Generator Rotor End Turn Support with Integrated Cooling
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Solution Overview
Problem
High-power generators face challenges in maintaining structural integrity and heat management at the end turn portions of the rotor winding due to the insufficient strength of aluminum wedges, which can lead to stress issues and reduced durability.
Innovation Solution
The use of a rotor assembly with end plates made from materials like titanium or steel, combined with thermally conductive wedges formed from aluminum, and a cooling fluid distribution system that includes fluid passages and a manifold to enhance cooling efficiency and structural support for the rotor winding end turns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If aluminum wedges are used for thermal conductivity, then heat removal is improved, but structural strength is insufficient
Solution Approach 1:
The invention employs a composite material system where aluminum wedges (providing thermal conductivity) are integrated with a titanium or steel end plate (providing structural strength). The aluminum wedges are installed in core slots and abutted by the stronger end plate, creating a composite structure that simultaneously achieves both thermal management and mechanical support functions.
2Temperature
If aluminum material is used for wedges, then thermal conductivity is improved, but wedge strength under loading is insufficient
Solution Approach 1:
The patent creates a composite support system where the aluminum wedge (thermally conductive but mechanically weaker) works in conjunction with the titanium/steel end plate (mechanically strong). The end plate provides the necessary structural support and loading capacity, while the aluminum wedge maintains thermal performance, thus achieving both thermal conductivity and reliability under loading.
Solution Approach 2:
The end plate acts as an intermediary structural element that transfers and distributes mechanical loads away from the aluminum wedges. By positioning the end plate at the axial end to abut the wedges, it serves as a mediator that protects the aluminum material from excessive mechanical stress while allowing it to perform its thermal function.
3Strength
If end plate is made from titanium or steel for strength, then structural support is improved, but thermal conductivity is reduced
Solution Approach 1:
The invention applies local quality by using different materials in different locations for different functions. The end plate (titanium/steel) provides structural support where mechanical strength is needed, while the aluminum wedges in the core slots provide thermal conductivity where heat removal is critical. This spatial differentiation of material properties optimizes both strength and thermal performance.
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 improves the strength and thermal management of the rotor assembly, effectively addressing stress issues and heat removal while maintaining the thermal benefits of the wedges, thereby enhancing the durability and performance of high-power generators.
Implementation Method 1
The cooling fluid acts to remove heat generated by electrical losses from the rotor winding and the rotor core
Implementation Method 2
cooling fluid is circulated through wedges installed in the rotor core
Data Source
AI summary
A rotor assembly of a generator includes a rotor core including a plurality of core poles defining a plurality of core slots therebetween. The core poles extend from a first axial end of the rotor core to a second axial end of the rotor core. A rotor winding is installed to the rotor core and has a plurality of core segments located in the plurality of core slots, and a plurality of end turns connecting the plurality of core segments. An end plate is located at at least one of the first axial end or the second axial end and includes a plate portion and a plurality of wedge ends extending from the plate portion. Each wedge end is located at a corresponding core slot. The end plate is supportive of the plurality of end turns of the rotor winding.