Flexible Cable Stator Wiring for Wind Turbine Generators
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Large wind turbine generators face challenges in providing a compact and effective wiring arrangement for their stator assemblies due to spatial constraints and the need for numerous electrical connections, which complicates the mounting and operation of high-power generators.
Innovation Solution
The use of flexible, insulated cables for wiring arrangements that can be bent and shaped to fit spatial constraints, eliminating the need for rigid bus bars and allowing for a star-configuration where each stator segment is independently connected to the power interface, with EMC shielding to reduce electromagnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid bus bars are used for wiring arrangements, then electrical connection reliability is improved, but spatial flexibility and ease of installation deteriorate
Solution Approach 1:
The patent replaces rigid bus bars with flexible cables that have an insulating jacket. These cables can be bent and shaped to fit the spatial constraints of the stator assembly while maintaining reliable electrical connections. The flexibility allows for easier installation and adaptation to different generator configurations without compromising connection reliability.
Solution Approach 2:
The invention changes the physical state and properties of the wiring from rigid (bus bars) to flexible (cables with insulating jackets). This parameter change enables the wiring to adapt to spatial constraints while maintaining electrical reliability, resolving the contradiction between connection reliability and installation ease.
2Power
If the number of stator segments is increased to handle higher power, then power output is improved, but wiring complexity and spatial constraints worsen
Solution Approach 1:
The stator assembly is divided into multiple stator segments that can be independently wired. Each segment can be connected using the same flexible cable methodology, which simplifies the overall wiring complexity despite the increased number of segments. The segmentation allows for modular assembly and easier management of electrical connections.
Solution Approach 2:
Flexible cables with insulating jackets are used to connect each stator segment to the power interface. This approach manages the wiring complexity effectively by providing a standardized, adaptable connection method that can accommodate numerous segments without proportionally increasing system complexity.
3Adaptability or versatility
If flexible cables are used for wiring arrangements, then spatial adaptability and ease of installation are improved, but electromagnetic interference protection deteriorates
Solution Approach 1:
The flexible cables are provided with insulating jackets that also serve as protective shielding. This flexible shell structure maintains the spatial adaptability of the cables while providing a degree of electromagnetic interference protection through the insulating material.
Solution Approach 2:
The insulating jacket acts as an intermediary layer between the conductive cable core and the external electromagnetic environment. This intermediate protective layer reduces electromagnetic interference while allowing the cable to maintain its flexible, spatially adaptable characteristics.
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
This solution enables a compact, reliable, and efficient wiring arrangement that can be easily installed and maintained, even in large generators, ensuring high operational reliability and flexibility while minimizing electromagnetic interference.
Implementation Method 1
flexible cables which are insulated (with respect to each other and with respect to other parts of the stator assembly) can be used for a wiring arrangement which provides a plurality of electric connections
Implementation Method 2
EMC shielding to reduce electromagnetic interference
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A stator assembly (110) comprises (a) a stator frame structure having an outer annular frame (212) with an outer edge (212a) running around a center axis (190a); (b) a plurality of stator segments (230) mounted at the outer edge (212a) along a circumferential direction of the outer edge (212a), each stator segment (230) comprising at least one electric coil (231); and (c) a wiring arrangement (340) electrically connecting the stator segments (230) with an electric power interface (550). The wiring arrangement (340) comprises (c1) a plurality of wiring assemblies (648), each wiring assembly (648) electrically connecting one of the plurality of stator segments (230) with the power interface (550). Each wiring assembly (648) is routed along and next to the outer annular frame (212) and comprises electric cables (449a-c) connected in between the electric interface (550) and the respective stator segment (230), wherein the electric cables (449a, 449b, 449c) are provided with electric insulation structures each surrounding one of the electric cables (449a, 449b, 449c). Further described is an electric generator and a wind turbine with such a stator assembly.