Laminated HTS Conductor C-Axis Strength
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Solution Overview
Problem
Conventional wind turbines face challenges in scaling up power generation beyond 5 Megawatts due to the impracticality of increasing the size of geared power trains, primarily due to the size, weight, and cost of gearboxes, as well as potential unreliability, and existing high-temperature superconducting (HTS) coil windings require improved electrical conductors for efficient power transmission and generation.
Innovation Solution
A laminated electrical conductor design featuring a high-temperature superconductor insert between support lamina layers, with a filler material that bonds the insert to the lamina and provides a wide fillet structure, enhancing C-axis tensile strength and current carrying capacity, allowing for efficient power transmission and generation in high-power applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the size of geared power train is scaled up to increase power generation beyond 5 Megawatts, then power output is improved, but the size, weight, cost and reliability deteriorate due to the impracticality of accommodating larger gearboxes
Solution Approach 1:
The patent extracts and eliminates the gearbox component from the power train system by adopting a direct-drive configuration. The superconducting generator is directly coupled to the turbine rotor without any gear transmission mechanism, thereby removing the source of mechanical complexity, weight, and reliability issues associated with large gearboxes while maintaining the ability to generate high power levels
Solution Approach 2:
The patent replaces the mechanical gear transmission system with an electrical direct-drive system. By using high-temperature superconducting materials in the generator windings, the system achieves efficient power transmission directly from the turbine rotor to the electrical output, substituting mechanical complexity with electrical simplicity and enabling high power generation without proportional increases in mechanical component size
2Power
If conventional HTS electrical conductors are used in coil windings, then power transmission capability is improved, but the conductors are prone to delamination during cooling due to insufficient C-axis tensile strength
Solution Approach 1:
The patent employs a composite conductor structure consisting of multiple layers including superconducting tapes, stabilizer materials, and reinforcement layers. This composite construction provides both the necessary electrical performance for high current carrying capacity and the mechanical strength in the C-axis direction to prevent delamination during thermal cycling and cooling operations
Solution Approach 2:
The patent incorporates a fillet or curved transition region at the edges of the conductor where the superconducting tape meets the stabilizer material. This curved geometry distributes stress more evenly during cooling and prevents stress concentration that would lead to delamination, thereby improving reliability while maintaining electrical performance
3Power
If multiple turns of conductor with insulation are used to achieve high current density, then current carrying capacity is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges multiple functional requirements into a single conductor design. The high-temperature superconducting conductor is engineered to provide both the necessary current carrying capacity and the mechanical strength in one integrated structure, eliminating the need for separate insulation layers and multiple winding turns, thereby simplifying manufacturing while achieving high current density
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 laminated conductor design achieves reliable C-axis tensile strength greater than 21 MPa and high current carrying capacity, preventing delamination during cooling and enabling efficient power generation, reducing the need for multiple turns and insulation, thus lowering manufacturing costs and increasing current density.
Implementation Method 1
an insert including a high temperature superconductor disposed between the first support lamina and the second support lamina
Implementation Method 2
a filler material surrounding the insert that bonds the insert to each of the first support lamina and the second support lamina
Data Source
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AI summary
A rotating machine includes a stator and a rotor configured to rotate within the stator. Rotor windings are supported in the rotor and are formed of a laminated electrical conductor in a single-layer saddle coil configuration. The conductor includes a first support lamina, a second support lamina, an insert including a high temperature superconductor disposed between the first and second support lamina, and a filler material surrounding the insert that bonds the insert to each of the first support lamina and the second support lamina. At the location between the first support lamina and second support lamina corresponding to the location of the insert, the width dimension of the filler material on each side of the insert is at least 10 percent of a width of the conductor. The conductor is configured to carry at least 600 Amperes per turn and have a C-axis tensile strength of at least 21 MPa.