Generator Air-Guiding Layout for Direct-Drive Winding Head Cooling
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Solution Overview
Problem
The cooling efficiency of stator windings in direct drive permanent magnet generators is limited due to the complex geometry of the winding heads, resulting in increased operating temperatures and reduced output power.
Innovation Solution
A generator design with an air guiding arrangement that separates the cooling volume into radial inner and outer sections, using air deflection sheets to create a nozzle effect and increase the contact surface between cooling air and winding heads, enhancing heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If forced air-cooling system is applied with cool air entering from NDE and DE sides, then cooling coverage is provided, but contact surface with winding heads is small and heat dissipation is insufficient
Solution Approach 1:
The cooling volume is segmented into a radial inner section and a radial outer section using an air guiding arrangement. This segmentation directs cooling air specifically to the winding heads, increasing the contact surface area and heat dissipation efficiency without significantly increasing overall system complexity.
Solution Approach 2:
An air guiding arrangement acts as an intermediary component between the cooling air source and the winding heads. This intermediary structure optimizes the flow path and contact between cooling air and winding heads, improving heat transfer efficiency while maintaining a relatively simple cooling system structure.
2Temperature
If large chamber volume is provided on NDE and DE side, then cooling air flow is accommodated, but contact surface with winding heads is reduced and cooling performance decreases
Solution Approach 1:
Instead of uniformly distributing cooling air throughout the large chamber volume, the air guiding arrangement creates localized high-velocity flow regions directly at the winding heads. This local quality enhancement ensures effective cooling at critical locations while accepting larger overall chamber volume.
3Power
If complex geometry of stator winding heads is maintained, then electrical performance is optimized, but cooling efficiency is reduced due to limited air contact
Solution Approach 1:
The air guiding arrangement introduces a radial dimension to the cooling air flow, directing air from the radial inner section through the air inlet opening into the radial outer section where winding heads are located. This dimensional approach increases contact surface area without altering the complex three-dimensional geometry of the winding heads themselves, thereby maintaining electrical performance while improving cooling efficiency.
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
Improved cooling efficiency leads to reduced winding temperatures, increased generator power, and extended component lifespan, with higher reliability and efficiency.
Implementation Method 1
The air guiding arrangement forms an air inlet opening, such that cooling air is flowable from the radial inner section against the air guiding arrangement and through the air inlet opening into the radial outer section
Implementation Method 2
cooling air enters the generator from the non-drive end (NDE) and drive end (DE) sides, and after passing over the stator winding heads, it enters an axial gap between the rotor and the stator and is distributed between a number of radial air ducts in the stator body to remove heat
Data Source
Figure 1~2A
Figure 2B
Figure 3~4
AI summary
The present invention describes a generator (100) for a wind turbine, comprising a rotor device (101) rotatable around a rotary axis (107), a stator device (102) comprising a winding arrangement (103),wherein between an axial end of the stator device (102) and the rotor device (101) a cooling volume is formed, and an air guiding arrangement (120) arranged within the cooling volume for separating the cooling volume into a radial inner section (112) and a radial outer section (113). The air guiding arrangement (120) forms an air inlet opening (104), such that cooling air (111) is flowable from the radial inner section (112) against the air guiding arrangement (120) and through the air inlet opening (104) into the radial outer section (113), wherein the winding arrangement (103) extends from the axial end of the stator into the radial outer section (113).