Gear Integrated Generator for Wind Turbines
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Solution Overview
Problem
Large multimegawatt wind turbines face challenges with direct drive generators due to increasing mass and thermal growth issues, as well as lower efficiency and shorter lifetimes, particularly in offshore applications.
Innovation Solution
A gear integrated generator design with a compact, single-stage planetary gear system that reduces weight and increases efficiency, featuring a medium rotating speed and improved thermal management through forced air cooling, allowing for extended component lifetimes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If direct drive generators are used in large multimegawatt wind turbines, then the generator can directly convert mechanical energy to electrical energy, but the mass increases and thermal growth control becomes difficult
Solution Approach 1:
The direct drive generator is segmented into modular components (stator, rotor, bearing assemblies, cooling systems) that can be manufactured separately and assembled. This segmentation allows for optimized weight distribution and thermal management zones, reducing overall mass while maintaining energy conversion efficiency.
Solution Approach 2:
The generator employs a nested structure where the rotor is positioned within the stator, and cooling channels are integrated within the generator housing and component structures. This nesting approach minimizes the overall footprint and mass while ensuring effective thermal growth control through integrated cooling pathways.
2Power
If higher rotating speed generators are used, then power output increases, but efficiency decreases and lifetime of rotating parts is limited
Solution Approach 1:
The generator incorporates dynamic balancing mechanisms and adjustable operating speed ranges that allow optimization between power output and component stress. The system can dynamically adjust rotational speed based on wind conditions, maintaining high power output while preventing excessive stress on rotating parts that would reduce lifetime.
Solution Approach 2:
The generator design allows for parameter changes in magnetic field strength, rotational speed, and torque characteristics to optimize the balance between power output and component durability. By adjusting these parameters, the system achieves high power output during peak wind conditions while operating at lower stresses during normal conditions, extending rotating part lifetime.
3Power
If higher rotating speed generators are used, then power output increases, but efficiency decreases
Solution Approach 1:
The generator incorporates magnetic coupling and electromagnetic field optimization to reduce mechanical friction and energy losses associated with high-speed rotation. By substituting pure mechanical transmission with optimized electromagnetic coupling, the system maintains high power output while minimizing energy efficiency losses.
4Weight of moving object
If a compact generator design is implemented, then weight is reduced, but thermal management becomes more challenging
Solution Approach 1:
The compact generator design incorporates intermediate cooling structures and thermal pathways that act as mediators between heat-generating components and the external environment. These intermediate cooling channels and heat sinks enable effective thermal management in the compact design by providing dedicated pathways for heat dissipation without increasing overall 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
The gear integrated generator achieves a higher power output-to-weight ratio, increased efficiency, and extended component lifetimes, reducing downtime and operational costs while maintaining controlled thermal growth.
Implementation Method 1
improved thermal management through forced air cooling
Data Source
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AI summary
A gear integrated generator for a wind turbine having a tower, a nacelle, and a hub is described. The gear integrated generator includes: a stator supporting frame (101) having a stator supporting portion, a radially extending portion and a rotor frame supporting portion, wherein the stator supporting frame is stationarily mountable within the nacelle. A rotor frame (102) is rotatably supported on the rotor frame supporting portion of the stator supporting frame, wherein the rotor frame is connected to the hub, and a gear driven by the rotor frame. The gear includes a ring gear stationarily mounted to the stator support frame, a carrier gear assembly, and a ring-shaped sun gear. The gear integrated generator further includes: a rotor generator ring support frame (103) rotatably supported and radially positioned outward of the rotor frame supporting portion of the stator supporting frame.