Wind Turbine Generator Active Module Segmentation
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Solution Overview
Problem
Current wind turbine generators face challenges in handling and maintenance due to their large size and weight, particularly with permanent magnet generators, where the constant magnetic field complicates operations like installation, replacement, and repair, and existing modular solutions do not efficiently address these issues for both segmented and non-segmented generators.
Innovation Solution
The introduction of an independent active module unit with a sandwich structure that combines permanent magnets, magnetic cores, and coil windings, featuring removably attaching means, allowing the unit to be attached to both the rotor and stator without additional parts, facilitating easier assembly, replacement, and maintenance by maintaining a controlled air gap for magnetic flux.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the generator is made larger to produce more power, then power production increases, but handling and transportation become more difficult
Solution Approach 1:
The generator is divided into multiple segments (stator segments and rotor segments) that can be manufactured separately and assembled on-site. This segmentation allows large power-generating components to be handled in smaller, more manageable pieces during transportation and installation, while still achieving the required total power output when assembled together.
2Power
If permanent magnets are used in the rotor, then power density increases, but handling becomes more complex due to constant magnetic field
Solution Approach 1:
The rotor is segmented into multiple rotor segments that can be assembled separately. This segmentation allows the permanent magnets to be installed in controlled segments rather than as a complete rotor, reducing magnetic field interference during handling and assembly operations while maintaining high power density in the finished generator.
Solution Approach 2:
The rotor segments are pre-assembled with permanent magnets in a controlled manufacturing environment where magnetic field management is easier, before being transported and installed in the final generator assembly. This preliminary assembly allows for better handling during manufacturing while the final installation can be coordinated to minimize magnetic field issues.
3Ease of operation
If modular technology is applied to reduce logistics problems, then transportation ease improves, but device complexity increases
Solution Approach 1:
The generator is divided into standardized modular segments (stator segments, rotor segments, and active module units) that can be manufactured independently and assembled in various configurations. This modular approach simplifies transportation by breaking down large components into smaller standardized units, while the modular design actually reduces overall complexity by allowing standardized components to be reused and reconfigured.
Solution Approach 2:
The modular segments are designed with universal interfaces and standardized dimensions, allowing the same basic module type to be used in different generator configurations and applications. This universality reduces the total number of different component types needed, thereby reducing device complexity while maintaining transportation advantages.
4Manufacturing precision
If segmented rotor and stator are joined with connecting elements to maintain air gap, then manufacturing precision is improved, but ease of repair worsens
Solution Approach 1:
The generator is segmented into modular units with standardized interfaces that maintain precise air gaps through designed mechanical features. This segmentation allows individual segments to be removed and replaced independently for repair, actually improving ease of repair compared to traditional designs where the entire rotor or stator would need to be disassembled.
Solution Approach 2:
The connecting elements and positioning features are designed to allow for dynamic adjustment and replacement. The modular segments can be easily detached and reattached while maintaining the required air gap precision, enabling quick repairs by simply replacing segments rather than reassembling entire components.
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 convenient handling and maintenance of wind turbine generators by allowing the active module unit to be assembled and detached independently, improving operational efficiency and reducing the complexity of magnetic field interactions during assembly and repair processes.
Implementation Method 1
at least one permanent magnet; at least one coil module comprising at least one coil winding and a magnetic core
Implementation Method 2
Through such connecting elements, the rotor and the stator are spaced apart from each other via an air gap separating them
Data Source
Figure 1
Figure 2
Figure 3~3a
AI summary
It comprises a rotor (110) and a stator (120) that they both may be formed of a single piece or they may be formed of a number of sectors. The generator (100) further comprises at least one active module unit (200) as an independent unit from both the rotor (110) and the stator (120). The active module unit (200) includes at least one permanent magnet (210), a magnet support structure (215) attached thereto, first attaching means (220) to removably attach the magnet support structure (215) to the rotor (110) or the stator (120), at least one coil module (230) comprising at least one coil winding and a magnetic core, and second attaching means (240) to removably attach the coil module (230) to the other of the rotor (110) or the stator (120). The coil module (230) is spaced apart from the permanent magnet (210) a predetermined distance.