Coil support assembly having coil support structures joined together via respective joint structures and methods of assembling same

Abstract

A method of assembling a coil support assembly for an electrical machine is provided. The method includes providing a plurality of coil support structures, each of the plurality of coil support structures having a first face defining a cavity and opposing sides each defining a joint component, the joint components being one of a male joint component or a female joint component. The method also includes arranging a conducting coil within the cavity of each of the plurality of coil support structures. The method also includes arranging the plurality of coil support structures together in a generally circumferential arrangement. The method also includes securing the plurality of coil support structures together via the male and female joint components of adjacent coil support structures of the plurality of coil support structures to form the coil support assembly.

Description

COIL SUPPORT ASSEMBLY HAVING COIL SUPPORT STRUCTURES JOINED TOGETHER VIA RESPECTIVE JOINT STRUCTURES AND METHODS OF ASSEMBLING SAMESTATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0001] This invention was made with Government support under Contract No. DE-EE0008787 awarded by the Department of Energy (DOE). The Government has certain rights in the invention.FIELD

[0002] The present disclosure relates generally to superconducting machines and, more particularly, to a coil support assembly for a superconducting machine formed of coil support structures joined together via respective j oint structures.BACKGROUND

[0003] Generally, superconducting machines, such as superconducting generators and superconducting motors, include a plurality of superconducting coils for generating a static or rotating magnetic field and at least one armature coil for generating a rotating magnetic field or a stationary magnetic field in relation to the motion of the armature that interacts with the field from the superconducting coils. Wind turbine superconducting generators generally include a main shaft, an armature with at least one armature winding arranged with respect to the main shaft, and a coil support assembly including a plurality of superconducting coils secured thereto. The superconducting coils (which typically carry a direct current) are typically constructed of a superconducting material (“superconductor”) instead of conventionally conducting material with an electrical resistance (e.g., copper, aluminum, etc ).

[0004] The current-carrying capacity of superconducting materials in their superconducting state is typically over an order of magnitude higher than that of traditional conductors such aluminum or copper at room temperature, particularly in DC operation or low frequency. Thus, the use of superconductors in power applications, such as wind turbine generators, provides numerous benefits, including but not limited to more efficient performance, non-gearbox direct drive operation,potentially reduced manufacturing and installation costs, and / or lower generator weight as a result of the stronger magnetic fields requiring less ferromagnetic material to direct the magnetic fields. Such benefits are particularly useful for offshore wind turbine applications.

[0005] However, mechanical interactions can occur as a result of placing superconducting coils in close proximity to each other. Moreover, assembly complications can occur as a result of assembling a coil support assembly for the superconducting coils having components and / or fasteners that cause electromagnetic interference or mechanical interactions with each other. In particular, the mechanical interactions between the superconducting coils are tied to the proximity of the coils. The electromagnetic interference and / or mechanical interactions between the superconducting coils and the coil support assembly are tied to the materials of the assembly.

[0006] As a result of this, it would be advantageous to reduce electromagnetic interference and / or mechanical interactions between the superconducting coils and the coil support assembly and amongst the superconducting coils. Accordingly, the present disclosure is directed to an improved coil support assembly of a superconducting machine and methods of assembling same that address the aforementioned issues.BRIEF DESCRIPTION

[0007] Aspects and advantages of the disclosure 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 disclosure.In one aspect, the present disclosure is directed to a method of assembling a coil support assembly for an electrical machine. The method includes providing a plurality of coil support structures, each of the plurality of coil support structures having a first face defining a cavity and opposing sides each defining a joint component, the joint components being one of a male joint component or a female joint component; arranging a conducting coil within the cavity of each of the plurality of coil support structures; arranging the plurality' of coil support structures together in a generally circumferential arrangement; and securing the plurality of coil supportstructures together via the male and female joint components of adjacent coil support structures of the plurality of coil support structures to form the coil support assembly.

[0008] In an embodiment, providing the plurality of coil support structures further comprises casting the plurality of coil support structures.

[0009] In another embodiment, the male and female joint components of the plurality of coil support structures together define a joint structure defining at least one gap therebetween.

[0010] In a further embodiment, the method further includes arranging at least one joint spacer within the at least one gap

[0011] In yet another embodiment, the at least one joint spacer comprises a carrying portion and a contacting portion.

[0012] In another further embodiment, the method further includes securing the carrying portion to either of the male or female joint components; and securing the contacting portion to the carrying portion.

[0013] In still another embodiment, the method further includes assembling a plurality of sections of the plurality of coil support structures; and securing the plurality of sections together to form the coil support assembly.

