Horizontal Armature Assembly for Wind Turbine Stator Segments
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Solution Overview
Problem
The assembly of direct-drive wind turbine generators is complex and hazardous due to the large, heavy, and unwieldy components, requiring expensive and time-consuming handling and maintenance, which can result in damage and increased costs.
Innovation Solution
An armature assembly apparatus with a horizontal rotation axis, an armature holding apparatus, and a ring segment conveyance system that allows for secure, damage-free handling and mounting of stator ring segments without the need for cranes, using a rotating device and adjustable trolley to position and align ring segments relative to the armature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional vertical assembly with cranes and hoists is used, then heavy ring segments can be lifted, but the risk of damage and distortion increases
Solution Approach 1:
The patent inverts the conventional vertical assembly approach by implementing horizontal assembly. The armature is positioned horizontally on a turntable, and ring segments are conveyed horizontally into place using a conveyor system. This inversion eliminates the need for vertical lifting with cranes, thereby preventing damage to vulnerable parts such as insulation and connectors while maintaining the ability to handle heavy ring segments.
Solution Approach 2:
The patent introduces intermediary devices between the ring segments and the armature assembly process. A conveyor system acts as an intermediary to transport ring segments horizontally into position, and a turntable serves as an intermediary to rotate the armature horizontally. These intermediaries eliminate direct vertical handling, thereby preventing damage while enabling precise positioning of heavy components.
2Weight of moving object
If cranes and hoists are used for assembly, then heavy components can be handled, but assembly time and cost increase
Solution Approach 1:
By inverting the assembly orientation from vertical to horizontal, the patent eliminates the need for time-consuming crane operations. The horizontal conveyor system continuously transports ring segments into position, and the turntable rotates the armature to present the next segment for assembly. This inversion dramatically reduces assembly time while maintaining the capability to handle heavy components.
Solution Approach 2:
The patent implements a self-service assembly system where the conveyor automatically transports ring segments and the turntable automatically rotates the armature to present the next assembly position. This automation eliminates manual intervention and time-consuming manual handling, allowing continuous assembly operations without the delays associated with crane setup and operation.
3Ease of operation
If manual handling is used, then flexibility is maintained, but precision and safety decrease
Solution Approach 1:
The patent introduces precision intermediaries between manual operation and the assembly process. The conveyor system provides precise, controlled horizontal transport of ring segments to exact mounting positions. The turntable provides precise rotational positioning of the armature. These intermediaries maintain operational flexibility while ensuring high mounting precision and safety by eliminating rough manual handling.
Data Source
AI summary
An armature assembly apparatus for assembling an armature of an electrical machine is provided. The armature assembly apparatus has an armature holding apparatus to hold a partially assembled armature such that a rotation axis of the armature is horizontal. The armature assembly apparatus has a rotating device for rotating the partially assembled armature about a rotation axis. The armature assembly apparatus also has a ring segment conveyance for conveying an armature ring segment to a mounting position relative to a free ring segment portion of the partially assembled armature.