Segmented Annular Rotor for Large Wind Turbine Transport
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Solution Overview
Problem
The increasing size and weight of gearless wind turbines with large generators pose challenges in assembly, transport, and logistics, particularly due to the difficulty in handling and assembling the large, heavy rotors with permanent magnets, which require strict safety measures and complex assembly processes.
Innovation Solution
The rotor is subdivided into partially annular segments with permanent magnets, allowing for easier transport and assembly by pairing rotor and stator segments, which are connected using air gaps and mechanical flanges, eliminating the need for electrical connections and simplifying the assembly process while shielding magnets from environmental forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the rotor is designed as a complete ring shape with permanent magnets, then the electrical machine achieves high power output and efficient operation, but the rotor becomes extremely large and heavy, making transport and assembly difficult
Solution Approach 1:
The rotor is divided into multiple partially annular rotor segments that can be transported separately and assembled on-site to form the complete ring-shaped rotor. This segmentation reduces the transport volume of individual components while maintaining the high power output capability of the complete rotor structure.
2Power
If the rotor is designed as a complete ring shape with permanent magnets, then the electrical machine achieves high power output, but the assembly process becomes complex and requires strict safety measures due to strong magnetic forces
Solution Approach 1:
Dividing the rotor into segments allows for simplified assembly where each segment can be handled with reduced magnetic interference. The segments are equipped with mounting structures that facilitate step-by-step assembly on-site, reducing the complexity and safety risks associated with handling a complete large-scale rotor with strong permanent magnets.
Solution Approach 2:
The rotor segments are pre-equipped with mounting structures, connection elements, and positioning features before transport. This preliminary preparation enables straightforward on-site assembly without requiring complex assembly equipment or procedures, thereby reducing assembly complexity while maintaining high power output capability.
3Volume of moving object
If the rotor is divided into segments, then transport and assembly become easier, but electrical connections between segments would be required which increases complexity
Solution Approach 1:
The invention extracts the excitation function from the rotor segments by using permanent magnets instead of electromagnetic windings. This eliminates the need for electrical connections between rotor segments, as the permanent magnets provide the necessary magnetic field independently. The rotor segments are connected only mechanically through mounting structures, significantly reducing assembly complexity while enabling easier transport.
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 segmented design significantly reduces the volume of the rotor, facilitates easier handling and transport, and allows for the assembly of large electrical machines like wind turbines with diameters up to 14 meters, enabling the construction of machines with higher outputs such as 5 MW, 8 MW, or 10 MW without the complexities of traditional assembly methods.
Implementation Method 1
each rotor segment has at least one permanent magnet. This results in particular in a permanently excited synchronous machine. The permanent magnets are arranged in magnet pockets that are located on the rotor segments.
Implementation Method 2
Hysteresis and eddy current losses in the rotor are reduced by constructing the rotor from individual electrical steel sheets that are insulated from one another.
Implementation Method 3
Hysteresis and eddy current losses in the rotor are reduced by constructing the rotor from individual electrical steel sheets that are insulated from one another.
Data Source
Figure 1~2
Figure 3~6
Figure 7
AI summary
The invention relates to an annular rotor having a hollow shaft for an electric machine. In order to allow transport of such a machine, particularly for a very large model, the rotor is divided in the circumferential direction into a plurality of partial annular rotor segments (1). The rotor further comprises a hollow shaft, wherein the closed ring shape of the rotor can be broken by separating the rotor segments (1) from each other.