[0014] In still a further embodiment, the plurality of sections each define an arc having an angle ranging from 10 degrees to 180 degrees.

[0015] In yet still another embodiment, the method further includes securing the plurality of sections together via at least one connecting member.

[0016] In still another further embodiment, the method further includes arranging one or more shims between the male and female joint components of adjacent coil support structures.

[0017] In yet a further embodiment, each coil support structure further defines a second face opposite the first face. Moreover, in the same embodiment, the method further includes forming a plurality of support structures; securing an individual support structure to the second face of each coil support structure; and securing a torque tube to each of the plurality of support structures.

[0018] In still yet another embodiment, the method further includes coating each of the plurality of coil support structures with a coating material.

[0019] In still yet a further embodiment, wherein the coating material comprises at least one of polytetrafluoroethylene (PTFE) or acetal homopolymer to provide dry lubrication.

[0020] In yet still a further embodiment, the coating material comprises an anodization of a metal.

[0021] In yet still another further embodiment, the electrical machine is a superconducting generator and the plurality of conducting coils are superconducting coils.

[0022] In another aspect, the present disclosure is directed to a method for assembling a coil support structure for a coil support assembly of an electrical machine. The method includes providing the coil support structure having a first face defining a cavity and opposing sides each defining a joint component, the joint components defining a male joint component on a first side of the opposing side and a female joint component on a second side of the opposing sides, the male and female joint components being securable to adjacent coil support structures of the coil support assembly to form multiple joint structures; and arranging a conducting coil within the cavity of the coil support structure, wherein, when arranged together, the coil support structure and the adjacent coil support structures form the coil support assembly having a generally circumferential arrangement.

[0023] In an embodiment, the method further includes arranging at least one joint spacer on the male joint component or the female joint component.

[0024] In another embodiment, the at least one joint spacer comprises a carrying portion and a contacting portion.

[0025] In still another embodiment, the method further includes arranging one or more shims adjacent the male joint component or the female joint component.

[0026] In a further embodiment, the method further includes coating the coil support structure with a coating material.

[0027] These and other features, aspects and advantages of the present disclosure 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 disclosure and, together with the description, serve to explain the principles of the disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0028] A full and enabling disclosure of the present disclosure, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

[0029] FIG. 1 illustrates a side, perspective view of an embodiment of a wind turbine according to the present disclosure;

[0030] FIG. 2 illustrates an internal, perspective view of an embodiment of a nacelle of the wind turbine of FIG. 1 according to the present disclosure;

[0031] FIG. 3 illustrates a partial, perspective view of an embodiment of an electrical machine according to the present disclosure;

[0032] FIG. 4 illustrates a perspective view of an embodiment of a coil support assembly of an electrical machine according to the present disclosure;

[0033] FIG. 5a illustrates a perspective view of an embodiment of a first side of a coil support structure with a conducting coil arranged therein according to the present disclosure;

[0034] FIG. 5b illustrates a perspective view of an embodiment of a second side of a coil support structure according to the present disclosure;

[0035] FIG. 6 illustrates a side view of an embodiment of a coil support structure according to the present disclosure;

[0036] FIG. 7 illustrates a partial, side view of an embodiment of a coil support assembly at a joint between adjacent coil support structures according to the present disclosure,;

[0037] FIGS. 8a-8b illustrate side views of various embodiments of joint structures between adjacent coil support structures of a coil support assembly according to the present disclosure;

[0038] FIGS. 9a-9b illustrate various views of an embodiment of a coil support structure of a coil support assembly according to the present disclosure;

[0039] FIG. 10 illustrates a side view of an embodiment of a coil support assembly of an electrical machine, particularly illustrating sections of the coil support assembly assembled together according to the present disclosure; and

[0040] FIG. 11 illustrates a flow diagram of an embodiment of a method ofassembling a coil support assembly according to the present disclosure.DETAILED DESCRIPTION

[0041] Reference now will be made in detail to embodiments of the disclosure, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the disclosure, not limitation of the disclosure. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present disclosure without departing from the scope or spirit of the disclosure. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present disclosure covers such modifications and variations as come within the scope of the appended claims and their equivalents.

[0042] As used herein, the terms “first”, “second”, and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components.

[0043] The terms “coupled,” “fixed,” “attached to,” and the like refer to both direct coupling, fixing, or attaching, as well as indirect coupling, fixing, or attaching through one or more intennediate components or features, unless otherwise specified herein.

[0044] Approximating language, as used herein throughout the specification and claims, is applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about”, “approximately”, and “substantially”, are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components and / or systems. For example, the approximating language may refer to being within a 10 percent margin.

[0045] Here and throughout the specification and claims, range limitations are combined and interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. For example, allranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other.

