Dual cooling system and wind turbine generator system

Abstract

The application discloses a double cooling system and a wind turbine, and relates to the technical field of wind power generation, wherein the double cooling system comprises a tower drum, a nacelle, a first cooling system and a second cooling system, a heat exchange space is formed in the tower drum; the nacelle is installed at the top end of the tower drum, the nacelle forms a containing cavity, the containing cavity is communicated with the heat exchange space, and a generator is installed in the containing cavity; the first cooling system comprises a liquid cooling plate and a heat pipe, the liquid cooling plate is arranged in the heat exchange space, and the heat pipe is connected with the liquid cooling plate and the generator, so that the heat generated by the generator is conducted to the liquid cooling plate; the second cooling system comprises an air inlet fan, an air outlet fan and a radiator, the radiator is connected with the liquid cooling plate, the air inlet fan is installed on the side wall of the tower drum, the air outlet of the air inlet fan is communicated with the heat exchange space, the air outlet fan is installed in the heat exchange space, and the air outlet fan is used for leading the heat in the heat exchange space out of the tower drum; the application improves the heat dissipation reliability of the wind turbine and reduces the risk of leakage of the cooling liquid.

Description

Technical Field

[0001] This invention relates to the field of wind power generation technology, and in particular to a dual cooling system and a wind turbine generator set. Background Technology

[0002] During wind turbine operation, the generator generates copper losses, iron losses, mechanical losses, and stray losses during electromagnetic conversion. These losses ultimately accumulate as heat in critical components such as the stator windings, stator core, rotor, and bearings, causing temperature rise. When the temperature exceeds the heat resistance rating of the insulation material or the allowable operating temperature of the bearings, it will directly shorten the life of the generator insulation and may even cause insulation breakdown, high-temperature bearing failure, demagnetization of permanent magnets, and other faults, leading to unit shutdown and power generation interruption in severe cases.

[0003] Currently, the mainstream cooling methods for wind turbines are divided into two types: air cooling and water cooling. Air cooling is simple in structure and low in cost, but its heat dissipation capacity is limited by ambient wind speed, wind direction, and the internal space of the nacelle, and its heat dissipation effect decreases significantly in high-temperature environments. Water cooling removes heat through circulating coolant and has advantages such as high heat transfer coefficient, uniform cooling, and less susceptibility to environmental influences, making its cooling capacity significantly superior to air cooling. In water cooling, the typical arrangement is to attach the cooling plate to the outer circle of the generator stator core or the inner wall of the casing. Since the cooling plate is fixed to the stator core by interference fit or welding, there is only a thin wall separating the cooling channel from the stator core. When the cooling plate cracks, leaks in the weld, or loosens the joint due to vibration, thermal fatigue, corrosion, or manufacturing defects, if the coolant leaks, the high-pressure coolant will directly seep into the generator stator windings, core, and bearing cavity, causing winding insulation deterioration, core corrosion, bearing lubrication failure, and ultimately leading to generator short circuits, grounding, or even scrapping. Furthermore, water cooling alone still suffers from insufficient system heat dissipation margin, making it difficult to meet the heat dissipation requirements of high-power generators under extreme operating conditions.

[0004] To address the aforementioned issues, existing technologies urgently need improvement. Summary of the Invention

[0005] The main objective of this invention is to propose a dual cooling system and wind turbine generator set, which has the advantages of improving heat dissipation reliability and reducing the risk of coolant leakage.

[0006] To achieve the above objectives, the dual cooling system proposed in this invention is applied to wind turbine generator sets, comprising:

[0007] A tower, wherein a heat exchange space is formed inside the tower;

[0008] The nacelle is installed at the top of the tower and forms a receiving cavity that connects to the heat exchange space. A generator is installed inside the receiving cavity.

[0009] A first cooling system, comprising a liquid cooling plate and heat pipes, wherein the liquid cooling plate is disposed within the heat exchange space, and the heat pipes connect the liquid cooling plate and the generator to conduct the heat generated by the generator to the liquid cooling plate;

[0010] The second cooling system includes an intake fan, an exhaust fan, and a radiator. The radiator is connected to the liquid cooling plate. The intake fan is installed on the side wall of the tower. The exhaust port of the intake fan is connected to the heat exchange space. The exhaust fan is installed inside the heat exchange space and is used to draw heat from the heat exchange space to the outside of the tower.

[0011] In one embodiment, the heat pipe includes an evaporation section and a condensation section disposed opposite to each other, with a heat exchange channel between the evaporation section and the condensation section filled with a heat-conducting medium. The evaporation section is connected to the generator, and the condensation section is connected to the liquid cooling plate.

[0012] In one embodiment, the generator includes a stator and a thermostatic substrate, the thermostatic substrate is mounted on the side wall of the stator, the thermostatic substrate has a groove, and the evaporation section is inserted into the groove.

