Laminated Busbar Structure for Compact Wind Turbine Nacelles
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Solution Overview
Problem
Wind turbines face space and heat dissipation challenges due to the size and thermal energy management requirements of electrical components in the nacelle, particularly with existing solid copper busbar systems.
Innovation Solution
A laminated busbar system with conducting and insulating layers, featuring contacting holes with insulating sleeves and conducting pins, is used to create a compact and thermally efficient bus plate for mounting electrical components, reducing weight and metal usage while enhancing insulation and cooling surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If solid copper bars are used for wiring electrical components in the nacelle, then electrical conductivity is ensured, but weight and space requirements increase
Solution Approach 1:
The solid copper bar is segmented into multiple thin conducting layers separated by insulating layers, forming a laminated structure. This segmentation reduces the overall weight and volume while maintaining electrical conductivity through the distributed conducting layers.
Solution Approach 2:
The busbar system uses a composite structure combining conducting layers (copper or copper alloy), insulating layers (resin, plastic, or ceramic), and liquid resin impregnation. This composite material approach provides both electrical conductivity and mechanical strength with reduced weight compared to solid copper.
2Temperature
If electrical components are arranged in the nacelle, then power conversion function is achieved, but thermal energy dissipation becomes problematic
Solution Approach 1:
The liquid resin impregnated laminated structure creates a porous-like thermal pathway network that facilitates heat dissipation. The liquid resin fills gaps and creates thermal conduction paths between conducting layers and the housing, improving thermal management without increasing volume.
Solution Approach 2:
The liquid resin acts as an intermediary thermal conductor between the conducting layers and the housing. It fills the gaps and interfaces, providing efficient thermal pathways for heat transfer from the electrical components to the housing for dissipation.
3Reliability
If copper sheets are used for conducting layers, then electrical conductivity is maintained, but material costs increase
Solution Approach 1:
The copper material is segmented into multiple thin layers rather than using a single thick solid bar. This segmentation allows for optimized material distribution, reducing the total amount of copper needed while maintaining equivalent electrical conductivity through the laminated structure.
Solution Approach 2:
The invention changes the dimensional parameters of the copper material from a solid thick bar to thin laminated sheets with optimized thickness and spacing. This parameter optimization reduces material consumption while maintaining electrical performance through the distributed conducting paths.
4Productivity
If the nacelle size is reduced to optimize air flow, then aerodynamic efficiency improves, but space for electrical wiring is limited
Solution Approach 1:
The electrical wiring transitions from a three-dimensional solid busbar structure to a two-dimensional laminated sheet structure. This dimensional change allows the wiring to be more compact and flexible, fitting into the reduced nacelle volume while maintaining electrical functionality.
Solution Approach 2:
The thin conducting sheets and insulating layers form a flexible laminated structure that can be configured to fit compact spaces. This thin-film approach allows the electrical wiring to adapt to the constrained nacelle geometry, enabling reduced nacelle size while accommodating all necessary electrical connections.
Data Source
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AI summary
The invention is related the usage of a laminated structure (1) of conducting layers (4) and insulating layers (6) comprising a plurality of contacting holes (8) penetrating one or more conducting layers (4) of said laminated structure (1), wherein each contacting hole (8) comprises an insulating sleeve (8a) and a conducting pin (10) arranged therein which contacts an associated conducting layer (4) with one end portion end and extends to the outside of said laminated structure (1) with a second end portion, as a bus plate (110) for mounting a phase power converter (120) for converting an electric AC current supplied by an electric generator (130) into an electric AC current of a grid (300), in a busbar system (100) which is accommodated in the nacelle (210) of a wind turbine (200). The invention is further related to a wind turbine (200) including such a busbar system (100).