[0046] In general, the present disclosure is directed to an electrical machine, such as a superconducting generator, that includes a coil support assembly composed of multiple coil support structures arranged together in a generally circumferential arrangement. Further, each coil support structure is configured to receive one of a plurality of superconducting coils. Though the present disclosure is described herein with reference to a superconducting generator in general, and more particularly to a wind turbine superconducting generator, the present disclosure is not limited to superconducting generators. For example, the present disclosure can be employed with any electrical machine that includes a coil support assembly composed of coil support structures.

[0047] More specifically, each of the coil support structures includes a first face defining a cavity for receiving one of the plurality of conducting coils and opposing sides each having a joint component. In particular, joint components of adjacent coil support structures may include corresponding male and female joint components secured together at a joint structure.

[0048] Thus, an advantage of the present disclosure is the reduction or elimination of fasteners required to assemble a coil support assembly. Specifically, the reduction or elimination of fasteners may improve the overall resiliency of the coil support assembly and the coil support structures. In particular, by reducing or eliminating the need for fasteners, the coil support assembly is less susceptible to potential mechanical failure. Another advantage includes ease of assembly and disassembly of the coil support structures due to the interlocking male and female joint components (i.e., the connection is simpler and requires less component parts). Particularly, by designing the male and female joint components of respective coil support structures with specific shapes, the male and female joint components may interlock with each other and be easily assembled. Thus, the assembly of coil support structures may be more streamlined as a result of utilizing male and female joint components according to the present disclosure. Utilizing coil support structures with joint components as described herein according to the present disclosure provides, at least, the aforementioned advantages.

[0049] Referring now to the drawings, FIG. 1 illustrates a side, perspective view of a wind turbine 100 having an electrical machine 114, such as a generator 115 according to the present disclosure. As further explained herein, the generator 115 may be a superconducting generator. As shown, the wind turbine 100 generally includes a tower 108 extending from a support surface, a nacelle 102 mounted on the tower 108, and a rotor 104 coupled to the nacelle 102. The rotor 104 includes a rotatable hub 110 and at least one rotor blade 112 (three are shown) coupled to and extending outwardly from the hub 110. Each rotor blade 112 may be spaced about the hub 110 to facilitate rotating the rotor 104 about an axis of rotation 106 to enable kinetic energy to be transferred from the wind into usable mechanical energy, and subsequently, electrical energy. For this purpose, the rotor 104 is coupled to the generator 115 via a shaft (not shown). For purposes of the present disclosure, the generator 115 is a direct drive superconducting generator.

[0050] Referring now to FIG. 2, a simplified, internal view of the nacelle 102 of the wind turbine 100 shown in FIG. 1 is illustrated according to the present disclosure. As shown, the electrical machine 114 or the generator 115 is housed within the nacelle 102 and includes a field assembly 120 and an armature 118. Moreover, as shown, the generator 115 is generally coupled to the rotor 104 for producing electrical power from the rotational energy generated by the rotor 104. For example, as shown, the rotor 104 may include a rotor shaft 122 coupled to the hub 110 for rotation therewith. The rotor shaft 122 may, in turn, be rotatably coupled to a armature 118 of the generator 115. As is generally understood, the rotor shaft 122 may provide a torque input to the armature of the generator 115 in response to rotation of the rotor blades 112 and the hub 110.

[0051] Electrical power may then be generated using the commonly known principles of induction by applying a torque input to the armature 118 of the generator 115. The armature 118 may then spin within a magnetic field provided by the field assembly 120 of the generator 115 (e.g., in an internal rotor configuration). However, the outer component may be the armature 118 of the generator 115, and the inner component may be the field assembly 120 of the generator 115 (e.g., in an external rotor configuration). Further, as shown, additional space may be defined between the outer component and the inner component so as to allow movement (e.g., rotation)therebetween. It should be understood that the armature 118 may also be the stationary element operating within a rotating magnetic field established by rotation of the field winding.

[0052] Referring still to FIG. 2, the magnetic field generated by the armature 118 may be due to the magneto-motive force (MMF) setup by the current which flows through the armature 118 (as shown in FIGS. 2 and 3). The MMF has both spatial and temporal harmonics associated with it due to the discretization of the coils and the magnetic saturation within the steel structures, and current harmonics imposed by the electronic converter feeding the armature (not shown).

