Segmented Stator Protrusions Reduce Torque Harmonics
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Solution Overview
Problem
The existing segmented stators in wind turbines face challenges in securing mechanical support at the circumferential ends of segments, which affects torque harmonics and thermal performance due to varying coil design topologies and slot configurations.
Innovation Solution
A segmented stator design with complementary shaped protrusions and recesses on adjacent end-surfaces, along with a strap wound around end-coil windings and spacers between iron sheets for air-cooling, reduces torque harmonics and enhances thermal and mechanical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the gap between two circumferentially adjacent stator segments is reduced to reduce torque harmonics, then torque harmonics amplitude is reduced, but mechanical and thermal performance deteriorates due to insufficient mechanical support and thermal management
Solution Approach 1:
The stator is divided into multiple stator segments arranged circumferentially, each with end surfaces containing protrusions and recesses. This segmentation allows for modular assembly while maintaining electrical performance through the complementary mating features that reduce gaps between segments, thereby reducing torque harmonics while preserving mechanical integrity.
Solution Approach 2:
The end surfaces of stator segments feature asymmetric complementary protrusions and recesses rather than symmetric flat surfaces. This asymmetric design enables precise positioning and reduced gaps between adjacent segments when assembled, minimizing torque harmonics while maintaining adequate mechanical support and thermal management capabilities.
2Strength
If the width of teeth closing end-coil slots is increased to provide mechanical support, then mechanical strength is improved, but the distance between end-coils of adjacent segments increases, affecting electrical performance
Solution Approach 1:
The stator is segmented with each segment containing teeth that provide mechanical support for end-coils. The segmentation allows for optimized tooth dimensions within each segment while the complementary protrusion-recess features between segments minimize overall gap distances, balancing mechanical support requirements with electrical performance.
Solution Approach 2:
The teeth at the end surfaces of stator segments are designed with specific local characteristics, including complementary protrusions and recesses that create localized mechanical interlocking. This local quality enhancement provides sufficient mechanical support for end-coils while minimizing the overall gap between adjacent segments, thereby reducing torque harmonics.
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
The solution effectively minimizes torque harmonics and improves thermal and mechanical durability, leading to enhanced electrical performance and reduced costs in manufacturing.
Implementation Method 1
spacers between iron sheets for air-cooling
Data Source
AI summary
A segmented stator for a generator, for a wind turbine is provided. The stator includes a plurality of teeth and slots for coil windings, wherein the teeth extend from a yoke of the stator in a radial direction of the stator. The stator includes at least a first stator segment having a first end-surface in a circumferential direction of the stator and a second stator segment having a second end-surface in the circumferential direction of the stator, wherein the first and second end-surfaces are arranged adjacent to each other to form the stator. The first end-surface includes first protrusions protruding the circumferential direction of the stator and first recesses therebetween, the first protrusions forming first teeth extending from the yoke of the stator in the radial direction of the stator.