Generator Rotor Manufacturing via Rolling and Welding
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Solution Overview
Problem
The manufacturing process of rotors for large-scale wind turbine generators is time-consuming and expensive due to complex machining processes required to achieve precise dimensions, which also reduces the usability of the generators.
Innovation Solution
A method involving rolling a metal plate into a circumferentially open circular cylinder, welding the ends to form a closed cylinder with an inner diameter slightly smaller than the desired end diameter, and then rolling to achieve the final dimensions, eliminating the need for time-consuming machining processes and utilizing cold or hot rolling techniques with heat treatment for mechanical property adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex machining processes are used to achieve precise rotor dimensions, then manufacturing precision is improved, but manufacturing time and cost increase
Solution Approach 1:
The metal plate is pre-formed into a cylindrical shape by rolling before welding, establishing the basic geometry in advance. This preliminary forming action allows the final rolling step to only make minor dimensional adjustments rather than creating the entire shape from scratch, significantly reducing total manufacturing time while maintaining precision
Solution Approach 2:
The invention changes the manufacturing approach by using rolling (a plastic deformation process) instead of traditional machining (material removal). The final rolling step adjusts dimensional parameters directly on the welded cylinder, achieving precise dimensions through controlled deformation rather than time-consuming machining operations
2Manufacturing precision
If complex machining processes are used to achieve precise rotor dimensions, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The invention replaces complex mechanical machining systems with a simpler rolling process. Instead of using lathes and cutting tools for multiple machining steps, the process uses rolling mills to deform the metal into the final shape, which is inherently simpler and more cost-effective while achieving the same dimensional precision
Solution Approach 2:
The invention extracts and eliminates the complex machining steps from the manufacturing process entirely. By using rolling to achieve final dimensions instead of machining, the time-consuming and expensive machining operations are removed from the process while maintaining the required precision through controlled plastic deformation
3Manufacturing precision
If material is removed during machining to achieve precise dimensions, then manufacturing precision is improved, but material loss increases
Solution Approach 1:
The invention changes the fundamental approach from material removal (machining) to material deformation (rolling). By using plastic deformation to achieve precise dimensions, no material is removed from the workpiece, eliminating waste while maintaining the required dimensional precision through controlled shape change
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 method significantly reduces manufacturing time and costs, enabling a high production rate of rotors with precise dimensions without material removal, and allows for improved mechanical properties through strain hardening or dimensional stability depending on rolling techniques used.
Implementation Method 1
rolling represents a plastic deformation process whereby a work piece or plate of metal is led through a roller mill comprising a number of rotating rolls
Implementation Method 2
welding the two free ends of the rolled metal plate to form a closed cylinder
Data Source
AI summary
A method for manufacturing a rotor for a generator is provided. In accordance with this method, a metal plate is rolled to a circumferentially open circular cylinder having two free ends, the circumferentially open cylinder having an inner diameter smaller than a desired end inner diameter of the rotor. The two free ends of the rolled metal plate are then welded to form a closed cylinder. The closed cylinder is rolled to obtain the desired end diameter of the rotor.