Generator Stator Retention Component for Magnetic Loss Reduction
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Solution Overview
Problem
High-power generators in the 500 kW to 1 MW range require high efficiency and low weight and volume, but existing designs with open stator slots lead to non-uniform air-gaps and increased losses due to distorted magnetic flux.
Innovation Solution
A retention component with a combination of magnetic and non-magnetic materials, featuring a V-shaped configuration and a channel system to maintain coil position within semi-closed slots, reducing magnetic losses and maintaining efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If open stator slots are used to install coils from the radial direction, then coil installation is enabled, but non-uniform air-gap is created causing distorted magnetic flux and increased losses
Solution Approach 1:
The slot is divided into two functional parts: an open upper portion for coil installation and a closed lower portion for magnetic flux uniformity. The retention component further segments the slot structure, creating distinct zones for coil retention and magnetic field management, allowing both manufacturing ease and magnetic performance.
Solution Approach 2:
Different portions of the slot have different magnetic properties: the upper open portion allows easy coil installation while the lower closed portion maintains magnetic flux uniformity. The retention component uses magnetic material in specific locations to locally control flux distribution without affecting the entire slot structure.
2Ease of operation
If non-magnetic or semi-magnetic wedge material is used to retain coils in slots, then coil positioning is achieved, but magnetic flux distortion and additional losses occur
Solution Approach 1:
The retention component is constructed from laminated magnetic material sheets, creating a composite structure that combines mechanical retention functionality with magnetic flux management. This eliminates the need for non-magnetic wedges by integrating both functions into a single magnetic material component.
3Power
If high-speed generation is implemented to achieve high power density, then power output increases, but copper and eddy current losses increase
Solution Approach 1:
The invention changes the magnetic material parameters and slot structure to reduce eddy current losses. By using laminated magnetic material with specific permeability characteristics and optimizing the slot geometry, the design reduces circulating currents while maintaining high-speed operation capability.
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 solution minimizes weight and volume while maximizing efficiency by maintaining coil position within semi-closed slots, reducing magnetic losses and maintaining efficient power generation.
Implementation Method 1
these open slots create a non-uniform air-gap (i.e., air space between rotor 14 and stator 10) which results in a distorted magnetic flux
Implementation Method 2
a stator 20, which is built of soft magnetic material laminations such as Hiperco 50
Implementation Method 3
slots having a cut-out portion adjacent a slot opening; wherein the cut-out portion is V-shaped
Data Source
AI summary
A retention component for retaining a coil in a slot of a stator for a generator having a rotor includes a first segment and a second segment, both of which are configured to be inserted into the slot. At least one of the first and second segments is made entirely of laminated sheets that together form a unitary structure of magnetic material. At least one of the first and second segments has an interfacing surface configured to directly interface a rotor surface in the absence of a structure therebetween. A channel is between the first and second segments, and a third segment that extends along and within the channel. The third segment is less magnetic or non-magnetic than at least one of the first and second elements.