Wind Turbine Generator Coil Repair Without Full Disassembly
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Solution Overview
Problem
Existing methods for repairing wind turbine generators with preformed coils require complete disassembly and result in compromised thermal conductivity, insulation, and service life due to moisture penetration and electromagnetic forces.
Innovation Solution
A method for repairing wind turbine generators by decoupling and replacing defective preformed coils within the generator housing, using connections like screw, plug, or welded joints, and injecting resin to secure new coils, ensuring equivalent thermal conductivity and insulation properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the generator is completely disassembled for repair, then the defective coil can be replaced, but the thermal conductivity and insulation are compromised allowing moisture penetration
Solution Approach 1:
The invention divides the repair process into segments: only the defective coil is removed and replaced, while the rest of the generator remains assembled. The slot insulation is selectively replaced only where needed, rather than completely disassembling and rebuilding the entire generator, thus maintaining thermal conductivity and insulation integrity.
Solution Approach 2:
The repair applies local quality by replacing insulation materials only in the specific slots where coils are defective, rather than uniformly treating the entire generator. This localized approach preserves the thermal conductivity and insulation properties of unaffected areas while addressing repair needs.
2Manufacturing precision
If the slot is completely cleared and rebuilt, then the insulation can be restored, but the service life is minimized due to electromagnetic forces causing relative movement
Solution Approach 1:
The invention applies preliminary action by pre-securing the new coil to the slot insulation using adhesive before inserting it into the slot. This preliminary bonding prevents relative movement between the coil and slot under electromagnetic forces during operation, thereby extending service life while maintaining insulation restoration.
3Ease of repair
If the generator is disassembled and transported to a factory, then repair can be performed, but the cost increases and disassembly is required
Solution Approach 1:
The invention enables self-service repair by providing a repair method that can be performed on-site at the wind turbine location without requiring complete disassembly or transport to a factory. The simplified procedure allows maintenance personnel to replace defective coils directly in the generator, reducing repair costs and complexity.
4Manufacturing precision
If resin is applied to coating the winding overhangs, then the insulation is improved, but moisture can still penetrate the slot during operation
Solution Approach 1:
The invention introduces an intermediary substance - adhesive - that bonds the new coil to the slot insulation. This adhesive layer acts as an additional barrier against moisture penetration while maintaining the insulation quality provided by the resin coating, thereby addressing both insulation and moisture protection requirements.
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 method allows for cost-effective repair without disassembly, improving thermal conductivity and insulation, reducing moisture sensitivity, and extending the service life of the generator.
Implementation Method 1
ensuring equivalent thermal conductivity and insulation properties
Implementation Method 2
ensuring equivalent thermal conductivity and insulation properties
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
Method for repairing a generator with preformed coils, in particular a generator of a wind turbine with preformed coils, comprising the steps of: decoupling (1010) the first and second terminals (18, 19) of a defective preformed coil (11) from two further ones of the plurality of preformed coils (10); separating (1020) the first and second coil heads (14, 16) of the defective preformed coil (11); separating (1030a) a slot closure wedge which closes a slot in which a first leg (12a) of the defective preformed coil (11) is inserted; removing (1040a) the first leg (12a) of the defective preformed coil (11) from the slot (38); inserting (1050a) a first leg (12a) of a new preformed coil (13) with an electrical conductor made of copper or aluminum;Inserting (1060a) a new slot closure wedge (39) into the slot (38) into which the first leg (12a) of the new preformed coil (13) was inserted, wherein the slot (38) is closed by the new slot closure wedge (39) in the direction of the air gap existing between the stator and rotor in the operating state; introducing (1070a) resin into the slot into which the first leg (12a) of the new preformed coil (13) was inserted; connecting (1080) the first leg (12a) to the second leg (12b); and coupling (1090) the first and second terminals to the first terminal and second terminal of the two further preformed coils (10).