Segmented Stator Lamination with Integrated Support Structure
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Solution Overview
Problem
The mechanical instability of laminated stator cores in wind turbine generators requires external support structures, increasing manufacturing costs and complexity.
Innovation Solution
A self-supporting laminated stator core design featuring segment laminations with a third radial section that forms a support structure, incorporating stiffening struts and through-openings for bracing elements, eliminating the need for external add-on parts and enhancing mechanical integrity and damping of acoustic vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If external support structures are added to stiffen the stator lamination packages, then mechanical stability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the stator lamination structure with the support structure by integrating radial sections into the segmented sheet itself. The segmented sheet includes a first radial section for the magnetic yoke, a second radial section forming slots for stator windings, and a third radial section forming the support structure. This integration eliminates the need for separate external support components while maintaining mechanical stability.
Solution Approach 2:
The segmented sheet is designed to perform multiple functions simultaneously: it provides the magnetic yoke (first radial section), accommodates stator windings (second radial section), and provides structural support (third radial section). This multi-functionality reduces the overall number of components and simplifies the generator stator assembly.
2Stability of the object's composition
If external support structures are added to stiffen the stator lamination packages, then mechanical stability is improved, but manufacturing cost increases
Solution Approach 1:
The patent combines multiple structural functions into a single segmented sheet component, eliminating the need for separate support structures. This reduction in part count directly lowers manufacturing costs by reducing material usage, assembly operations, and quality control steps.
Solution Approach 2:
The segmented sheet is divided into multiple radial sections (first, second, and third radial sections) that can be manufactured and assembled efficiently. This segmentation allows for optimized production processes while maintaining the mechanical stability provided by the integrated third radial section.
3Strength
If the segmented sheet is radially extended to form self-supporting structure, then mechanical integrity is improved, but material usage increases
Solution Approach 1:
The third radial section is strategically positioned adjacent to the second radial section where support is most needed. The segmented design allows material to be concentrated in specific locations (radial extensions for support) rather than uniformly distributed, optimizing the strength-to-material ratio.
Data Source
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AI summary
The invention relates to a segment sheet (11) for a stator lamination stack (10) of a generator (1) of a wind turbine (100), comprising a base sheet (13) in the form of a ring segment, wherein the segment sheet (11) has a first radial section (15) in which recesses (21) are provided for receiving a stator winding, and a second radial section (17), radially next to the first radial section (15), which forms a segment of a magnetic yolk of the generator (1). In particular, the segment sheet (11) has a third radial section (19) next to the second radial section (17), which forms a segment of a stator-carrier structure of the generator (1), and which is also configured, in particular, to form the stator-carrier structure of the generator together with the third radial sections of further segment sheets. The invention also relates to a stator lamination stack (10), a generator (1) and a wind turbine (100), each having segment sheets (11) of this type.