[0013] In one embodiment, the liquid cooling plate forms a flow channel, and the two ends of the flow channel form an inlet and an outlet that are interconnected. The liquid cooling plate has a plug groove, and the flow channel is arranged adjacent to the plug groove. The condensation section is inserted into the plug groove.

[0014] In one embodiment, the liquid cooling plate is connected to a plug-in terminal and a circuit board. The plug-in terminal is used to connect to an external power source. A valve body is provided in the flow channel. The circuit board is communicatively connected to the valve body. The circuit board is used to control the valve body to open or close, so as to adjust the flow rate of the coolant in the flow channel.

[0015] In one embodiment, a temperature sensor is also provided inside the receiving cavity. The temperature sensor is communicatively connected to the circuit board. The temperature sensor is used to sense the temperature information of the generator, and the control board is used to receive the temperature information.

[0016] In one embodiment, the second cooling system further includes a diversion fan, which is disposed within the receiving cavity and is used to introduce hot airflow from the receiving cavity into the heat exchange space.

[0017] In one embodiment, both the intake fan and the exhaust fan are communicatively connected to the circuit board.

[0018] In one embodiment, the intake fan is installed at the lower end of the inlet of the wind turbine generator platform.

[0019] In addition, the present invention also provides a wind turbine generator set, which applies the above-mentioned dual cooling system.

[0020] The technical solution of this invention combines an active cooling system consisting of a liquid cooling plate and a heat pipe with a forced air cooling system formed by an intake fan and an exhaust fan. This improves heat dissipation efficiency while isolating the liquid cooling components from the generator, effectively avoiding equipment failure caused by coolant leakage. It has the advantages of improving heat dissipation reliability and reducing the risk of coolant leakage. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0022] Figure 1 A schematic diagram of an embodiment of the dual cooling system provided by the present invention;

[0023] Figure 2 for Figure 1 A magnified view of a section at point A in the middle;

[0024] Figure 3 This is a schematic diagram of an embodiment of the liquid cooling plate provided by the present invention.

[0025] Explanation of icon numbers:

[0026] 1. Tower; 11. Heat exchange space; 2. Cabin; 21. Receiving cavity; 22. Generator; 221. Stator; 222. Constant temperature base plate; 2221. Groove; 31. Liquid cooling plate; 32. Heat pipe; 321. Condensation section; 322. Evaporation section; 323. Heat exchange channel; 41. Inlet fan; 42. Outlet fan; 43. Radiator; 44. Drainage fan; 311. Water inlet; 312. Water outlet; 313. Insertion slot.

[0027] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0028] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0029] It should be noted that if the embodiments of the present invention involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a specific posture. If the specific posture changes, the directional indicators will also change accordingly.

[0030] Furthermore, if the embodiments of this invention involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the use of "and / or" or "and / or" throughout the text includes three parallel solutions. For example, "A and / or B" includes solution A, solution B, or a solution where both A and B are satisfied simultaneously. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0031] In existing technologies, wind turbine generators primarily rely on air-cooling or water-cooling systems for heat dissipation. Air-cooling systems are significantly affected by environmental factors; their efficiency drops dramatically when external wind speeds are insufficient or when airflow inside the nacelle is turbulent. While water-cooling systems offer higher heat transfer efficiency, the direct contact between the cooling plates and the generator poses a risk of leakage. If coolant seeps into the generator, it can cause irreversible damage such as insulation degradation and component corrosion. Furthermore, a single water-cooling system can be insufficient in heat dissipation under extreme operating conditions, causing the generator temperature to exceed safe thresholds.

[0032] To address these issues, the designers first identified the root cause of coolant leakage as the physical contact between the cooling plate and the generator. Isolating the coolant circulation system from the generator set by introducing an indirect heat transfer medium became a key approach. Secondly, recognizing the limitations of traditional air-cooled systems due to ambient wind speed, they considered utilizing the internal space of the tower to construct independent airflow channels, enhancing heat dissipation stability through active ventilation. Ultimately, a dual cooling architecture combining heat pipe conduction and forced convection was adopted, achieving both physical isolation and increased overall heat dissipation margin.

[0033] Therefore, this application proposes a dual cooling system for wind turbine generator set 22, please refer to... Figures 1 to 3The dual cooling system includes a tower 1, a nacelle 2, a first cooling system, and a second cooling system. A heat exchange space 11 is formed within the tower 1. The nacelle 2 is installed at the top of the tower 1 and forms a receiving cavity 21, which connects to the heat exchange space 11 and houses a generator 22. The first cooling system includes a liquid-cooled plate 31 and heat pipes 32. The liquid-cooled plate 31 is disposed within the heat exchange space 11, and the heat pipes 32 connect the liquid-cooled plate 31 to the generator 22 to conduct heat. The second cooling system includes an intake fan 41, an exhaust fan 42, and a radiator 43. The intake fan 41 is installed on the side wall of the tower 1 and supplies air to the heat exchange space 11. The exhaust fan 42 exhausts heat from the heat exchange space 11 outside the tower 1. The radiator 43 is connected to the liquid-cooled plate 31.

