Segmented Stator Cooling via Notch-Like Spacer Plates
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Solution Overview
Problem
Offshore wind turbines with high power ratings face challenges in manufacturing and assembling segmented stator structures due to limited structural support and cooling efficiency, particularly for large diameters, which complicates transportation and installation.
Innovation Solution
The stator assembly incorporates stator laminations with embedded spacer and structural plates featuring notch-like structures for radial cooling and enhanced structural integrity, using connectors to connect segmented stator portions, allowing for improved cooling and support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the stator assembly uses segmented structure for transportation, then the transportability and installation ease are improved, but the structural integrity and manufacturing complexity deteriorate
Solution Approach 1:
The stator assembly is divided into multiple segmented portions that can be transported separately and assembled at the installation site. Each segment maintains structural integrity through embedded structural plates with notch-like structures that provide connection points while enabling modular transportation and assembly.
Solution Approach 2:
The spacer plates and structural plates are embedded within the stator laminations, creating a nested structure where smaller components are integrated into the larger stator assembly. This nesting provides structural support while maintaining a compact segmented design suitable for transportation.
2Ease of manufacture
If traditional spacers are used for stator cooling, then the manufacturing simplicity is maintained, but the cooling efficiency and structural support capability deteriorate
Solution Approach 1:
The spacer plates serve multiple functions: they provide cooling channels for fluid flow, offer structural support through their rigid construction, and maintain spacing between stator laminations. This multi-functionality eliminates the need for separate cooling components while improving overall cooling efficiency compared to traditional spacers.
3Ease of manufacture
If traditional spacers are used for stator support, then the manufacturing simplicity is maintained, but the structural support capability deteriorates for large stator assemblies
Solution Approach 1:
The stator assembly combines different materials and structures: spacer plates and structural plates are embedded within stator laminations to create a composite structure. This composite design provides enhanced structural support capability for large stator assemblies while maintaining manufacturing feasibility through standardized embedding processes.
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 facilitates cost-effective shipping and installation while maintaining structural integrity and cooling efficiency, enabling the use of large stator assemblies in wind turbines and other electric machines.
Implementation Method 1
The portion of each of the spacer plates and each of the structural plates has notch-like structures that create openings to allow a cooling medium to flow between the notch-like structures to provide radial cooling of the stator windings
Data Source
AI summary
A stator assembly includes a segmented stator having stator portions. Each stator portion includes stator laminations having stator windings, spacer plates having a portion embedded within the stator laminations, and structural plates having a portion embedded within the stator laminations. The portion of each of the spacer plates and each of the structural plates has notch-like structures that create openings to allow a cooling medium to flow between the notch-like structures to provide radial cooling of the stator windings. Connectors are provided to connect the stator portions of the segmented stator together.