Mixed-Conductor Stator Coils for Fixed-Size Power Scaling
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Solution Overview
Problem
Direct-drive permanent magnet wind turbines face challenges in reducing design and production costs due to the large volume of electrical machinery components, which change with rated power requirements, necessitating costly redesign and mold investments.
Innovation Solution
A method for forming coils in electrical machinery by adjusting the turn numbers of conductors, specifically using a combination of aluminum and copper conductors, to achieve desired power levels without altering the size of the stator or other components, allowing for flexible power adjustment and reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the rated power of the electrical machinery is increased, then the power output is improved, but the volume of the electrical machinery increases, requiring redesign and new production molds
Solution Approach 1:
The patent applies parameter changes by modifying the conductor configuration parameters (turn numbers of first and second conductors) to achieve different rated powers while maintaining the same stator volume. The method calculates specific turn numbers based on desired power levels, allowing power adjustment without physical redesign of the stator structure.
Solution Approach 2:
The patent creates a universal stator design that can serve multiple power levels. By configuring the stator with specific conductor arrangements that can be adjusted through turn numbers, a single stator mold can produce electrical machinery with different rated powers, making the design universally applicable across multiple power requirements.
2Volume of stationary object
If the volume of the electrical machinery is reduced to match lower power requirements, then the production cost is reduced, but the power output capability is limited
Solution Approach 1:
The patent uses parameter changes in the conductor turn numbers to enable a fixed-volume stator to deliver different power outputs. By adjusting the turn numbers of the first and second conductors according to the desired power level, the same physical stator can be configured for different power ratings without volume changes.
3Adaptability or versatility
If the stator size is changed to accommodate different power levels, then the power adaptability is improved, but the redesign and mold investment costs increase
Solution Approach 1:
The patent achieves power adaptability through a universal stator design that can be configured for different power levels by adjusting conductor turn numbers rather than redesigning the stator itself. This multi-functional approach allows a single stator mold to serve multiple power requirements, eliminating the need for separate molds for each power level.
Solution Approach 2:
The patent maintains adaptability by changing electrical parameters (conductor turn numbers) rather than physical dimensions. The method provides formulas to calculate the required turn numbers for first and second conductors based on desired power levels, enabling flexible power adaptation without physical redesign.
Data Source
AI summary
The application discloses coils of an electrical machinery and a method for forming the coil, a stator of an electrical machinery and a method for forming the stator, and an electrical machinery. The method includes: providing a first conductor and a second conductor, a resistivity of the second conductor being lower than a resistivity of the first conductor; obtaining a rated current rising coefficient according to a desired power of the electrical machinery, the rated current rising coefficient being a ratio of a rated current of the electrical machinery with the desired power to a rated current of a reference electrical machinery; obtaining, according to the rated current rising coefficient, a first conductor turn number of the first conductor and a second conductor turn number of the second conductor in each coil; forming the coil according to the first conductor turn number and the second conductor turn number.