[0034] The liquid-cooled plate 31 refers to a metal plate with internal flow channels, which can be manufactured using aluminum alloy extrusion molding. The internal flow channels can be designed as a serpentine or mesh structure to increase the heat exchange area. Its function is to provide a heat exchange interface for the heat conducted by the heat pipe 32 using a liquid cooling medium. The heat pipe 32 refers to a closed tubular device filled with a phase change medium, which can be copper tubes encapsulated with ethanol or ammonia as the working fluid. It absorbs heat from the generator 22 through the evaporation section 322 and releases it to the liquid-cooled plate 31 in the condensation section 321, achieving heat transfer without power. The intake fan 41 refers to an axial flow ventilation device, which can be a variable frequency speed control fan installed on the lower side wall of the tower 1, used to deliver external low-temperature air to the heat exchange space 11 to form forced convection. The exhaust fan 42 refers to a centrifugal exhaust device, which can be installed at the top of the heat exchange space 11 and connected to the guide shroud on the outer wall of the tower 1, used to exhaust hot air outside the tower 1.

[0035] Specifically, the heat generated by the generator 22 is conducted to the liquid cooling plate 31 through the heat pipe 32. The coolant flowing inside the liquid cooling plate 31 transfers the heat to the radiator 43. The intake fan 41 introduces outside air into the heat exchange space 11, and as it flows over the surface of the radiator 43, it carries away the heat. The heated air is then exhausted by the exhaust fan 42. The separate arrangement of the heat pipe 32 and the liquid cooling plate 31 makes the coolant circulation system completely independent of the generator 22, avoiding the risk of leakage. At the same time, the vertical airflow channel formed inside the tower 1 utilizes the air density difference to create a chimney effect, enhancing the heat exchange efficiency between the radiator 43 and the air. When the two cooling systems work together, the heat pipe 32 conducts the basic heat dissipation load, while the air-cooled system dynamically adjusts the heat dissipation intensity according to temperature changes, jointly ensuring that the temperature rise of the generator 22 remains within a safe range.

[0036] Compared to existing technologies, traditional water-cooling systems require the cooling plate to be directly attached to the surface of the generator stator 221. This solution, however, achieves non-contact heat transfer through heat pipes 32, completely eliminating the possibility of coolant contact with the generator 22. Existing air-cooling systems rely on natural convection or internal fans in the nacelle 2, while this solution utilizes the height of the tower 1 to create an independent ventilation path, forming a stable airflow through the coordinated control of the intake fan 41 and the exhaust fan 42. Furthermore, existing single-cooling systems easily reach their heat dissipation limits under high-temperature environments, while this solution's dual-cooling architecture, through the heat pipes 32 and staged air cooling, significantly improves the system's heat load capacity.

[0037] Through the above technical solution, this application effectively isolates the coolant circulation system from the generator 22 body, fundamentally avoiding equipment damage caused by coolant leakage. The synergistic effect of heat pipe 32 conduction and forced air cooling enables heat dissipation capacity to overcome the physical limitations of a single cooling method, maintaining stable heat dissipation performance even under ambient temperature fluctuations or generator 22 overload conditions. The directional airflow channel formed inside the tower 1 reduces the interference of external wind speed changes on heat dissipation efficiency, improving the system's environmental adaptability.

[0038] This application further proposes that the heat pipe 32 includes an evaporation section 322 and a condensation section arranged opposite to each other, and a heat exchange channel 323 is provided between the evaporation section 322 and the condensation section 321. The heat exchange channel 323 is filled with a heat-conducting medium. The evaporation section 322 is connected to the generator 22, and the condensation section 321 is connected to the liquid cooling plate 31.

[0039] The evaporation section 322 refers to the tube portion that directly contacts the generator 22 for heat absorption. It can be made of copper alloy and has a finned surface to increase the contact area. The condensation section is the tube portion connected to the liquid cooling plate 31, and can be made of an aluminum shell encasing a copper core, with a porous capillary structure inside to promote condensate reflux. The heat exchange channel 323 is a closed cavity connecting the evaporation section 322 and the condensation section, and can be formed using vacuum welding to create a closed loop. The inner wall of the channel can have micron-level grooves to enhance phase change heat transfer. The heat transfer medium is a working fluid with phase change heat transfer characteristics, and can be water, ethanol, or liquid metal, with a boiling point temperature range compatible with the operating temperature range of the generator 22.

[0040] Specifically, the heat generated by the generator 22 is transferred to the wall of the evaporation section 322 through physical contact, causing the heat transfer medium to undergo a vaporization phase change within the heat exchange channel 323. Driven by the pressure difference, the gaseous working fluid flows along the heat exchange channel 323 towards the condensation section, releasing latent heat and re-liquefying upon contact with the low-temperature region of the liquid cooling plate 31. The liquid working fluid returns to the evaporation section 322 through capillary action or gravity, completing the cycle. This process achieves non-contact heat transfer from the generator 22 to the liquid cooling plate 31, avoiding direct contact between the coolant and the internal components of the generator 22.

