Segmented Stator Bus Bar Layout for Lower Copper Wind Generators
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Solution Overview
Problem
The existing stator designs for large electrical machines, such as wind turbine generators, face challenges with space constraints and high copper costs due to the extensive use of pre-installed bus bar segments and complex connection processes, especially when multiple electrical systems need to be connected.
Innovation Solution
The proposed stator design reduces the number of pre-installed bus bar segments and uses additional continuous bus bars to connect segmented bus bars across stator segments, bypassing unnecessary segments and using a flexible bus bar system to simplify assembly and reduce material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple pre-installed bus bar segments are provided on each stator segment to connect to multiple electrical systems, then the electrical connection capability is improved, but the space constraints and manufacturing complexity worsen
Solution Approach 1:
The bus bar system is divided into modular bus bar segments that can be pre-installed on stator segments and later connected using segment connection means. This segmentation allows the electrical connection capability to be built incrementally while keeping each individual component simple to manufacture.
Solution Approach 2:
Bus bar segments are pre-installed on stator segments during stator segment manufacturing, before the final stator assembly. This preliminary action simplifies the overall manufacturing process by preparing components in advance, reducing the complexity of final assembly while maintaining the capability to connect to multiple electrical systems.
2Adaptability or versatility
If six bus bar segments are provided per stator segment to support multiple connectors, then the electrical connection capability is improved, but the copper cost and space constraints worsen
Solution Approach 1:
Instead of providing six bus bar segments on every stator segment, the solution uses a partial approach where bus bar segments are selectively provided and connected only where needed. Segment connection means are used to create segmented bus bars that extend across multiple stator segments, reducing total copper usage while maintaining the capability to connect to multiple electrical systems.
Solution Approach 2:
Adjacent bus bar segments from different stator segments are connected using segment connection means to form continuous segmented bus bars. This merging approach allows fewer individual segments to be used while achieving the same electrical connection capability, thereby reducing total copper consumption.
3Adaptability or versatility
If six bus bar segments per stator segment are used to connect to two connectors, then the electrical connection capability is improved, but the assembly effort and connection complexity worsen
Solution Approach 1:
The bus bar system is segmented into modular units that can be independently manufactured and then connected using standardized segment connection means. This segmentation reduces assembly complexity by breaking down a complex six-segment configuration into simpler, repeatable connection operations.
Solution Approach 2:
Segment connection means are designed to be universal connectors that can join bus bar segments regardless of their specific position or orientation. This multi-functionality reduces assembly effort by using the same connection methodology throughout, rather than requiring different assembly procedures for different configurations.
Data Source
AI summary
Provided is a stator for an electrical machine, in particular a generator of a wind turbine, wherein the cylindrical stator includes multiple similar stator segments, each stator segment constituting a fraction of the circumference of the stator and having at least one coil element and one pre-installed bus bar segment per phase provided to or by the electrical machine, wherein each bus bar segment is electrically connected to a coil element of the respective phase, wherein at least two circumferentially adjacent stator segments form a section and multiple subsets of an even number of radially opposing sections are respectively assigned to a connector at a respective connection position along the circumference of the stator, wherein in each section, segmented bus bars for each phase are provided by connecting bus bar segments of adjacent stator segments.