Segmented Stator Assembly for Offshore Wind Turbines
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Solution Overview
Problem
Offshore wind turbines with ratings of 3MW and higher face challenges in transportation and assembly due to their large size and weight, with conventional segmentation of stator structures being difficult to manufacture and assemble, and alternative configurations like axial lengthening or double-sided designs presenting manufacturing complexities and weight issues.
Innovation Solution
A segmented stator assembly with structural plates and stabilizing elements that provide structural integrity, allowing for easier transportation and assembly by accommodating conventional shipping constraints, while maintaining performance through harmonic coupling and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the generator is made larger to achieve 3MW and higher ratings, then the power output is improved, but the transportation and assembly become difficult and costly
Solution Approach 1:
The stator assembly is divided into multiple segments that can be transported separately and assembled on-site. Each segment includes stator laminations, structural plates, and windings that are pre-assembled as modular units, allowing the large 3MW+ generator to be broken down into transportable pieces while maintaining overall performance
2Shape
If the machine is made axially longer to fit within 4m diameter, then the diameter constraint is satisfied, but the weight increases significantly
Solution Approach 1:
Instead of increasing axial length to reduce diameter, the invention uses radial segmentation where multiple stator segments are arranged circumferentially around the rotor. This dimensional reconfiguration allows the magnetic circuit to achieve the required power density without excessive axial length or weight
3Ease of manufacture
If conventional segmented stator structures are used, then transportation cost is reduced, but manufacturing and assembly difficulty increases
Solution Approach 1:
Multiple functional elements are merged into integrated stator segments: the stator laminations, structural plates, windings, and stabilizing elements are pre-assembled as complete modular units. This reduces on-site assembly complexity while maintaining the transportation benefits of segmentation, as each segment is a self-contained functional module
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
An electric machine and a stator assembly 114 include a segmented stator having stator portions. Each stator portion includes end plates 126 arranged axially on opposing sides of the stator portion, support plates arranged interior to the end plates, stator laminations arranged between the support plates, and stabilizing elements 148 coupling the end plates and the support plates together. Each of the stabilizing elements 148 has a dovetail portion coupled to the end plates and to the support plates. Connectors are provided to connect the stator portions of the segmented stator together.