[0041] Compared to existing technologies, traditional water-cooling systems require welding the cooling plate to the generator 22 casing, which carries the risk of coolant leakage due to weld cracking. This solution, however, achieves physical isolation of the heat conduction path through an independent heat pipe 32 structure, ensuring that even if the liquid cooling plate 31 leaks, it will not affect the interior of the generator 22. Simultaneously, the heat flux density of phase change heat transfer is two orders of magnitude higher than that of traditional heat transfer oil circulation systems, allowing for the transfer of more heat within the same heat dissipation area.

[0042] Through the above technical solution, this application effectively blocks the risk path of coolant leakage into the generator 22. At the same time, through the synergistic effect of phase change heat transfer and liquid cooling, it achieves high heat flux density heat dissipation capacity while maintaining structural separation, thus solving the technical contradiction of insufficient heat dissipation margin and leakage risk in traditional water cooling systems.

[0043] This application further proposes that the generator 22 includes a stator 221 and a thermostatic substrate 222. The thermostatic substrate 222 is mounted on the side wall of the stator 221. The thermostatic substrate 222 has a groove 2221, and the evaporation section 322 is inserted into the groove 2221.

[0044] The constant-temperature substrate 222 is a heat-conducting metal plate independent of the stator core 221. It can be made of aluminum alloy or copper alloy and is fixed to the side wall of the stator 221 by bolts or welding. Its function is to establish a contact interface with the evaporation section 322 of the heat pipe 32, replacing the traditional cooling plate structure directly fixed to the stator core 221. The groove 2221 is a U-shaped or rectangular channel formed on the surface of the constant-temperature substrate 222. It can be formed by machining or casting, and the depth of the groove matches the outer diameter of the evaporation section 322 of the heat pipe 32. Its function is to fix the evaporation section 322 of the heat pipe 32 by mechanical engagement, preventing displacement caused by vibration or thermal stress.

[0045] Specifically, the constant temperature substrate 222 is fixed to the side wall of the stator 221, maintaining physical isolation from the stator core. The geometry of the groove 2221 forms an interference fit with the outer contour of the evaporation section 322 of the heat pipe 32. When the evaporation section 322 is embedded in the groove 2221, its outer wall makes surface contact with the inner surface of the groove. The heat-conducting medium inside the heat pipe 32 absorbs heat from the stator 221 and is transferred to the constant temperature substrate 222 in the evaporation section 322, then undergoes a phase change and vaporizes. The heat is then conducted to the liquid cooling plate 31 through the heat pipe 32. This structure completely isolates the cooling medium circulation path from the stator windings and core of the generator 22, while maintaining stable contact between the heat pipe 32 and the substrate through mechanical clamping.

[0046] Compared to existing technologies, conventional solutions involve directly welding or interference-fitting the cooling plate to the outer wall of the stator 221 core, with the coolant channels separated from the core by only a single layer of metal wall. This solution, through an independently designed constant-temperature substrate 222, separates the contact interface between the cooling medium and the core components of the generator 22. Even if the liquid cooling plate 31 leaks, the coolant will not directly intrude into the stator 221 windings or core. Furthermore, the mechanical snap-fit ​​method of the groove 2221, compared to traditional welding or adhesive bonding, avoids the risk of interface cracking caused by thermal cycling stress.

[0047] Through the above technical solution, this application effectively blocks the path of coolant leakage into the generator 22. At the same time, through the mechanical interlocking structure between the constant temperature substrate 222 and the heat pipe 32, a stable heat conduction interface can still be maintained under vibration or temperature change conditions, thus solving the reliability problem caused by the traditional fixed connection between the cooling plate and the stator 221.

[0048] This application further proposes that the liquid cooling plate 31 forms a flow channel, with an inlet end 311 and an outlet end 312 that are interconnected at both ends of the flow channel. The liquid cooling plate 31 is provided with a plug groove 313, and the flow channel and the plug groove 313 are arranged adjacent to each other. The condensing section 321 is inserted into the plug groove 313. The dual cooling system also includes a water pump. The inlet end 311 is connected to the water pump, and the outlet end 312 is connected to the radiator 43. The radiator 43 is connected to the water pump. The radiator 43 cools the hot water from the outlet end 312 into cooling water and then delivers it to the water pump. The water pump delivers its cooling water to the inlet end 311 of the liquid cooling plate 31.

