Integrated Generator Cooling Circuit for Stator Heat Control
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Solution Overview
Problem
Electric generators, particularly in wind turbines, face efficiency and reliability issues due to high operating temperatures in stator windings, which limit power output and reduce component lifespan.
Innovation Solution
The implementation of a dual cooling system within the electric generator, comprising a first liquid cooling circuit for the stator and a second cooling circuit, either air-based or liquid-based, with heat exchangers to efficiently manage heat, ensuring that the cooling power is provided entirely within the generator, minimizing complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a cooling system is added to reduce stator and rotor temperatures, then temperature control and component lifespan are improved, but device complexity increases
Solution Approach 1:
The patent combines the cooling of the stator and rotor into a single integrated cooling system. The stator cooling circuit and rotor cooling circuit share common components including coolant reservoirs, pumps, and heat exchangers, allowing temperature control of both components through one unified system rather than separate independent systems.
Solution Approach 2:
The cooling system is designed with multi-functionality where the same coolant circulation infrastructure serves multiple purposes: cooling the stator windings, cooling the rotor permanent magnets, and providing thermal management for the entire generator assembly. The heat exchangers and coolant distribution networks perform multiple cooling functions simultaneously.
2Temperature
If a dual cooling circuit system is implemented within the generator, then temperature control efficiency is improved, but device complexity and installation cost increase
Solution Approach 1:
The rotor cooling circuit is nested within the stator cooling system architecture. The rotor coolant channels are positioned inside the rotor structure, while the stator cooling circuits surround the rotor assembly. This nested arrangement allows the smaller rotor cooling system to be integrated within the larger stator cooling framework, sharing common coolant supply and return lines.
Solution Approach 2:
The patent introduces coolant reservoirs and heat exchangers as intermediary components that facilitate efficient heat transfer between the cooling circuits and the generator components. These intermediaries enable the dual cooling system to manage heat from both stator and rotor effectively while maintaining system organization and reducing direct complexity.
3Reliability
If cooling power is provided entirely within the generator, then independence from external cooling systems is improved, but device complexity increases
Solution Approach 1:
The cooling system is segmented into distinct stator cooling circuits and rotor cooling circuits, each with dedicated coolant flow paths, pumps, and heat exchangers. This segmentation allows independent control and optimization of cooling for each component while maintaining overall system independence from external cooling sources.
Solution Approach 2:
The generator is designed to be self-sufficient for cooling through integrated coolant reservoirs, pumps, and heat exchangers that are all contained within the generator assembly. The system draws ambient air through heat exchangers and circulates coolant through internal channels, providing complete thermal management without requiring external cooling infrastructure.
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 effectively reduces and controls stator and rotor temperatures, enhancing efficiency, increasing Annual Energy Production (AEP), and extending the lifespan of generator components while reducing installation costs.
Implementation Method 1
a first heat exchanger for exchanging heat between the first coolant and a second coolant being circulated in a second cooling circuit
Implementation Method 2
exchanging heat between the first coolant and a second coolant
Implementation Method 3
a first liquid cooling circuit for cooling the stator, a liquid first coolant being circulated in the first liquid cooling circuit
Data Source
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AI summary
An electric generator (10) comprises a stator (20) and a rotor (30), the rotor (30) being rotatable with respect to the stator (20) about a rotation axis (Y), an air gap (15) being interposed between the stator (20) and the rotor (30). The electric generator (10) further comprises a first liquid cooling circuit (100) for cooling the stator (20), a liquid first coolant being circulated in the first liquid cooling circuit (100). The first liquid cooling circuit (100) comprises a first heat exchanger (101a, 101b) for exchanging heat between the first coolant and a second coolant being circulated in a second cooling circuit (120, 200), the electric generator (10) comprising at least a portion of the second cooling circuit (120, 200).