Modular Permanent Magnet Rotor with Axial Cooling Channels
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Solution Overview
Problem
The manufacturing and maintenance of large permanent magnet generators, such as those in wind turbines, are cumbersome due to the complexity of attaching and replacing hundreds of magnets, and the incorporation of cooling systems complicates assembly and leads to non-homogeneous cooling.
Innovation Solution
A permanent magnet rotor design featuring modular permanent magnet modules with integrated axial cooling channels, allowing for easier assembly and maintenance, and improved cooling efficiency without complicating the assembly process, where magnets are inclined for concentrated magnetic flux and power characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hundreds of magnets are attached by screwing or gluing to the circumference of the rotor, then the generator can be assembled, but the manufacturing process becomes cumbersome and maintenance becomes very expensive
Solution Approach 1:
The rotor is divided into modular segments, each containing a set of permanent magnets mounted on a common mounting structure. This segmentation allows the magnets to be pre-assembled in manageable units rather than attaching hundreds of individual magnets to the entire rotor circumference, significantly simplifying the manufacturing process and enabling easier maintenance through replacement of individual modules.
2Temperature
If radial cooling holes are drilled in the rotor, then cooling can be provided, but the manufacture and assembly are further complicated and cooling is not homogeneous
Solution Approach 1:
The cooling channels are merged with the modular rotor structure itself, with cooling passages integrated into the mounting structure and magnet holders. This integration eliminates the need for separate cooling systems and complex drilling operations, while the modular design ensures homogeneous cooling distribution as each module contains its own cooling pathways that uniformly distribute coolant across the rotor.
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
Facilitates simplified assembly and maintenance of large generators by allowing easy insertion and removal of modules, and provides effective cooling without complicating the assembly, enhancing power and torque characteristics.
Implementation Method 1
a plurality of permanent magnet modules arranged on the outer or inner circumference of the rotor rim... one or more permanent magnets... The permanent magnets have a circumferential magnetic orientation
Implementation Method 2
The permanent magnet modules comprise an axial cooling channel extending substantially along the length of the modules
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
A permanent magnet rotor comprising a rotor rim and a plurality of permanent magnet modules arranged on the outer or inner circumference of the rotor rim, the permanent magnet modules extending generally along an axial direction and being of substantially constant axial-cross section, and comprising a base adapted to be fixed to the rim of the generator rotor, one or more permanent magnets, and one or more pole pieces, wherein the permanent magnet modules comprise an axial cooling channel extending substantially along the length of the modules.