Segmented Stator Bus Bar Layout for Lower-Copper Wind Generators
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Solution Overview
Problem
The existing stator designs for large electrical machines, such as wind turbine generators, face challenges with heavy and extensive manufacturing due to the need for multiple stator segments, which results in constrained space and high copper costs for bus bar segments, as well as complex assembly processes.
Innovation Solution
The design reduces the number of pre-installed bus bar segments on each stator segment to the number of phases used, with additional continuous bus bars bypassing stator segments to connect segmented bus bars to distanced connectors, simplifying the layout and reducing material and assembly costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple pre-installed bus bar segments are provided on each stator segment to support multiple connectors, then the stator can be assigned to different electrical systems, but the space for bus bar segments becomes constrained and production becomes difficult
Solution Approach 1:
The stator is divided into multiple stator segments that can be assembled in different configurations. Each stator segment can be independently manufactured with fewer bus bar segments, and the segmented structure allows flexible assignment of different sections to different electrical systems without constraining the space on individual segments
Solution Approach 2:
The bus bar segments are designed to be multi-functional, serving both as electrical connectors and as structural components that can be adapted to different connector configurations. The same bus bar segment design can be used across different stator segments, providing universality in the manufacturing process
2Adaptability or versatility
If six pre-installed bus bar segments are provided on each stator segment to support two connectors, then multiple electrical systems can be connected, but the copper cost and assembly effort increase significantly
Solution Approach 1:
Adjacent bus bar segments from different stator segments are electrically connected to form longer continuous bus bar structures. This merging approach reduces the total number of separate bus bar segments needed, thereby reducing copper usage while still supporting multiple connectors. The electrical connection between adjacent segments achieves the same functionality as having more pre-installed segments on each individual segment
Solution Approach 2:
The bus bar segments are pre-installed on stator segments during manufacturing, but the final electrical connections between segments are established after assembly. This allows the stator to be manufactured with fewer pre-installed segments, reducing copper usage, while still achieving the required connectivity through post-assembly connections
3Adaptability or versatility
If multiple pre-installed bus bar segments are provided on each stator segment, then connectors can be provided at different positions, but the number of segment connection means and assembly effort increase
Solution Approach 1:
Adjacent bus bar segments are electrically connected to form continuous electrical paths that span multiple stator segments. This merging reduces the number of separate connection points needed, thereby reducing the number of segment connection means required while still enabling connectors to be positioned at different locations around the stator
Solution Approach 2:
The segment connection means are designed to be universal, serving both mechanical joining and electrical connection functions. The same connection structure is used throughout the stator assembly, providing a standardized approach that reduces the variety of different connection components needed while supporting multiple connector positions
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
Stator (1) for an electrical machine, in particular a generator (24) of a wind turbine (21), wherein the cylindrical stator (1) comprises multiple similar stator segments (3), each stator segment (3) constituting a fraction of the circumference of the stator (1) and having at least one coil element (8) and one pre-installed bus bar segment (9) per phase provided to or by the electrical machine, wherein each bus bar segment (9) is electrically connected to a coil element (8) of the respective phase, wherein at least two circumferentially adjacent stator segments (3) form a section (4, 5, 6, 7) and multiple subsets of an even number of radially opposing sections (4, 5, 6, 7) are respectively assigned to a connector (13, 14) at a respective connection position (15, 16) along the circumference of the stator (1), characterized in that in each section (4, 5, 6, 7), segmented bus bars (12) for each phase are provided by connecting bus bar segments (9) of adjacent stator segments (3), which belong to the same phase, using segment connection means (11), and the segmented bus bars (12) of each section (4, 5, 6, 7) whose segmented bus bars (12) are distanced from their associated connection position (15, 16) are connected to the respective connector (13, 14) by additional, continuous bus bars (17) bypassing each stator segment (3) between an end of the segmented bus bars (9) closest to the connection position (15, 16) and the connection position (15, 16).