Flexible Stator Cabling for Wind Turbine Generators
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Solution Overview
Problem
Large wind turbines face challenges in providing a compact and cost-effective current transmission arrangement for their stator assemblies due to increased spatial dimensions and the need for numerous stator segments, which complicates electrical connections and maintenance.
Innovation Solution
The use of flexible stator and main cabling arrangements with connecting devices and cable holders, supported by mounting plates and cable holders made from materials like glass fiber composite or plastic, allows for easier handling and mounting of stator segments, enabling efficient electrical connections along the circular circumference of the stator assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid bus bars are used for current transmission in large generators, then electrical connection reliability is improved, but device complexity and ease of manufacture deteriorate due to significant amounts of heavy material requiring expensive and complicated fitting
Solution Approach 1:
The patent replaces rigid bus bars with flexible cables that have a soft, bendable structure. These flexible cables can be easily routed and connected to stator segments, eliminating the need for complex rigid bus bar arrangements while maintaining electrical connection reliability through proper cable design and mounting.
Solution Approach 2:
The patent substitutes the mechanical bus bar connection system with an electrical cable-based system. This replacement simplifies the mechanical assembly process, reduces material weight, and improves ease of manufacture while maintaining the necessary electrical connectivity through standardized cable connectors and mounting arrangements.
2Power
If the number of stator segments is increased to meet larger generator requirements, then power output is improved, but ease of operation deteriorates due to more numerous electrical connections requiring compact mounting
Solution Approach 1:
The flexible cable design allows for easy routing and connection to multiple stator segments. The cables can be bent and positioned to accommodate the increased number of connections required for higher power output, making mounting and maintenance operations significantly easier compared to rigid bus bar systems.
Solution Approach 2:
The patent employs modular stator segments that can be independently connected via flexible cables. This segmentation approach allows for systematic organization of electrical connections, where each segment can be mounted and connected separately, simplifying the overall assembly process despite the increased number of segments required for high power output.
3Power
If generator diameter is increased to provide more than 10MW electrical power, then power output is improved, but weight of stationary object increases due to larger spatial dimensions and more material required
Solution Approach 1:
The flexible cable system replaces heavy rigid bus bars, significantly reducing the weight of the stationary stator assembly. This weight reduction becomes increasingly important as generator diameter increases to achieve higher power outputs, allowing for more efficient support structures and reduced mechanical loads.
Solution Approach 2:
The patent changes the physical parameters of the electrical connection system by transitioning from thick, rigid bus bars to thinner, flexible cables. This parameter change maintains electrical conductivity while dramatically reducing material weight and volume, enabling the design of larger diameter generators without proportionally increasing stationary component weight.
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 simplifies the mounting and maintenance of stator assemblies in large wind turbines by reducing the need for heavy, rigid bus bars, providing a more flexible and cost-effective cabling system that can handle the increased size and complexity of larger generators.
Implementation Method 1
each electric coil being electrically connected to the connecting device by means of a flexible cable
Implementation Method 2
The plurality of flexible cables is arranged to be mounted to a mounting plate in a flexible and easily accessible manner
Data Source
Figure 1
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AI summary
There is described a stator assembly comprising (a) a stator frame structure having an outer annular frame with a circular outer edge extending concentrically around a center axis, which defines an axial direction, (b) a plurality of stator segments mounted at the outer edge along a circumferential direction of the outer edge, wherein each stator segment comprises a set of electric coils, a connecting device, and a stator cabling arrangement comprising a set of flexible electric cables arranged to provide electrical connection between each electric coil in the set of electric coils and the connecting device, and (c) a main cabling arrangement connecting the connecting device of each stator segment with an electric power interface for collecting electric power generated by the stator segments. Furthermore, an electric generator and a wind turbine comprising such a stator assembly are described.