Modular Generator Modules for Variable Speed Turbines
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Solution Overview
Problem
Conventional electric power generation systems face challenges in adapting to varying fluid stream characteristics, such as wind speed and power density, which limits their geographical suitability and increases transmission costs, and often require expensive variable pitch turbines or mechanical gearboxes for efficient operation.
Innovation Solution
An electric power generation system comprising multiple generator modules arranged between a rotor and a stator, where the rotor is coupled to a turbine that rotates in a fluid stream, with magnetic bearings maintaining separation and power electronics modules controlling the rotational speed to optimize energy production across a wide range of fluid stream conditions without a mechanical gearbox.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional generation systems are designed to operate efficiently within a narrow range of characteristic values, then operational efficiency is improved, but geographical suitability and adaptability deteriorate
Solution Approach 1:
The patent applies dynamics by enabling the turbine to operate across a wide range of rotational speeds without a gearbox, allowing the system to adapt to varying fluid stream conditions (wind speed, water flow) while maintaining efficient power generation. The direct-drive configuration with variable speed capability allows the turbine to optimize its operation for different geographical locations and environmental conditions.
Solution Approach 2:
The patent changes the operational parameters by allowing the turbine to operate efficiently across a broad range of rotational speeds and fluid stream conditions. By eliminating the gearbox and implementing variable pitch control, the system can adjust its operational parameters to match different geographical locations, thereby improving both productivity and adaptability simultaneously.
2Adaptability or versatility
If variable pitch turbines are incorporated to expand the range of operationally suitable characteristic values, then adaptability is improved, but cost and reliability deteriorate
Solution Approach 1:
The patent segments the turbine blade pitch control into independent, adjustable sections that can be modified electronically without mechanical complexity. This segmentation allows for adaptability across different operational conditions while maintaining reliability by avoiding the use of complex variable pitch mechanisms in extreme environments.
Solution Approach 2:
The patent substitutes mechanical variable pitch mechanisms with electronic control systems that can adjust blade pitch remotely. This replacement eliminates the reliability issues associated with mechanical gearboxes and variable pitch mechanisms operating in harsh environments, while still providing the necessary adaptability for different fluid stream conditions.
3Adaptability or versatility
If a mechanical gearbox is incorporated to expand the range of operationally suitable characteristic values, then adaptability is improved, but cost and complexity deteriorate
Solution Approach 1:
The patent extracts and removes the mechanical gearbox from the system entirely, replacing it with a direct-drive configuration. This elimination of the gearbox simplifies the overall system architecture, reduces mechanical complexity, and removes a major source of maintenance and reliability issues, while still achieving adaptability through electronic control and variable speed operation.
Solution Approach 2:
The patent replaces the mechanical gearbox with an electronic control system that manages speed and power conversion. This substitution eliminates the need for complex mechanical transmission components, thereby reducing device complexity and improving reliability, while maintaining the ability to operate across a wide range of characteristic values through electronic regulation.
4Productivity
If conventional generation systems are custom manufactured for particular geographical locations, then operational efficiency is improved, but manufacturing cost and time deteriorate
Solution Approach 1:
The patent implements universality by designing a standardized turbine and generator configuration that can be deployed across multiple geographical locations without custom manufacturing. The system's ability to operate efficiently across a wide range of rotational speeds and fluid stream conditions allows a single design to serve multiple locations, thereby reducing manufacturing costs and lead times while maintaining operational efficiency.
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
This configuration allows for efficient operation across a broader range of fluid stream conditions, reducing costs and increasing geographical suitability by eliminating the need for expensive gearboxes and custom manufacturing, while enabling hot-swapping of modules for maintenance and adapting to failures.
Implementation Method 1
Each generator module may have a rotor portion coupled to the rotor and configured to generate a magnetic field having at least one characteristic that changes with respect to the rotational speed of the rotor. Each generator module may further have a stator portion coupled to the stator and configured to generate an alternating electric current responsive to the magnetic field.
Implementation Method 2
The generated electric current may be controlled by the stator portion of the generator module in order to magnetically control (e.g., decelerate) the rotational speed of the rotor and the turbine.
Implementation Method 3
Separation between the rotor and stator portions of the generator module may be magnetically maintained.
Data Source
AI summary
An electric power generation system may be constructed of multiple similar generator modules arranged between a rotor and a stator. The rotor may be coupled to and/or integrated with a turbine that is configured to rotate in the presence of a fluid stream such as wind or water. Each generator module may have a rotor portion configured to generate a magnetic field having at least one characteristic that changes with respect to the rotational speed of the rotor. Each generator module may further have a stator portion configured to generate an alternating electric current responsive to the magnetic field. The generated electric current may be controlled by the stator portion of the generator module in order to magnetically control the rotational speed of the rotor and the turbine. Separation between the rotor and stator portions of the generator module may be magnetically maintained.