[0049] The flow channel refers to the continuous channel formed inside the liquid cooling plate 31, which can be implemented using a serpentine or spiral structure. The connection between the inlet end 311 and the outlet end 312 forms a closed-loop coolant circulation path, ensuring continuous flow of the cooling medium to remove heat. The insertion slot 313 refers to the groove 2221 structure opened on the surface of the liquid cooling plate 31, which can be implemented using a rectangular or trapezoidal cross-section. It is used to accommodate the condensing section 321 of the heat pipe 32 and form a physically isolated plug-in connection, avoiding stress concentration caused by traditional welding or interference fits. The insertion of the condensing section 321 into the insertion slot 313 means that the end of the heat pipe 32 is embedded in the groove 2221. This can be implemented using an interference fit or a flexible snap-fit ​​structure. By increasing the contact area and using a mechanical insertion method, the connection reliability is enhanced, thereby increasing the heat exchange efficiency.

[0050] Specifically, the coolant is driven by a water pump into the flow channel from the inlet 311. As it flows through the area adjacent to the insertion slot 313, it directly absorbs heat transferred from the condenser section 321 of the heat pipe 32. The coolant, carrying heat, is then discharged from the outlet 312 to the radiator 43 for cooling. The adjacent arrangement of the insertion slot 313 and the flow channel shortens the heat conduction path, allowing the heat from the condenser section 321 to be quickly transferred to the coolant within the flow channel. After the condenser section 321 of the heat pipe 32 is inserted into the insertion slot 313, its outer wall forms a mechanical connection with the inner wall of the insertion slot 313, avoiding residual stress caused by welding or interference fits. Simultaneously, the physical isolation design between the insertion slot 313 and the flow channel prevents coolant from seeping into the connection area of ​​the heat pipe 32 due to structural defects in the liquid cooling plate 31.

[0051] Compared to existing technologies, traditional liquid cooling plates 31 typically use welding or interference fits to fix heat pipes 32, which are prone to cracking at the connection due to vibration or thermal cycling. The mechanical connection method of the insertion slot 313 eliminates the risk of welding defects and reduces the possibility of coolant leakage through physical isolation. In existing technologies, the contact area between the coolant channel and the heat pipe 32 is often directly welded, requiring heat to be transferred to the coolant through multiple layers of metal walls. This solution, however, uses an adjacent arrangement between the channel and the insertion slot 313, allowing the coolant to directly flush the outer wall of the insertion slot 313, significantly improving heat transfer efficiency.

[0052] Understandably, the dual cooling system also includes a circulating water pump. The inlet 311 of the liquid cooling plate 31 is connected to the outlet of the water pump, and the outlet 312 of the flow channel is connected to the radiator 43; the outlet of the radiator 43 is then connected back to the inlet of the water pump. During operation, the hot water flowing out of the liquid cooling plate 31 enters the radiator 43 to be cooled and becomes cooling water. The cooling water is then sent back to the water pump, which repressurizes it and sends it back to the inlet 311 of the liquid cooling plate 31, forming a continuous and efficient closed-loop circulation.

[0053] Through the above technical solutions, this application solves the risk of coolant leakage caused by structural connection defects. Simultaneously, by shortening the heat conduction path and enhancing the contact efficiency between the coolant and heat pipe 32, the overall performance of the heat dissipation system is improved. The mechanical connection method of the plug slot 313 and the coordinated design of the flow channel achieve efficient heat exchange while ensuring structural reliability, avoiding damage to internal components of the generator 22 caused by coolant leakage.

[0054] This application further proposes that the liquid cooling plate 31 is connected to a plug-in terminal and a circuit board. The plug-in terminal is used to connect to an external power supply. A valve body is provided in the flow channel. The circuit board is connected to the valve body for communication. The circuit board is used to control the valve body to open or close, so as to regulate the flow rate of coolant in the flow channel.

[0055] The plug-in terminal refers to the interface component used to establish electrical connections, and its function is to provide a stable external power input to the circuit board. The circuit board refers to the electronic component integrating control circuitry, specifically implemented by using a PCB board with a microprocessor and driver module, and its function is to generate control signals according to preset logic and transmit them to the valve body. The valve body refers to the mechanical device that regulates the flow of fluid, specifically implemented by using a solenoid valve or an electric ball valve, and its function is to control the flow rate of coolant in the flow channel by changing the opening degree.

[0056] Specifically, when generator 22 generates heat, the circuit board receives signals from external sensors to determine the current heat dissipation demand and sends pulse or analog signals to the valve body. The valve body adjusts its opening according to the instructions; for example, it increases the opening to increase coolant flow under high-temperature conditions and decreases the opening or closes completely under low-temperature conditions. The connector continuously supplies power to the circuit board, ensuring stable operation of the control loop. This adjustment process forms a closed-loop control, ensuring that the coolant flow rate matches the heat dissipation demand in real time.

[0057] Compared to existing technologies, traditional liquid cooling systems employ a fixed flow rate design, which cannot automatically adjust according to temperature changes. This can easily lead to the coolant operating at full flow for extended periods, accelerating pipe aging. This solution introduces an adjustable valve body and an intelligent control unit, ensuring heat dissipation efficiency while reducing mechanical losses in the coolant circulation system and avoiding the risk of seal failure due to continuous high-pressure flow.

