Segmented Stator Support Structure for Longer Lamination Stacks
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Solution Overview
Problem
Conventional segmented stator designs for large electric machines, such as wind turbine generators, fail to utilize the maximum length of the stator due to boundary conditions, resulting in reduced torque and output power, while attempting to maximize length would significantly increase costs.
Innovation Solution
A support structure with a frame of parallel end plates and side plates, featuring internal and external connecting members that extend beyond the frame, allowing for a larger lamination stack to be secured, thereby optimizing the effective length without adding complexity or cost, utilizing u-shaped external connecting members with decreasing height and variable lengths for flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional segmented stator designs are used with simple machined pressure plates, then manufacturing complexity and cost are kept low, but the effective length of the stator is reduced and torque output is lower
Solution Approach 1:
The patent extends the connecting members beyond the frame boundaries into the end regions, utilizing the axial dimension that was previously unused. This allows the lamination stack to extend beyond the frame width while maintaining structural support, effectively increasing the stator length without adding complex multi-dimensional structures.
Solution Approach 2:
The support structure is divided into modular components: frame, internal connecting members, and external connecting members. This segmentation allows each component to be optimized independently and assembled flexibly to achieve the desired effective length while keeping manufacturing complexity manageable through standardized parts.
2Power
If the stator length is maximized to increase torque output, then power production is improved, but the support structure complexity and cost increase significantly
Solution Approach 1:
The connecting members serve multiple functions: they provide structural support within the frame, extend support into the end regions, and enable flexible configuration for different stator lengths. This multi-functionality allows the same basic component design to achieve length maximization without proportionally increasing complexity.
Solution Approach 2:
The support structure is designed with adjustable and configurable connecting members that can be positioned and dimensioned according to specific application requirements. This dynamic configurability allows optimization of stator length for maximum torque output while maintaining manufacturing simplicity through standardized connection methods.
Data Source
AI summary
A support structure for supporting a lamination stack and a winding structure in order to form a stator segment for an electric machine, in particular a wind turbine generator including (a) a frame including two parallel end plates and two side plates, the side plates extending between corresponding end portions of the end plates, (b) a plurality of internal connecting members extending within the frame between the end plates, and (c) a plurality of external connecting members extending outside of the frame, each external connecting member forming an extension of a corresponding internal connecting member beyond one of the end plates, wherein (d) the internal and external connecting members are adapted to engage with corresponding fastening members for securing a lamination stack. A stator segment, a wind turbine generator, and a method of manufacturing a support structure are also described.