[0053] Referring now to FIG. 3, a cutaway, perspective view of an embodiment of the electrical machine 114 or generator 115 according to the present disclosure is provided. In particular, as shown, the generator 115 may include a housing 116 for housing the internal components thereof, e.g., such as the armature 118 described herein that may be secured to the rotor shaft 122 and the field assembly 120 that may be secured to the stationary' housing 116. Moreover, as shown, the superconducting generator 115 may also include at least one winding set. For example, as shown, the winding set(s) may include one or more current carrying conductors formed into coils 124, such as superconducting coils, that may be attached to a coil support assembly, such as the amrature 118 or the field assembly 120. Furthemrore, the generator 115 may also include a coil support assembly 200 having a plurality of coil support structures 202 that each contain one or more of the coils 124 as will be discussed in greater detail hereinbelow.

[0054] Referring now to FIG. 4, a perspective view of an embodiment of the coil support assembly 200 of an electrical machine (such as the generator 115) is illustrated. As shown, the coil support assembly 200 includes the coil support structures 202 and coils 124, such as superconducting coils, arranged therein. Further, as shown, the coil support structures 202 may be joined or arranged together such that the coil support assembly 200 has a generally circumferential arrangement. Thus, in an embodiment, the circumferential arrangement may generally correspond to a shape of a magnetic field required when operating the generator 115. Accordingly, in an embodiment, the circumferential arrangement allows for the magnetic field produced by the armature 118 to work in concert with the magnetic field produced by the fieldassembly 120 to produce torque and convert mechanical energy into electrical energy.

[0055] Referring now to FIGS. 5a-5b, various views of an embodiment of one of the coil support structures 202 according to the present disclosure are illustrated. As shown in FIG. 5 a, for example, the coil support structure 202 includes a first face 204 defining a cavity 206 for receiving one of the coils 124. In particular, as shown, the cavity 206 generally has an oval or racetrack shape. However, it should be understood that the cavity 206 may have any other suitable shape and is not limited to the illustrated embodiment. Moreover, as shown in FIG. 5b, the coil support structure 202 includes a second face 208 opposite the first face 204. In addition, as shown in FIGS. 5a-5b, the coil support structure 202 further includes a first side 210 and a second side 212 opposite the first side 210.

[0056] In further embodiments, the coil support structure(s) 202 may be formed from a variety of materials using a variety of methods. For example, the coil support structure 202 may be formed from a metal such as a metal alloy, or more specifically, an aluminum alloy or an austenitic stainless steel. Further, the coil support structure 202 may be formed via a casting from a mold, such as a sand cast mold.

[0057] In still further embodiments, the coil support assembly 200 may include one or more support plates 214 arranged on the first face 204 and over the coil 124 such that the coil 124 is enclosed within the coil support structure 202. (See FIGS. 6- 7).

[0058] Referring now to FIG. 6, a side view of an embodiment of one of the coil support structures 202 according to the present disclosure is illustrated. As shown, the first side 210 and the second side 212 each include joint components 216, 218, specifically a male joint component 216 and a female joint component 218. Thus, as shown in FIG. 7, when adjacent coil support structures 202 including male and female joint components 216, 218 are secured together, the male and female joint components 216, 218 of adjacent coil support structures 202 together form ajoint structure 220. In further embodiments, as shown in FIG. 9a and 9b, for example, the male and female joint components 216, 218 may span an entirety of the length of the coil support structure 202 as will be discussed in greater detail hereinbelow.

[0059] In particular embodiments, the male and female joint components 216, 218 may have a variety of cross-sectional shapes. For example, in an embodiment, themale and female joint components 216, 218 may together form a dovetail joint including a tongue and groove shape, respectively. A dovetail joint is particularly advantageous when used with the coil support structures 202 because they assemble easily and more quickly while distributing stress more evenly than threaded fasteners. In addition, dovetails make aligning adjacent coil support structures straightforward. For example, because a dovetail joint only consists of two parts, it allows for the simplified design of coil support structure that only include a male joint component 216 and a female joint component 218. Further, each coil support structure 202 can be inserted into a defined slot from one end.

[0060] In further embodiments, the male joint component 216 may have a radius of curvature ranging from about 2.5 millimeters (mm) to about 100 mm, such as about 5 mm to about 75 mm, such as about 10 mm to about 50 mm. Similarly, the female joint component 218 may have a radius of curvature ranging from about 2.5 millimeters (mm) to about 100 mm, such as about 5 mm to about 75 mm, such as about 10 mm to about 50 mm.

[0061] Referring now to FIG. 7, the male and female joint components 216, 218 may be designed such that a gap 224 may exist between adjacent coil support structures 202. For example, if the male joint component 216 has smaller radius of curvature than the female joint component 218, the gap 224 may exist when the joint components 216, 218 are joined to each other. Further, by providing the gap 224, assembly of the male and female joint components 216, 218 may be simplified. For example, the male joint component 216 with a smaller radius of curvature may be more easily placed within the female joint component 218 with a larger radius of curvature.