[0058] Through the above technical solution, this application realizes dynamic adjustment of coolant flow rate, effectively reduces the probability of pipeline leakage caused by excessive flow rate, and ensures that heat dissipation requirements under different operating conditions are accurately met, thus solving the technical contradiction of insufficient heat dissipation margin and leakage risk in a single water cooling system.

[0059] This application further proposes a technical solution in which a temperature sensor is installed in the cavity 21, the temperature sensor is connected to the circuit board, the temperature sensor is used to sense the temperature information of the generator 22, and the control board is used to receive the temperature information.

[0060] The temperature sensor is an electronic component capable of detecting real-time temperature changes of the generator 22. It can be implemented using a thermistor or thermocouple and can be installed near the stator winding 221 of the generator 22 or on the bearing housing surface to directly acquire temperature data from key components. The circuit board communication connection refers to the data transmission channel established between the temperature sensor and the control system. This can be implemented using RS-485 or CAN bus protocols to ensure real-time transmission of temperature signals to the control unit. Temperature information refers to quantitative data reflecting the thermal state of the generator 22, specifically including temperature values, temperature rise rates, and temperature distribution characteristics. The control board parses this information using a preset algorithm to generate control commands.

[0061] Specifically, temperature sensors are placed in high-temperature sensitive areas of the generator 22, such as the contact surface between the stator core and windings of the stator 221, continuously collecting temperature data through physical contact or non-contact temperature measurement methods. When changes in the load of the generator 22 cause abnormal temperature rise, the temperature sensors convert the detected temperature signal into an electrical signal, which is transmitted to the circuit board via a shielded cable. The microprocessor built into the circuit board analyzes the received temperature information in real time and compares it with a preset safe temperature threshold. When the detected temperature exceeds the set threshold, the control board sends an opening command to the valve in the flow channel to increase the coolant flow rate and enhance heat dissipation; when the temperature drops back to a safe range, the control board gradually reduces the valve opening to reduce energy consumption. This closed-loop control mechanism achieves a dynamic balance between the cooling system's response speed and energy efficiency.

[0062] Compared to existing technologies, traditional wind turbine cooling systems often employ fixed coolant flow rates or indirect control based on ambient temperature, resulting in delays in temperature detection and insufficient control accuracy. For example, some systems only monitor the ambient temperature of the nacelle 2 rather than the temperature of the generator 22 itself, failing to accurately reflect the actual heat load on critical components; others use timers to control valve movements, which cannot adapt to instantaneous temperature rises caused by sudden load changes. This solution, by directly monitoring temperature changes in the core components of the generator 22 and combining this with a real-time feedback adjustment mechanism, effectively eliminates the time and space delay in temperature detection and avoids energy waste caused by excessive coolant supply.

[0063] Through the above technical solution, this application solves the problem of control signal distortion caused by improper temperature monitoring point settings during generator 22 operation, as well as the problem of low system efficiency caused by mismatch between coolant flow and heat load. The direct installation position of the temperature sensor ensures the accuracy of data acquisition, while the dynamic adjustment mechanism based on real-time temperature data enables the cooling system to quickly match the actual heat dissipation needs of generator 22, preventing both the risk of equipment overheating due to insufficient cooling and energy loss caused by excessive cooling.

[0064] This application further proposes that the second cooling system also includes a duct fan 44, which is disposed in the receiving cavity 21 and is used to introduce the hot airflow in the receiving cavity 21 into the heat exchange space 11.

[0065] The induced draft fan 44 is a mechanical device that actively drives airflow. It can be an axial flow fan or a centrifugal fan. The rotation of its impeller generates a pressure difference, causing the hot air inside the nacelle 2 to move directionally to the heat exchange space 11. The heat exchange space 11 is a closed area formed inside the tower 1. It can be formed by enclosing the inner wall of the tower 1 and is used to house the liquid cooling plate 31 and exchange heat with the external environment. An exhaust fan 42 is installed inside the space to form an airflow discharge channel.

[0066] Specifically, when the generator 22 generates heat, the air temperature inside the containment cavity 21 gradually increases. After the induced draft fan 44 starts, the hot air is forcibly drawn into the fan inlet, pressurized, and then transported to the heat exchange space 11. Inside the heat exchange space 11, the hot air comes into contact with the surface of the liquid cooling plate 31, and the heat is carried away by the circulation of the coolant within the liquid cooling plate 31. Simultaneously, the exhaust fan 42 continuously exhausts the air from the heat exchange space 11 to the outside of the tower 1, forming a continuous airflow path from the nacelle 2 to the heat exchange space 11 and then to the outside. This forced convection mechanism prevents the hot air from naturally accumulating at the top of the nacelle 2, ensuring that the heat is quickly transferred to the liquid cooling plate 31 for secondary heat dissipation.

