Turbo Generator Stator Header Connection Design
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Solution Overview
Problem
High power turbo generators face increased axial dimensions and electrical current overload at connection zones due to the high number of connection segments at headers, which complicates cooling and assembly.
Innovation Solution
The stator design incorporates connection devices that share paths with isopotential electrical windings, reducing the number of connection segments and axial dimensions at headers, and employs ventilated connection devices to manage current distribution effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of isopotential electrical windings connected in parallel between each pair of terminals is increased to decrease current value and increase cooling surface, then the current carrying capacity and cooling efficiency are improved, but the number of connection segments at headers increases, leading to increased axial dimensions and electrical current overload at connection zones
Solution Approach 1:
The patent merges the connection segments with the electrical windings by having connection devices define path segments that are common with the isopotential electrical windings. This integration reduces the total number of separate connection segments at the headers, thereby reducing axial dimensions while maintaining the increased current carrying capacity achieved through multiple parallel windings.
Solution Approach 2:
The connection devices serve dual functions: they act as both connection elements for electrical windings and as path-defining elements that are shared with the windings themselves. This multi-functionality eliminates the need for separate dedicated connection segments, reducing axial dimension at headers while supporting multiple parallel electrical windings for enhanced power capacity.
2Power
If the number of isopotential electrical windings connected in parallel between each pair of terminals is increased to decrease current value and increase cooling surface, then the current carrying capacity and cooling efficiency are improved, but the axial dimension of the stator is increased due to the wiring configuration
Solution Approach 1:
The connection devices are integrated with the electrical windings such that they define common path segments. This merging eliminates redundant connection segments and reduces the axial space required at headers, allowing multiple parallel windings to be accommodated without proportionally increasing overall stator axial dimension.
Solution Approach 2:
The patent optimizes the spatial arrangement of connection devices and electrical windings in the axial dimension by having connection devices define path segments that are common with windings. This dimensional optimization allows multiple parallel windings to be packed more efficiently, reducing the axial footprint while maintaining enhanced current carrying capacity.
3Temperature
If each axial cavity is occupied by two different electrical windings with sixteen straight segments each, then the cooling surface is increased, but the connection zones at terminal pairs become overloaded with electrical current
Solution Approach 1:
Multiple electrical windings share common connection devices and path segments, which distributes the current load more evenly across the connection zones. This merging approach maintains the increased cooling surface from multiple windings while preventing current overload at terminal connections through shared current paths.
4Reliability
If ventilated connection devices are used to connect each isopotential electrical winding to a respective terminal, then the current overload issue is addressed, but the axial dimensions are further increased
Solution Approach 1:
The ventilated connection devices are merged with the path definition function, where connection devices define path segments that are common with electrical windings. This integration provides ventilation for current distribution while eliminating redundant connection segments, thereby maintaining reliability without proportionally increasing axial dimensions.
Data Source
AI summary
A stator of a turbo generator for the generation of electrical energy is provided with: a cylindrical core, which extends along a longitudinal axis and presents a plurality of axial cavities and two opposite headers; connection terminals of the turbo generator; a plurality of electrical windings, which are split into groups and which extend along paths defined in part in the axial cavities and in part at the headers; the electrical windings of each group being isopotential and connected in parallel between a pair of terminals; and a plurality of connection devices, each of which is adapted to define, at least at one of the headers, a segment of path in common with the isopotential electrical windings.