Stator Structure with Circumferential Air Distribution Channel
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Solution Overview
Problem
Large electrical machines, such as wind turbine generators, face inefficiencies due to non-uniform cooling fluid flow rates affecting electromagnetic components like electrical windings, particularly in direct drive systems where integrating dedicated cooling inlets is complicated by stator structures and electrical connections.
Innovation Solution
A stator structure with a circumferential support featuring an air entrance, air distribution channel, and axial air openings that distribute air flow uniformly along the circumference, ensuring consistent cooling of electrical windings and minimizing the need for multiple cooling inlets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single cooling fluid inlet is used in large electrical machines, then the device complexity is reduced, but the cooling fluid flow rate distribution becomes non-uniform causing different electromagnetic components to operate at different temperatures
Solution Approach 1:
The single cooling fluid inlet is segmented into multiple outlet channels that distribute cooling fluid to different electromagnetic components. The cooling system is divided into multiple independent cooling circuits, each serving specific components, thereby achieving uniform temperature distribution while maintaining a single inlet structure.
Solution Approach 2:
Different sections of the cooling system are designed with locally optimized characteristics. Each cooling circuit is tailored to the specific thermal requirements of the electromagnetic components it serves, with adjustable flow rates and cooling capacities matched to local heat generation patterns.
2Temperature
If dedicated fluid cooling inlets are provided for each electrical component, then the temperature uniformity is improved, but the device complexity and integration difficulty increase significantly
Solution Approach 1:
Multiple dedicated cooling inlets are merged into a single inlet structure that internally branches into multiple cooling circuits. The stator structure integrates multiple cooling channels within a unified framework, combining the benefits of dedicated component cooling with simplified external integration.
Solution Approach 2:
The single cooling inlet structure serves multiple functions by distributing cooling fluid to various electromagnetic components through integrated cooling circuits. The stator structure acts as a multi-functional element that both supports electrical windings and provides thermal management for multiple components simultaneously.
3Reliability
If multiple cooling inlets are integrated into the stator structure, then the cooling fluid flow rate distribution is improved, but the manufacturing complexity and structural design difficulty increase
Solution Approach 1:
Cooling circuits are nested within the stator structure, with cooling channels integrated into the existing stator geometry. The cooling system is embedded within the stator body, utilizing the stator structure itself as part of the cooling pathway, thereby simplifying manufacturing compared to adding separate external cooling components.
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 solution ensures uniform air flow distribution, maintaining electromagnetic components within a predetermined temperature range, enhancing efficiency and simplifying integration in complex electrical machine configurations like direct drive wind turbines.
Implementation Method 1
The air distribution channel extends through a portion of the circumferential support structure to circumferentially distribute an air flow from the air entrance
Implementation Method 2
The plurality of axial air openings provides a passage between the air distribution channel and an outer side of the external rim to guide the air flow from the air distribution channel to the outer side of the external rim
Implementation Method 3
The apertures are sized and spaced such that the air flow is substantially uniform along the circumference of the outer side of the external rim
Implementation Method 4
ensuring consistent cooling of electrical windings
Data Source
AI summary
In a first aspect, a stator structure for an electrical machine is provided. The stator structure comprises a circumferential support having an external rim to support a plurality of electrical windings. The circumferential support comprises an air entrance, an air distribution channel and a plurality of axial air openings. The air entrance provides a passage between the air distribution channel and an outside of the stator structure. The air distribution channel extends through a portion of the circumferential support to circumferentially distribute an air flow from the air entrance. The plurality of axial air openings provides a passage between the air distribution channel and an outer side of the external rim to guide an air flow from the air distribution channel to the outer side of the external side. The plurality of axial air openings comprises an aperture, wherein the apertures are sized and spaced such that the air flow is substantially uniform along the circumference of the outer side of the external rim. In a further aspect, an electrical generator comprising a stator structure according to any of the examples herein described is provided.