[0062] Moreover, as shown, the coil support assembly 200 may include a joint spacer 222 arranged in the gap 224 between adjacent coil support structures 202. Thus, in an embodiment, the joint spacer 222 is configured to lock the two coil support structures 202 together while distributing interface stress uniformly over the length of the joint. Specifically, by providing the joint spacer 222, the friction between the coil support structures 202 may be reduced by eliminating relative motion of the coil support structures 202. Further, the joint spacer 222 may help account for any extra space that exists between the coil support structures 202 whenthe joint structure 220 is formed.

[0063] The joint spacer 222 may be sized such that it is smaller than the gap 224.For example, the joint spacer 222 may include a maximum height Hl and the gap 224 may include a maximum height H2. (See FIG. 8A). Here, the maximum height Hl of the joint spacer 222 may be smaller than the maximum height H2 of the gap 224. Specifically, the height Hl may range from about 80% to 99% of the height of H2, such as about 85% to 97.5%, such as about 90% to about 95%. By sizing the joint spacer 222 to be smaller than the gap 224, the joint structure 220 may be locked more easily.

[0064] Furthermore, the joint spacer 222 may be formed of multiple portions, such as a carrying portion 226 and a contacting portion 228. More specifically, the carrying portion 226 may be secured or affixed to one of the joint components 216, 218 of the coil support structure 202. Furthermore, in an embodiment, the carrying portion 226 may be formed from a variety of materials. However, in an exemplary embodiment, the carrying portion 226 may be constructed of at least one of a metal alloy such as an aluminum alloy or an austenitic stainless steel. It will be appreciated that temperature effects can be reduced by making the carrying portion 226 and the contacting portion 228 of the same material as the coil support structure 202.

[0065] The carrying portion 226 and contacting portion 228 may have a variety of cross sections that interlock with each other. For example, the carrying portion 226 and the contacting portion 228 may each have a wedge shape that interlocks to form the joint spacer 222. For example, when the two wedge shapes are interlocked, they may form a joint spacer 222 having a rectangular shape. The shape of the wedges or the joint spacer 222 may also be further modified with chamfers, bevels, fillets, or the like such that the joint spacer 222 fits within the gap 224. Further, the shapes of the contacting and carrying portion 226, 228 may be individually sized such that they fit within the gap 224 as described above in reference to the height Hl and height H2.

[0066] Once the carrying portion 226 is affixed to the joint component 216, 218, the contacting portion 228 may then be attached to the carry ing portion 226 such that a tight fit is formed between the joint components 216, 218 when adjacent coil support structures 202 are attached to each other. As such, in an embodiment, the contacting portion 228 may be detachable or removable from the carrying portion226. By providing the joint spacer 222 with such a configuration, the contacting portion 228 of the joint spacer 222 may be removed during, e g., maintenance of the coil support assembly 200 or one or more individual coil support structures 202.

[0067] Further, in an embodiment, the contacting portion 228 may be easily removed and replaced with another contacting portion 228. Such removal can be advantageous if the joint spacer 222 undergoes stress or mechanical deformation that renders the contacting portion 228 inoperable when contacting with the joint components 216, 218 during operation of the electrical machine 114 or the generator 115. Like the carrying portion 226, the contacting portion 228 may be formed from a variety of materials. However, in an exemplary embodiment, the contacting portion 228 may be constructed of at least one of a metal alloy such as an aluminum alloy or an austenitic stainless steel. It will be appreciated that installation of the carrying portion 226 and the contacting portion 228 is simplified if each is tapered so that engagement over the entire length happens uniformly.

[0068] To further improve the mechanical properties between the coil support structures 202 and alleviate mechanical stresses therebetween, the coil support structures 202 may further be coated with a coating material 229. For example, the coating material 229 may include at least one of polytetrafluoroethylene (PTFE) or acetal homopolymer to provide dry lubrication as the carrying portion 226 and contacting portion 228 are installed. Further, the coating material 229 may include an anodization of a metal such as aluminum. Such an anodization may make the coil support structure 202 more wear resistant, corrosion resistant, providing surface lubricity, and prevent galling between the coil support structures 202.

[0069] Referring back to FIG. 6, each of the coil support structures 202 may taper in width W1 from the first face 204 to the second face 208 or vice versa. For example, the width at the first face 204 may be smaller than the width at the second face 208, or vice versa. Further, the taper may include an angle 0 on each side 210, 212 of the coil support structure 202. The angle 0 may range from about 5 degrees to about 20 degrees, such as about 7.5 degrees to about 15 degrees, such as about 10 degrees to about 12.5 degrees. By providing a tapering width W1 between the faces 204, 208, the coil support structures 202 may be capable of being connected in a generally circumferential arrangement when connected to each other with the jointstructure 220.

