers, wood fibers, ceramic fibers, metal fibers, carbon fibers, or combinations thereof.

17. The armature winding assembly according to claim 13, wherein: The fiber reinforced composite structure is wrapped around the body and the subset of the plurality of coils and cured thereon to form one of the plurality of winding modules.

18. The armature winding assembly according to claim 13, wherein: Each of the plurality of winding modules further includes one or more axially extending studs for providing compression to the corresponding winding module.

19. The armature winding assembly according to claim 13, wherein: The adjacent teeth include a plurality of wedge-shaped teeth disposed within a plurality of recesses formed in the body, and wherein the armature winding support structure further includes a coil cover structure extending around the plurality of coils within the fiber reinforced composite structure.

20. The armature winding assembly according to claim 13, wherein: Each of the plurality of winding modules extends from about 10 degrees to about 20 degrees of the circumference of the armature winding assembly.

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