Bus Bar Retaining Structure for Compact Stator Cooling

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Solution Overview

Problem

Existing bus bars in large dynamoelectric machines, particularly in directly driven wind power generators, face challenges with weight, electrical clearance, and cooling, necessitating improved retention systems that maintain dielectric strength and facilitate integration into the machine structure for a compact design.

Innovation Solution

A retaining system comprising a basic element fastened to the stator end face with fixing elements, allowing bus bars to be securely attached, reducing weight through optimized cross-sections and enabling efficient ventilation and cooling, with bus bars arranged radially beneath the winding overhangs for a compact design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If massy bus bars are used in directly driven wind power generators, then electrical conductivity is improved, but dead weight increases

Engineering Contradiction:

Improveelectrical conductivityVSAvoiddead weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The bus bar system is divided into multiple segments that can be separately supported and connected. The retaining system divides the bus bar into sections that are independently mounted on the retaining structure, allowing for reduced material usage while maintaining electrical continuity through connection elements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The bus bars are arranged in a three-dimensional configuration within the retaining system, utilizing vertical and radial spaces. This spatial arrangement allows for optimized electrical pathways without requiring excessive material mass, as the electrical connection is achieved through multiple-dimensional routing rather than simply increasing cross-sectional area.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Device complexity

If bus bars are attached directly to winding heads, then electrical connection is simplified, but electrical clearances cannot be maintained

Engineering Contradiction:

Improveelectrical connection simplicityVSAvoidelectrical clearance

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The retaining system acts as an intermediary structure between the bus bars and the stator assembly. It provides a dedicated mounting platform that maintains proper electrical clearances while facilitating electrical connections through integrated connection elements, thus mediating between the electrical connection requirement and the clearance requirement.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The retaining system separates the electrical connection function from the mechanical support function. By dividing the assembly into distinct components (retaining structure, bus bar segments, connection elements), it maintains electrical clearances while simplifying connections through modular interfaces.

Inventive Principle:

Principle #1Segmentation

3Volume of moving object

If bus bars are arranged for compact generator design, then space utilization is improved, but ventilation and cooling become difficult

Engineering Contradiction:

Improvegenerator compactnessVSAvoidcooling efficiency

Core Design Contradiction:

Volume of moving objectVSTemperature

Solution Approach 1:

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Reliability

If additional fixing components are used to secure bus bars, then connection reliability is improved, but assembly complexity increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The retaining system combines multiple functions into a single integrated structure: mechanical support, electrical connection, and positioning are all achieved through the unified retaining assembly. The basic element and fixing elements work together as a coordinated system rather than separate components, reducing assembly steps while maintaining connection reliability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The retaining system serves multiple functions simultaneously: it provides mechanical support for the bus bars, maintains electrical clearances, facilitates electrical connections through integrated connection elements, and enables positioning for ventilation channels. This multi-functionality reduces the need for additional specialized components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12456895B2Retaining system with basic element and fixing elements to fix a bus bar on stator or stator segment of dynamoelectric machine

Publication Date: 2025.10.28 FLENDER GMBH

AI summary

A retaining system for bus bars includes a basic element for fastening to an end face of a stator or stator segment of a dynamoelectric machine, and a predefined number of fixing elements configured to fix the bus bars to the basic element, wherein, when assembled, the retaining system has openings to suppress eddy currents when the bus bars are energized.