Segmented Stator Assembly for Offshore Wind Turbines

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Solution Overview

Problem

Offshore wind turbines with direct drive generators face challenges in transportation and assembly due to their large size and weight, and segmented stator structures, while facilitating cost-effective shipping, are difficult to manufacture and assemble on-site.

Innovation Solution

A segmented stator assembly with stator portions, end plates, and structural plates featuring notch-like structures embedded within stator laminations, connected by connectors and stabilizing elements to provide structural integrity and ease of assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If the generator is made larger to achieve 3 MW rating, then power output is improved, but transportation difficulty and cost increase

Engineering Contradiction:

Improvepower outputVSAvoidtransportation ease

Core Design Contradiction:

PowerVSEase of operation

Solution Approach 1:

The stator is divided into multiple segments that can be transported separately and assembled on-site. Each segment includes stator laminations, end plates, and structural plates that can be independently handled and shipped, resolving the transportation difficulty while maintaining the required power output capability

Inventive Principle:

Principle #1Segmentation

2Area of stationary object

If the generator is made axially longer to fit within 4 m diameter, then diameter constraint is satisfied, but weight increases significantly

Engineering Contradiction:

Improvediameter constraintVSAvoidweight

Core Design Contradiction:

Area of stationary objectVSWeight of moving object

Solution Approach 1:

The stator is segmented radially rather than extending axially, allowing the generator to maintain a compact diameter while achieving the required power output through multiple segments. This approach avoids the weight penalty of an axially longer single-piece design

Inventive Principle:

Principle #1Segmentation

3Ease of operation

If segmented stator structure is used to facilitate shipping, then transportation cost is reduced, but manufacturing and assembly difficulty increases

Engineering Contradiction:

Improveshipping easeVSAvoidassembly ease

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The end plates and structural plates are merged into integrated components that provide both structural support and assembly features. The structural plates are embedded within the stator laminations, creating a unified structure that simplifies handling and assembly while maintaining shipping advantages

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The structural plates are pre-embedded within the stator laminations during manufacturing, and the end plates are pre-configured with connection features. This preliminary preparation reduces on-site assembly complexity while preserving the segmented shipping benefits

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS8319389B2Segmented stator assembly

Publication Date: 2012.11.27 GE INFRASTRUCTURE TECH LLC

AI summary

An electric machine and stator assembly includes a segmented stator having stator portions. Each stator portion includes stator laminations, end plates arranged axially on opposing sides of the stator portion, and structural plates arranged interior to the end plates. Each of the support plates has a portion with notch-like structures that is embedded within the stator laminations. Stabilizing couple the end plates and the structural plates together. Connectors are provided to connect the stator portions together.