Adjustable Stator Mounting for Wind Turbine Air Gap Alignment
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Solution Overview
Problem
Existing wind turbine generators face challenges in maintaining an optimal air gap between the rotor and stator due to manufacturing and assembly tolerances, leading to inefficiencies in electrical power generation, especially when the rotor is mounted on a gearbox output shaft, which can result in gravitational sag and off-circular stator cross-sections.
Innovation Solution
A stator mount system with adjustable elongate bolt holes allows for in-situ adjustment of the stator's position relative to the generator frame, using a support member with adjustable devices to fine-tune the stator's alignment and air gap, ensuring optimal positioning and symmetry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manufacturing and assembly tolerances are relied upon to centre the rotor within the stator, then the generator can be assembled using standard tolerances, but the air gap between rotor and stator becomes asymmetric leading to reduced electrical power generation efficiency
Solution Approach 1:
The stator mount incorporates an adjustment mechanism that allows the stator position to be dynamically modified after assembly. The mounting member can be repositioned along the beam relative to the support member, enabling fine-tuning of the air gap symmetry to optimize electrical power generation efficiency while accommodating manufacturing tolerances.
2Ease of manufacture
If the stator position is optimised in the factory with the rotor mounted on jig bearings, then initial assembly is simplified, but the stator position will not correspond to an optimised position when the rotor is mounted on the gearbox output shaft due to gravitational sag
Solution Approach 1:
The stator is pre-mounted to the frame using the adjustable stator mount during factory assembly. The adjustment mechanism is designed to allow subsequent repositioning, so that while initial assembly can be performed with jig bearings, the system is prepared in advance for final position optimization when the rotor is mounted on the gearbox output shaft.
Solution Approach 2:
The stator mount provides a dynamic adjustment capability that allows the stator position to be modified after initial assembly. This enables the system to transition from a preliminary factory assembly state to a final optimized state that accounts for gravitational sag when the rotor operates on the gearbox output shaft.
3Productivity
If the air gap is set to minimize reluctance and flux leakage for maximum efficiency, then electrical power generation is optimized, but the rotor and stator may come into contact during rotation
Solution Approach 1:
The adjustable stator mount enables dynamic optimization of the air gap dimensions. The mounting member can be repositioned to achieve the precise air gap size that balances magnetic efficiency with mechanical clearance requirements, ensuring both maximum electrical power generation and reliable operation without rotor-stator contact.
Data Source
AI summary
A stator mount and a tool for adjusting the position of a stator mount of a stator of a generator of a wind turbine. The stator mount comprises a support member having a plurality of elongate both holes which provide adjustability between the stator mount and the frame of a generator housing, or between separate components of the stator mount itself. The stator mount may comprise one or more adjustment devices for adjusting the position of the stator mount in use. A tool is provided which may be used to adjust the position of the stator mounts. The tool attaches to the frame of the generator and comprises one or more adjustment devices for adjusting the position of the stator in use.