[0067] Compared to existing technologies, traditional solutions rely on natural convection or passive heat dissipation by a single exhaust fan 42, resulting in areas of stagnant hot air inside the nacelle 2. This solution, however, actively introduces hot air from high-temperature areas within the nacelle 2 into the heat exchange space 11 by adding an exhaust fan 44. The air then comes into full contact with the liquid cooling plate 31 before being exhausted, forming a directional airflow circulation. This structure overcomes the reliance of traditional cooling systems on natural convection efficiency and solves the problem of ineffective heat dissipation within enclosed spaces.

[0068] Through the above technical solution, this application achieves efficient exhaust of hot air inside the engine compartment 2, avoiding a decrease in the heat dissipation efficiency of the generator 22 due to excessive local temperature rise. The synergistic effect of the induced flow fan 44 and the exhaust fan 42 enhances the airflow circulation intensity, allowing the hot air to fully contact the liquid cooling plate 31 within the heat exchange space 11, thereby improving the overall heat dissipation efficiency.

[0069] This application further proposes that both the intake fan 41 and the exhaust fan 44 are connected to the circuit board for communication.

[0070] The intake fan 41 is a device installed on the side wall of the tower 1 to introduce external cold air into the heat exchange space 11. Specifically, it can be implemented using a variable frequency axial flow fan, with the airflow volume controlled by adjusting the speed to adapt to different heat dissipation requirements. The exhaust fan 44 is a device installed inside the receiving cavity 21 to guide hot airflow into the heat exchange space 11. Specifically, it can be implemented using a centrifugal fan, with the airflow path optimized by adjusting the blade angle or speed. The circuit board refers to an electronic module integrating control logic, specifically implemented using a combination of a microcontroller and a communication interface, used to receive sensor signals and output fan control commands.

[0071] Specifically, the circuit board receives real-time temperature data from the generator 22 collected by the temperature sensor. When the temperature exceeds a set threshold, the circuit board sends an acceleration command to the intake fan 41, causing the cold air outside the tower 1 to enter the heat exchange space 11 at a higher flow rate. Simultaneously, the circuit board adjusts the operating parameters of the duct fan 44 to precisely guide the hot airflow within the receiving cavity 21 to the area where the liquid-cooled plate 31 is located. When the temperature drops back to a safe range, the circuit board reduces the speed of the intake fan 41 and shuts down the duct fan 44 to avoid energy waste. Through this closed-loop control strategy, the operating states of both fans are always synchronized with changes in heat load, maintaining heat dissipation efficiency while eliminating energy consumption from redundant operation.

[0072] Compared to existing technologies, traditional cooling systems use independent control modules for the intake fan 41 and the exhaust fan 44, which cannot coordinate their actions in real time according to temperature changes. For example, when the generator 22 temperature rises sharply, the intake fan 41 may experience delayed heat dissipation due to response delay, while the exhaust fan 44 continues to operate at a low speed, causing hot airflow to stagnate. This solution uses a unified control platform to create a linkage mechanism between the two fans, where the exhaust intensity increases synchronously with the increase in intake volume, ensuring that the heat exchange rate within the heat exchange space 11 always matches the heat output.

[0073] Through the above technical solution, this application effectively solves the problem of heat dissipation efficiency fluctuation caused by the independent operation of the intake fan 41 and the exhaust fan 44, realizes the dynamic balance between the energy consumption and heat dissipation demand of the cooling system, avoids energy waste caused by excessive air supply, and prevents the formation of local high temperature areas by precisely controlling the airflow path and flow rate.

[0074] This application further proposes a technical solution for installing the intake fan 41 at the lower end of the inlet of the wind turbine generator 22 platform.

[0075] The lower end of the platform inlet for wind turbine generator set 22 refers to the structural location at the bottom of tower 1 or near the ground. Specifically, it can be achieved by using an installation bracket extending upwards from the base of tower 1 for 1-2 meters. This area is located in a relatively stable low-altitude layer. The intake fan 41 refers to an axial flow ventilation device used to introduce outside air into the heat exchange space 11. Specifically, it can be implemented using an explosion-proof centrifugal fan with an IP55 protection rating, and its impeller diameter can be 500-800 mm.

[0076] Specifically, when the intake fan 41 is installed at the bottom of the tower 1, outside air enters the fan inlet in a laminar flow state through the space structure at the lower end of the platform inlet. Because this location is far from the turbulent zone at the top of the tower 1 and the turbulence generated by the rotating components of the nacelle 2, the airflow path is restricted within the guide channel formed by the outer wall of the tower 1 and the ground. When the ambient wind speed is at the common operating condition of 3-5 m / s, the intake fan 41 can capture a stable airflow and deliver it to the heat exchange space 11. The installation position is lower than the height of a conventional working platform, causing the rainwater trajectory to form a 30-45 degree angle with the fan axis, and dust particles naturally settle into the dust collection trough below the air inlet due to gravity.

