Flexible Stator Coil Retainer for Wind Turbine Generators

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Solution Overview

Problem

Existing wind turbine generator systems are cumbersome, complex, and costly due to the use of multiple parts like wedges, filler strips, and ripple springs to compensate for clearance increases in stator core slots, leading to inefficient retention and installation of winding coils.

Innovation Solution

A flexible supporting device with a leaf spring made of fiberglass or similar material is used, which transitions from a relaxed to a compressed state upon insertion between stator portions, providing efficient retention of winding coils without interfering with the air gap between the rotor and stator, and includes a pre-tensioning tool for easy installation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple parts (wedges, filler strips, ripple springs) are used to retain coil windings, then the retention reliability is improved, but the device complexity and manufacturing cost increase

Engineering Contradiction:

Improvecoil retention reliabilityVSAvoidnumber of parts

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple retention functions (wedge, filler strip, ripple spring) into a single integrated flexible member that performs all functions simultaneously, eliminating the need for separate components and reducing assembly complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The flexible member is designed to perform multiple functions: it acts as a wedge for radial retention, provides filler functionality to occupy slot space, and incorporates ripple springs for axial retention, making one component universal for all retention needs

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If multiple parts (wedges, filler strips, ripple springs) are used to retain coil windings, then the retention reliability is improved, but the manufacturing cost increases

Engineering Contradiction:

Improvecoil retention reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The flexible member is made from composite materials that provide the necessary mechanical properties for all retention functions, replacing multiple separate parts with a single cost-effective composite component

Inventive Principle:

Principle #40Composite materials

3Reliability

If rigid filler strips and ripple springs are compressed and bonded with adhesive, then the coil retention is improved, but the installation process becomes complex and time-consuming

Engineering Contradiction:

Improvecoil retentionVSAvoidinstallation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent extracts and eliminates the adhesive bonding step from the installation process by designing a flexible member that relies on elastic deformation and mechanical force alone, removing the time-consuming heating and bonding operations

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The flexible member is pre-formed with the necessary geometry and elastic properties during manufacturing, so that during installation it simply needs to be inserted and will automatically deform to the compressed state without requiring additional processing steps

Inventive Principle:

Principle #10Preliminary action

4Device complexity

If a simple flexible member is used to support winding coils, then the device complexity and cost are reduced, but the ability to prevent coil displacement and minimize vibrations must be maintained

Engineering Contradiction:

Improvenumber of partsVSAvoidcoil retention and vibration control

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent uses a dynamic flexible member that can elastically deform to adapt to clearance variations while maintaining continuous contact force on the coils, providing active retention that responds to operational conditions rather than static rigid support

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The flexible member's elastic properties allow it to change its physical state between relaxed and compressed configurations, enabling it to provide appropriate retention force while accommodating thermal expansion and operational variations

Inventive Principle:

Principle #35Parameter changes

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 reduces manufacturing and assembly costs, minimizes vibrations, prevents coil displacement, and enhances cooling through air channels, offering a lightweight, adaptable, and efficient means of supporting winding coils.

Implementation Method 1

the flexible member is in an operating configuration, i.e. in a compressed condition, that is, the flexible member is compressed by the stator portions and the winding coils of the wind turbine generator, applying a force on the winding coils for retaining them into slots formed in the stator core

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentEP3107194B1Supporting device and method for supporting winding coils in a wind turbine generator

Publication Date: 2018.11.28 GE RENEWABLE TECH WIND BV

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AI summary

The device comprises a flexible member that is in a relaxed, substantially concave configuration before being inserted between two adjacent stator portions, and in an operating, substantially flattened configuration when inserted between two adjacent stator portions in which the flexible member is compressed by the stator portions and the winding coils. The flexible member may be in an inserting, substantially convex configuration for being inserted between the adjacent stator portions.