Coreless Stator Sealing and Oil Cooling for Gas-Driven Generators
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Solution Overview
Problem
Existing non-combustion electric generators for remote locations suffer from inefficient energy conversion, manufacturing challenges, potential fluid ingress, and durability issues due to high temperatures and encapsulation flaws.
Innovation Solution
A coreless stator winding assembly with a dismantlable casing, hermetic connectors, and a cooling system using transformer oil and a recirculating pump to enhance efficiency, durability, and maintain insulation integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional encapsulation molding is used for stator windings, then manufacturing is completed, but the process is laborious, time-consuming, and difficult to repair
Solution Approach 1:
The stator winding assembly is divided into separate components: the stator winding, the hub, and the outer housing. These segments are manufactured independently and then assembled together using a dismantlable connection system, eliminating the need for laborious encapsulation molding and enabling easy disassembly for repairs.
2Reliability
If encapsulation molding is used to seal stator windings, then the stator is sealed, but cracks may form under pressure and fluid ingress may occur
Solution Approach 1:
The sealing system is segmented into multiple independent sealing interfaces: between the hub and outer housing, and at the connection points of electrical leads. This segmentation allows for targeted sealing at critical locations without requiring complete encapsulation, reducing the risk of cracks while maintaining sealing integrity.
Solution Approach 2:
Sealing elements such as gaskets or O-rings are introduced as intermediary components between the hub and outer housing, and at electrical lead connection points. These intermediaries provide reliable sealing that prevents fluid ingress while accommodating thermal expansion and contraction without cracking.
3Stability of the object's composition
If stator windings are encapsulated in molded housing, then the structure is fixed, but repair and maintenance are difficult and destructive
Solution Approach 1:
The stator assembly is segmented into removable components connected by a dismantlable system. The hub can be detached from the outer housing, and electrical leads can be disconnected, allowing the stator winding to be accessed for inspection and repair while maintaining structural stability during operation.
Solution Approach 2:
The connection system transitions from a static, permanent encapsulation to a dynamic, reversible connection. The dismantlable system allows the stator components to be easily assembled and disassembled, providing structural stability when connected and ease of access when disconnected for maintenance.
4Duration of action of moving object
If high temperature operation is endured, then continuous operation is maintained, but resistance of coil windings increases and efficiency decreases
Solution Approach 1:
A cooling medium is introduced as an intermediary substance that circulates between the stator winding and the outer housing. This cooling medium absorbs heat from the coil windings during continuous operation, maintaining optimal temperature and preventing resistance increase, thereby preserving working efficiency.
5Device complexity
If conventional stator windings with laminated cores are used, then traditional design is maintained, but energy conversion efficiency is low
Solution Approach 1:
The laminated core is extracted from the stator winding design, creating a coreless stator. This removal of the magnetic core eliminates energy losses associated with core hysteresis and eddy currents, significantly improving energy conversion efficiency while simplifying the overall stator design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides faster, cheaper manufacturing, efficient energy conversion, prevents fluid ingress, and maintains consistent performance under high pressure and temperature conditions.
Implementation Method 1
a coreless stator winding arranged to interact with said magnetic element
Implementation Method 2
a cooling system using transformer oil and a recirculating pump
Implementation Method 3
the transformer oil may circulate in between the stator winding assembly and oil tank
Implementation Method 4
a submersible miniature pump for consistent supply of the transformer oil into the stator winding assembly
Data Source
AI summary
An electric generator, comprising: a housing; an inlet for receiving gas into said housing; a rotor operatively rotatable through contact with said fluid; said rotor having at least one magnetic element attached to its inside; a stator winding assembly having a coreless stator winding arranged to interact with said magnetic element; wherein said stator winding assembly having a dismantlable casing arranged to seal the coreless stator winding from said gas inflow.