[0070] Further, as shown particularly in FIG. 7, the variable width provided by tapering between the faces 204, 208 can be sized such that one or more gaps 230 may be formed between ends of the coils support structures 202 when connected together via the joint structure(s) 220. Advantageously, one or more shims 232 may be placed within the gaps 230. Specifically, the shim(s) 232 may be placed within the gaps 230 such that a contact surface 231, 233 of the coil support structures do not contact each other except at the male and female joint components 216, 218. By providing the shim(s) 232 within the gap(s) 230, further dry lubrication may be provided between the coil support structures 202, thereby reducing overall mechanical stresses therebetween. Specifically , the shim(s) 232 may reduce the friction between the coil support structures 202 when provided within the gap(s) 230. Further, shim(s) 232 may help account for any extra space found between coil support structures 202 when the joint structure 220 is formed.

[0071] The shim(s) 232 may be formed from a variety of materials such as at least one a metal alloy such as an aluminum alloy or austenitic stainless steel. It will be appreciated that magnetic materials may unfavorably distort the magnetic fields produced by the field coils. In an exemplary embodiment, the shims are formed from a stainless steel to provide rigidity when inserting the shim(s) 232 within the gap(s) 230.

[0072] Further, if more than one shim 232 is used, the shims 232 may have the same or substantially the same width W2. By providing shims 232 with the same or substantially the same width W2 angular forces applied within the joint structure 220 can be reduced that would effect the integrity of the joint structure 220.

[0073] The shim(s) 232 may also include an extension 235 that extends outside of the gaps 230. The extension 235 may include a lip, a protrusion, a tab, or other similar features. By providing such an extension 235, the shim(s) may be more easily removed or the positioning of the shim(s) 232 within the gaps 230 may be adjusted if required.

[0074] Referring now to FIGS. 8a-8b, side views of various embodiments of the joint structures 220 according to the present disclosure are illustrated. Particularly, referring to FIG. 8a, the male and female joint components 216, 218 of the jointstructure 220 each have a generally arcuate cross-sectional shape arranged together such that gap 224 is formed having the joint spacer 222 placed therein. Referring to FIG. 8b, the male and femalejomt components 216, 218 of thejoint structure 220 are arranged together such that multiple gaps 224 are formed therebetween. In such an embodiment, thejoint spacer 222 is also placed in one of the gaps 224.

[0075] Referring now to FIGS. 9a-9b, various views of an embodiment of the coil support structure 202 are illustrated. As shown, the male and female joint components 216, 218 described herein may span an entirety of a length LI of the coil support structure 202. Specifically, the coil support structures 202 may include a first end 234 and a second end 236 with the male and female joint components 216, 218 extending from the first end 234 to the second end 236.

[0076] Still referring to FIGS. 9a- 9b, the coil support structure 202 may also include one or more support structures 238. In such embodiments, the support structure(s) 238 may be designed such that a torque tube or torque tube support structure (not shown) can be readily attachable to the support structure(s) 238. Thus, a torque tube or torque tube support structure may be securable to each of the coil support structures 238. Further, the support structures(s) 238 may be securable to each other. For example, as shown in FIG. 9b, the support structure 238 may align with another support structure 239 along thejoint structure 220.

[0077] Referring now to FIG. 10, a side view of an embodiment of the coil support assembly 200 described herein is illustrated. In particular, as shown, the coil support assembly may include one or more sections 240 assembled together according to the present disclosure. The sections 240 can be composed of multiple individual coil support structures 202. Thus, in such embodiments, the sections 240 can be joined together to form the coil support assembly 200. Each section 240 may define a specific portion of a 360-degree angle of a circumferential arrangement of the coil support assembly 200. In particular, one section 240 may define an arc having an angle ranging from about 5 degrees to about 200 degrees, such as about 7.5 degrees to about 190 degrees, such as about 10 degrees to about 180 degrees. Furthermore, as shown, adjacent sections 240 may be secured together via a connecting member 242. For example, in an embodiment, the connecting member 242 may be thejoint structure 220 or the shim(s) 232 as described hereinabove.

