Wind Turbine Generator Rotor Positioning via Segmented Brake Disk
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Solution Overview
Problem
Large electric generators for wind turbines face challenges in maintenance due to the need to prevent rotational movement between the stator and rotor assemblies, requiring precise and stable mechanisms to facilitate assembly and maintenance while maintaining a small air gap for efficient operation.
Innovation Solution
The electric generator incorporates a first turning device with an actuator and engagement element that can switch between active and passive operational states, allowing controlled rotation and temporary blocking of the rotor assembly, along with a brake system and rotor lock system for precise positioning and stability, enabling easy maintenance and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the air gap between stator and rotor is kept small for efficiency, then energy conversion efficiency is improved, but maintenance difficulty increases due to restricted access and need for precise rotational blocking
Solution Approach 1:
The rotor brake disk is segmented into multiple independent braking zones with separate actuators, allowing selective engagement of specific segments during maintenance operations. This segmentation enables precise control of rotor positioning without affecting the entire air gap structure, thus maintaining efficiency while facilitating maintenance access.
Solution Approach 2:
The rotor brake disk acts as an intermediary mechanism between the rotor assembly and the stator assembly. It provides a controlled interface for preventing rotational movement during maintenance while preserving the small air gap configuration for efficient operation. The brake disk mediates between the conflicting requirements of maintenance accessibility and operational efficiency.
2Ease of repair
If a rotor brake disk extending radially outward is added to prevent rotation during maintenance, then ease of maintenance is improved, but device complexity increases
Solution Approach 1:
The rotor brake disk is merged with the rotor assembly structure, integrating the braking function into the existing rotor components rather than adding a completely separate system. The brake disk shares the rotor's rotational movement and is controlled by actuators that are part of the rotor assembly, reducing overall device complexity while maintaining maintenance capability.
Solution Approach 2:
The rotor brake disk serves multiple functions: it prevents rotational movement during maintenance, enables precise angular positioning of the rotor, and can be selectively engaged or disengaged based on operational requirements. This multi-functionality reduces the need for separate mechanisms, thereby reducing device complexity while improving ease of maintenance.
Data Source
AI summary
An electric generator is provided including a stator assembly, a rotor assembly being rotatably supported at the stator assembly for rotating around a rotational axis, an annular device being fixed to the rotor assembly and including an engagement structure, and a first turning device being mounted to the stator assembly, the first turning device including an actuator and an engagement element being drivable by the actuator. The first turning device is configured for adopting two operational states, an active operational state and a passive operational state. In the active operational state there is an engagement between the engagement element and the engagement structure and in the passive operational state the engagement element and the engagement structure are mechanically decoupled from each other.