Wind Turbine Generator Coil End Section Width Reduction
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Solution Overview
Problem
Wind turbine generators with stator slots wider than teeth face challenges in using preformed coils due to the dense arrangement and width of the coils, making it difficult to connect adjacent coils without complex 90° rotation, which increases production costs and limits geometry.
Innovation Solution
A preformed coil design with a reduced width in the end section area, allowing for a greater slot width in the stator, produced with minimal effort through simple pressing, maintaining electrical properties and preventing material cracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the conductor width is increased to fill wider slots completely, then the slot fill factor is improved, but the ability to connect adjacent preformed coils becomes difficult
Solution Approach 1:
The conductor is designed with different widths at different locations: a first width in the winding area for complete slot filling, and a second, smaller width in the end section for easy connection. This local variation in geometry allows each part of the conductor to optimize its function at that location.
Solution Approach 2:
The conductor is divided into distinct functional sections: a winding area with larger width for slot filling, and an end section with smaller width for connections. This segmentation allows independent optimization of each section's dimensions for its specific purpose.
2Ease of operation
If a 90° rotation of the conductor end is performed to enable connection, then the connection possibility is improved, but the production complexity and cost increase significantly
Solution Approach 1:
Instead of rotating the conductor end to enable connection, the invention inverts the approach by making the conductor end inherently connectable through width reduction. This eliminates the need for complex rotation operations while achieving the same connection objective.
Solution Approach 2:
The conductor width parameter is changed in the end section to a smaller value, transforming the geometric parameter to enable connection without requiring rotational movement. This parameter change simplifies the production process significantly.
3Ease of manufacture
If the conductor width is reduced in the end section, then the connection ease is improved, but the electrical properties may be affected
Solution Approach 1:
The width reduction is applied locally only to the end section where connections are needed, while the winding area maintains its original larger width for optimal electrical performance. This localized modification preserves electrical properties in the critical winding region.
Solution Approach 2:
The conductor is segmented into a winding area and an end section, with the width reduction applied only to the end section. This segmentation ensures that electrical properties in the winding area remain unaffected while enabling easy connections in the end section.
Data Source
Figure 1
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AI summary
The invention relates to a coil (12) for a wind turbine generator. The coil (12) has a winding (22) formed with an electrical conductor (20). The winding (22) is formed between a first end section (26) and a second end section (28) by several turns (24) of the conductor. The conductor has, at least in the region of the winding (22), a substantially rectangular cross-section with a substantially constant width and a substantially constant height. The conductor (20) has, at least in one of the end sections (26), an end section region (34) in which the conductor (20) has a comparatively smaller width than in the region of the winding (22). The invention further relates to a method for manufacturing a coil (10), a wind turbine generator with several coils, and a wind turbine (100) with a wind turbine generator.