[0078] Referring now to FIGS. 11-12, various methods of assembly are provided. In particular, FIG. 11 provides a flow diagram of an embodiment of a method 300 of assembling a coil support assembly, such as the coil support assembly 200. Further, FIG. 12 provides a flow diagram of an embodiment of a method 400 of assembling a coil support structure, such as coil support structure 202. It should be understood that the methods 300, 400 may be implemented using, for instance, the electrical machine 114 or the generator 115 of the present disclosure discussed above with references to FIGS. 1-10. FIGS. 11-12 depict steps performed in a particular order for purposes of illustration and discussion. Those of ordinary skill in the art, using the disclosure provided herein, will understand that various steps of the methods 300, 400, or any of the methods disclosed herein, may be adapted, modified, rearranged, performed simultaneously, or modified in various ways without deviating from the scope of the present disclosure.

[0079] Referring to FIG. 11, as shown at (302), the method 300 includes providing a plurality of coil support structures, each of the plurality of coil support structures having a first face defining a cavity and opposing sides each defining a joint component, the joint components being one of a male joint component or a female joint component. Further, as shown at (304), the method 300 includes arranging a conducting coil within the cavity of each of the plurality of coil support structures. Further, as shown at (306), the method 300 includes arranging the plurality of coil support structures together in a generally circumferential arrangement. Further, as shown at (308), the method 300 includes securing the plurality of coil support structures together via the male and female joint components of adjacent coil support structures of the plurality of coil support structures to form the coil support assembly.

[0080] Moreover, the method 300 may further include the step of arranging at least one joint spacer within the at least one gap. If a joint spacer is provided, it should be understood that the joint spacer may be secured to the male joint component before the male joint component is secured with a female joint component. However, it should be also understood that the joint spacer may alternatively be placed within the female joint component before the female joint component is secured with the male joint component. The joint spacer may include a carry ing portion and a contacting portion where the carrying portion is secured to the male or female jointcomponents and the contacting portion is secured to the carrying portion after installation.

[0081] Moreover, the method 300 may also include a maintenance operation for the coil support assembly formed via the method 300. In particular, the method 300 may also include the step of removing the contacting portion from the carry ing portion during a maintenance operation and replacing the contacting portion with another contacting portion.

[0082] Referring now to FIG. 12, as shown at (402), the method 400 includes providing a coil support structure having a first face defining a cavity and opposing sides each defining a joint component, the joint components defining a male joint component on a first side of the opposing side and a female joint component on a second side of the opposing sides, the male and female joint components being securable to adjacent coil support structures of the coil support assembly to form multiple joint structures. Further, as shown at (404), the method 400 includes arranging a conducting coil within the cavity of the coil support structure.Specifically, when arranged together, the coil support structure and an adjacent coil support structures form a coil support assembly having a generally circumferential arrangement.

[0083] Various aspects and embodiments of the present disclosure are defined by the following numbered clauses:Clause 1. A method of assembling a coil support assembly for an electrical machine, the method comprising: providing a plurality of coil support structures, each of the plurality of coil support structures having a first face defining a cavity and opposing sides each defining a joint component, the joint components being one of a male joint component or a female joint component; arranging a conducting coil within the cavity of each of the plurality7of coil support structures; arranging the plurality of coil support structures together in a generally circumferential arrangement; and securing the plurality of coil support structures together via the male and female joint components of adjacent coil support structures of the plurality of coilsupport structures to form the coil support assembly.Clause 2. The method of clause 1, wherein providing the plurality of coil support structures further comprises casting the plurality of coil support structures.Clause 3. The method of any one of clauses 1 to 2, wherein the male and female joint components of the plurality of coil support structures together define a joint structure defining at least one gap therebetween.Clause 4. The method of clause 3, further comprising arranging at least one joint spacer within the at least one gap.Clause 5. The method of clause 4, wherein the at least one joint spacer comprises a carrying portion and a contacting portion.Clause 6. The method of clause 5, further comprising securing the carrying portion to either of the male or female joint components; and securing the contacting portion to the carry ing portion.Clause 7. The method of any one of the preceding clauses, further comprising: assembling a plurality of sections of the plurality of coil support structures; and securing the plurality of sections together to form the coil support assembly.Clause 8. The method of clause 7, wherein the plurality of sections each define an arc having an angle ranging from 10 degrees to 180 degrees.Clause 9. The method of any one of clauses 7 to 8, further comprising securing the plurality of sections together via at least one connecting member.Clause 10. The method of any one of clauses 3 to 9, further comprising arranging one or more shims between the male and female joint components of adjacent coil support structures.Clause 11. The method of any one of the preceding clauses, wherein each coil support structure further defines a second face opposite the first face, the method further comprising: forming a plurality of support structures; securing an individual support structure to the second face of each coil support structure; and securing a torque tube to each of the plurality of support structures.Clause 12. The method of any one of the preceding clauses, further comprising: coating each of the plurality of coil support structures with a coating material.Clause 13. The method of clause 12, wherein the coating material comprises at least one of polytetrafluoroethylene (PTFE) or acetal homopolymer to provide dry lubrication.Clause 14. The method of any one of clauses 12 to 13, wherein the coating material comprises an anodization of a metal.Clause 15. The method of any one of the preceding clauses, wherein the electrical machine is a superconducting generator and the plurality of conducting coils are superconducting coils.Clause 16. A method for assembling a coil support structure for a coil support assembly of an electrical machine, the method comprising: providing the coil support structure having a first face defining a cavity and opposing sides each defining a joint component, the joint components defining a male joint component on a first side of the opposing side and a female joint component on a second side of the opposing sides, the male and female joint components being securable to adjacent coil support structures of the coil support assembly to form multiple joint structures; and arranging a conducting coil within the cavity of the coil support structure, wherein, when arranged together, the coil support structure and the adjacent coil support structures form the coil support assembly having a generally circumferential arrangement.Clause 17. The method of clause 16, further comprising arranging at least one j oint spacer on the male j oint component or the female j omt component.Clause 18. The method of clause 17, wherein the at least one joint spacer comprises a carrying portion and a contacting portion.Clause 19. The method of any one of clauses 16 to 18, further comprising arranging one or more shims adjacent the male joint component or the female joint component.Clause 20. The method of any one of clauses 16 to 19, coating the coil support structure with a coating material.

