Segmented Wind Turbine Stator Insulation for Higher Power Density
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Solution Overview
Problem
Existing wind turbine generators face challenges with large ground wall insulation layers that reduce power density, increase costs, and limit design flexibility due to their dependence on voltage class, while also hindering thermal management and cooling.
Innovation Solution
A segmented stator core design with concentrated windings and insulation elements positioned between core segments, decoupling the insulation function from the ground wall insulation, using rigid insulation materials like Nomex®-Kapton® blends to isolate core segments and reduce thermal insulation effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large ground wall insulation layers are used to provide electrical insulation between stator coils and stator core, then electrical insulation reliability is improved, but power density is reduced and manufacturing cost increases
Solution Approach 1:
The patent extracts the ground wall insulation function from the coil assembly and relocates it to the stator core structure. Insulation layers are positioned between the stator core and the coil windings rather than being wrapped around each coil, separating the insulation function from the winding structure and reducing its impact on power density.
Solution Approach 2:
The patent introduces an intermediary insulation structure that is integrated into the stator core assembly. This intermediary layer serves as the ground wall insulation while being structurally part of the core, allowing for better space utilization and reduced thermal resistance compared to traditional external insulation wrapping.
2Reliability
If thick ground wall insulation layers are used to ensure electrical isolation, then insulation effectiveness is improved, but thermal conduction is hindered and cooling efficiency is reduced
Solution Approach 1:
The patent applies local quality by using thin insulation layers only where electrical isolation is critical (at the stator core interface), while maintaining direct thermal contact between the coil windings and the cooling structure in other areas. This localized insulation approach preserves thermal conduction pathways for effective cooling.
Solution Approach 2:
The patent employs thin film insulation layers integrated into the stator core structure rather than thick rigid insulation. These thin films provide sufficient electrical isolation while minimizing thermal resistance, allowing heat to conduct efficiently from the coils to the cooling system.
3Reliability
If extensive ground wall insulation is implemented for medium voltage and higher voltage machines, then electrical safety is improved, but design flexibility and adaptability across voltage classes are reduced
Solution Approach 1:
The patent creates a universal insulation structure that is integrated into the stator core assembly and can be used across different voltage classes. The modular insulation design allows the same basic structure to be adapted for various voltage levels by adjusting insulation thickness or material properties rather than redesigning the entire insulation system.
Solution Approach 2:
The patent enables adaptability across voltage classes by changing insulation parameters (thickness, material type, layer configuration) of the integrated insulation structure rather than changing the overall design. This allows the same stator core design to be used for different voltage ratings by simply adjusting insulation specifications.
4Reliability
If multiple layers of ground wall insulation are used to insulate coil windings from stator core, then electrical insulation is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the ground wall insulation layers with the stator core structure into a single integrated assembly. The insulation layers are positioned and secured as part of the core manufacturing process rather than being applied separately to each coil, reducing the number of discrete insulation components and simplifying the overall structure.
Solution Approach 2:
The patent implements preliminary action by pre-assembling the insulation structure with the stator core before coil installation. The insulation layers are positioned and secured in advance, allowing coils to be installed over the prepared insulation rather than requiring complex insulation application steps after coil winding, thereby reducing manufacturing complexity.
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 design enhances power density, reduces fabrication costs, and allows for greater design latitude across voltage classes by simplifying insulation design and reducing thermal barriers, while maintaining effective electrical isolation.
Implementation Method 1
An insulation element is positioned between adjacent core segments for electrically isolating adjacent core segments from each other
Implementation Method 2
A concentrated winding element is wound around each stator core segment for generating flux in the core segment
Data Source
AI summary
A wind turbine includes a generator with a stator and a rotor mounted for providing electrical power to an electric grid. The wind turbine includes a stator having a core with a plurality of individual adjacent segments coupled together for forming a segmented core. A concentrated winding element is wound around each stator core segment for generating flux in the core segment. An insulation element is positioned between adjacent core segments for electrically isolating adjacent core segments from each other, the stator core is coupled with a stator support element that is coupled to a generator housing, wherein the stator support element is an electrically insulative element or wherein the stator support element and each stator core segment are electrically isolated from each other.