Generator Lamination Torque Transfer
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Solution Overview
Problem
Direct drive wind turbines face challenges with heavy and expensive generator housings due to high torque requirements, thermal barriers, and corrosion protection, which hinder efficient heat transfer and increase costs.
Innovation Solution
The laminations take over the structural function of the housing, transferring torque axially without a separate housing, using coatings for corrosion protection, and incorporating permanent magnets and enlarged lamination surfaces for improved cooling, eliminating the need for active cooling systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a housing is used to transfer torque from laminations to mounting points, then torque transfer capability is improved, but weight and cost increase
Solution Approach 1:
The housing and lamination package are merged into a single integrated structure where the laminations directly form the torque-transferring component. The lamination package is secured between front and rear plates with bolts that transfer torque axially from the laminations to the mounting points, eliminating the need for a separate housing structure.
Solution Approach 2:
The housing is extracted from the design entirely, removing this non-essential component while retaining its torque transfer function through the integrated lamination package and mounting structure.
2Reliability
If a housing is used to protect laminations from corrosion, then corrosion protection is improved, but weight and cost increase
Solution Approach 1:
Instead of using a housing for overall protection, local corrosion protection is applied directly to the lamination surfaces through coatings. The front and rear plates provide localized protection at critical interfaces, while the laminations themselves are protected where needed.
Solution Approach 2:
The housing is removed from the design, and its protective function is replaced by direct coating applications on the laminations and selective protection at mounting interfaces.
3Strength
If a housing is used to transfer torque, then structural strength is improved, but heat transfer capability deteriorates
Solution Approach 1:
The housing is extracted from the design, removing the thermal barrier it created. The laminations are now directly exposed to ambient air, allowing efficient convective and radiative heat transfer from the rotating lamination package without the insulating effect of a housing enclosure.
4Weight of stationary object
If laminations are made thin to reduce weight, then material weight is reduced, but torque transfer capability deteriorates
Solution Approach 1:
The lamination package consists of many thin individual laminations stacked together. While each lamination is thin and lightweight, the collective stack of numerous laminations provides sufficient torque transfer capability through the cumulative effect of all laminations working together, secured by axial bolts.
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 configuration reduces the weight and cost of the generator while enhancing torque transfer and heat dissipation, increasing turbine efficiency and availability, particularly in larger turbines where active cooling is typically required.
Implementation Method 1
the laminations transfer the torque to the mounting points of the generator
Implementation Method 2
incorporating permanent magnets and enlarged lamination surfaces for improved cooling
Implementation Method 3
The outside of the lamination package is directly exposed to the ambient air
Implementation Method 4
using coatings for corrosion protection
Implementation Method 5
incorporating permanent magnets
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Direct driven wind turbine comprising a tower, a nacelle, a rotor blade, a radial flux generator with a stator and a rotor, wherein the lamination package of the generator is essential for the transfer of the torque in axial direction. By introducing this additional function to the lamination package, the generator can be provided without additional torque transferring housing. According to an embodiment of the invention the lamination package obtains this additional function by pressing together the laminations between the front plate and end plate by tensile bolts. This gives sufficient strength to transport the torque in axial direction through the laminations to the mounting points of the generator. Further advantage is obtained by supplying the laminations of cooling fins. Due to these measures the cooling of the generator improves and active cooling may become superfluous or the power can be increased. The housing of the laminations is an expensive, heavy and labour intensive part which is no longer required due to the invention.