Generator End-Winding Cooling via Air Guide Velocity Control
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Solution Overview
Problem
Current cooling methods for the end-windings of electric generators, such as those in wind turbines, are not optimized in terms of air flow velocity, leading to suboptimal heat removal.
Innovation Solution
The implementation of air guides both inside and outside the end-windings to control and enhance air flow velocity, with adjustable dimensions to achieve optimal air speed for cooling, balancing air flow and pressure drop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If air flow is provided between stator and rotor for cooling end-windings, then cooling effect is achieved, but air flow velocity is not optimally controlled
Solution Approach 1:
Air guides are specifically positioned at locations where end-windings require cooling, creating localized high-velocity air flow channels. The guides are strategically placed between stator and rotor at axial positions corresponding to end-winding locations, ensuring concentrated cooling where heat generation is highest rather than distributing cooling uniformly throughout the generator.
Solution Approach 2:
The dimensions of air guides (cross-sectional area, length, shape) are optimized to control air flow velocity parameters. By adjusting guide geometry, the patent achieves optimal air speed for heat removal while managing pressure drop characteristics, transforming the air cooling system from suboptimal to optimized performance.
2Temperature
If air flow velocity is increased to improve cooling, then heat removal efficiency increases, but pressure drop increases
Solution Approach 1:
The air guide system creates dynamic air flow paths that adapt to the rotating rotor-stator configuration. As the rotor rotates, the air guides maintain optimal positioning relative to end-windings, allowing sustained high-velocity cooling without requiring continuously increasing pressure differential. The system dynamically balances cooling effectiveness with acceptable pressure drop through rotational motion.
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 approach effectively reduces end-winding temperatures, thereby increasing the Annual Energy Production (AEP) of wind turbines by improving cooling efficiency.
Implementation Method 1
a flow of air between the stator and the rotor of the generator, which reaches also the end-windings
Implementation Method 2
adding air guides improves or optimizes the cooling of the end-windings... to force the air velocity up in speed
Data Source
AI summary
Provided is an electrical generator including a stator having a stator body extending axially between a first axial end and a second axial end, the stator body including a plurality of slots, the plurality of slots being circumferentially distributed around a longitudinal axis of the stator body. The stator includes a plurality of windings housed in the plurality of slots and a plurality of end-windings, each end winding having a curved shape and connecting the windings in two slots of the plurality of slots.The electrical generator further includes at least one air guide inside and/or outside the plurality of end-windings cool.