[0084] This writen description uses examples to disclose the disclosure, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure 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 with insubstantial differences from the literal languages of the claims.

Claims

WHAT IS CLAIMED IS:

1. A method of assembling a coil support assembly for an electrical machine, the method comprising: providing a plurality of coil support structures, each of the plurality of coil support structures having a first face defining a cavity and opposing sides each defining a joint component, the joint components being one of a male joint component or a female joint component; arranging a conducting coil within the cavity of each of the plurality' of coil support structures; arranging the plurality of coil support structures together in a generally circumferential arrangement; and securing the plurality of coil support structures together via the male and female joint components of adjacent coil support structures of the plurality of coil support structures to form the coil support assembly.

2. The method of claim 1, wherein providing the plurality of coil support structures further comprises casting the plurality of coil support structures.

3. The method of claim 1, wherein the male and female joint components of the plurality of coil support structures together define a joint structure defining at least one gap therebetween.

4. The method of claim 3, further comprising arranging at least one joint spacer within the at least one gap.

5. The method of claim 4, wherein the at least one joint spacer comprises a carrying portion and a contacting portion.

6. The method of claim 5, further comprising securing the carrying portion to either of the male or female joint components; and securing the contacting portion to the carry ing portion.

7. The method of claim 1, further comprising: assembling a plurality of sections of the plurality' of coil support structures; and securing the plurality of sections together to form the coil support assembly.

8. The method of claim 7, wherein the plurality of sections each define an arc having an angle ranging from 10 degrees to 180 degrees.

9. The method of claim 7, further comprising securing the plurality of sections together via at least one connecting member.

10. The method of claim 3, further comprising arranging one or more shims between the male and female joint components of adjacent coil support structures.

11. The method of claim 1, wherein each coil support structure further defines a second face opposite the first face, the method further comprising: forming a plurality of support structures; securing an individual support structure to the second face of each coil support structure; and securing a torque tube to each of the plurality of support structures.

12. The method of claim 1, further comprising: coating each of the plurality of coil support stmctures with a coating material.

13. The method of claim 12, wherein the coating material comprises at least one of polytetrafluoroethylene (PTFE) or acetal homopolymer to provide dry lubrication.

14. The method of claim 12, wherein the coating material comprises an anodization of a metal.

15. The method of claim 1, wherein the electrical machine is a superconducting generator and the plurality of conducting coils are superconducting coils.

16. A method for assembling a coil support structure for a coil support assembly of an electrical machine, the method comprising: providing the coil support structure having a first face defining a cavity and opposing sides each defining a joint component, the joint components defining a male joint component on a first side of the opposing side and a female joint component on a second side of the opposing sides, the male and female joint components being securable to adjacent coil support structures of the coil support assembly to form multiple joint structures; and arranging a conducting coil within the cavity of the coil support structure, wherein, when arranged together, the coil support structure and the adjacent coilsupport structures form the coil support assembly having a generally circumferential arrangement.

17. The method of claim 16, further comprising arranging at least one joint spacer on the male joint component or the female joint component.

18. The method of claim 17, wherein the at least one joint spacer comprises a carrying portion and a contacting portion.

19. The method of claim 16, further comprising arranging one or more shims adjacent the male joint component or the female joint component.

20. The method of claim 16, further comprising coating the coil support structure with a coating material.

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