[0077] In some specific embodiments, the mounting bracket of the intake fan 41 can be equipped with a height adjustment mechanism, such as a hydraulic lifting device, to adapt to changes in the platform inlet height under different terrain conditions. A louvered filter screen with a mesh size of 2-3 mm can be installed at the fan inlet to intercept larger particulate pollutants.

[0078] Compared to existing technologies, traditional solutions typically place the intake fan 41 in the upper part of the tower 1 or on the side of the nacelle 2. This location is susceptible to vortex-induced vibration of the tower 1, leading to fluctuations in intake efficiency. Furthermore, the wind speed variation in high-altitude areas can reach 1.5-2 times that at ground level. In contrast, this solution, through low-position installation, controls the deviation between the intake airflow velocity and the measured wind speed at ground level within ±10%, while simultaneously reducing the amount of sand and dust drawn in by approximately 40%.

[0079] Through the above technical solution, this application effectively avoids the problem of turbulent interference at the air inlet caused by high-level installation, ensuring that the heat exchange space 11 receives a continuous and stable supply of cooling airflow. The lowering of the installation position allows rainwater to flow naturally down the outer wall of the tower 1, preventing liquid from directly intruding into the fan. At the same time, the principle of gravity settling is used to reduce the content of suspended particulate matter in the air, avoiding the decrease in heat dissipation efficiency caused by blockage of the radiator 43 flow channel.

[0080] This application further proposes a wind turbine generator set 22, which employs a dual cooling system. Since this wind turbine generator set 22 adopts all the technical solutions of all the above embodiments, it possesses at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be elaborated upon here. Among them, ...

[0081] The above are merely exemplary embodiments of the present invention and do not limit the scope of the patent of the present invention. All equivalent structural transformations made using the contents of the present invention specification and drawings under the technical concept of the present invention, or direct / indirect applications in other related technical fields, are included within the scope of patent protection of the present invention.

Claims

1. A dual cooling system applied to a wind turbine generator unit, characterized in that, The utility model relates to a double cooling system for wind turbine generator system, comprising: a tower drum, a heat exchange space is formed in the tower drum; a nacelle is installed at the top of the tower drum, the nacelle forms a containing cavity, the containing cavity is communicated with the heat exchange space, and a generator is installed in the containing cavity; a first cooling system, the first cooling system comprises a liquid cooling plate and a heat pipe, the liquid cooling plate is arranged in the heat exchange space, and the heat pipe is connected with the liquid cooling plate and the generator to conduct heat generated by the generator to the liquid cooling plate; a second cooling system, the second cooling system comprises an air inlet fan, an air outlet fan and a radiator, the radiator is connected with the liquid cooling plate, the air inlet fan is installed on the side wall of the tower drum, the air outlet of the air inlet fan is communicated with the heat exchange space, the air outlet fan is installed in the heat exchange space, and the air outlet fan is used to lead heat in the heat exchange space out of the tower drum; the heat pipe comprises oppositely arranged evaporation sections and condensation sections, the evaporation sections and the condensation sections have a heat exchange channel therebetween, the heat exchange channel is filled with a heat conducting medium, the evaporation sections are connected with the generator, and the condensation sections are connected with the liquid cooling plate; the generator comprises a stator and a constant temperature substrate, the constant temperature substrate is installed on the side wall of the stator, the constant temperature substrate is provided with a groove, and the evaporation sections are clamped into the groove; the liquid cooling plate forms a flow channel, two ends of the flow channel form an inlet end and an outlet end communicated with each other, the liquid cooling plate is provided with a plug-in slot, the flow channel is arranged adjacent to the plug-in slot, and the condensation sections are inserted into the plug-in slot.

2. The dual cooling system of claim 1, wherein, the liquid cooling plate is connected with a plug-in terminal and a circuit board, the plug-in terminal is used to connect an external power supply, a valve body is arranged in the flow channel, the circuit board is communicated with the valve body, and the circuit board is used to control the valve body to open or close to adjust the flow of cooling liquid in the flow channel.

3. The dual cooling system of claim 2, wherein, a temperature sensor is further arranged in the containing cavity, the temperature sensor is communicated with the circuit board, the temperature sensor is used to sense temperature information of the generator, and the control board is used to receive the temperature information.

4. The dual cooling system of claim 3, wherein, the second cooling system further comprises a flow guide fan, the flow guide fan is arranged in the containing cavity, and the flow guide fan is used to lead hot air flow in the containing cavity into the heat exchange space.

5. The dual cooling system of claim 4, wherein, the air inlet fan and the flow guide fan are communicated with the circuit board.

6. The dual cooling system of claim 1, wherein, the air inlet fan is installed at the lower end of the wind turbine generator system platform entrance.

7. A wind power unit, characterized in that the wind turbine generator system is applied with the double cooling system according to any one of claims 1-6.

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