Stator Mounting Box Busbar Cabling Segmentation
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Solution Overview
Problem
Large rotating electrical machines with stator windings face issues with cable management and redundancy due to the need for extensive cabling and dual frequency converters, leading to potential imbalance and vibration problems when one converter fails.
Innovation Solution
The use of mounting boxes to distribute and simplify cabling from stator winding segments, allowing for even distribution around the stator circumference and connection to separate frequency converters for redundancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the stator is divided into two parts with equal number of winding segments to route cabling from segments, then cable management is simplified, but the machine loses redundancy and experiences high amplitude vibration and bending when one frequency converter fails
Solution Approach 1:
The stator winding segments are divided into two separate groups, with each group connected to its own frequency converter. This segmentation allows independent operation of each converter, providing redundancy while simplifying cable routing for each group separately.
Solution Approach 2:
A common busbar structure is introduced as an intermediary component that receives cabling from both groups of winding segments. This busbar system allows flexible connection and distribution of electrical connections without requiring complex cable routing between converters and segments.
2Reliability
If two frequency converters are used to supply winding segments in large machines, then redundancy is obtained, but the cabling from stator segments requires lot of space near the stator
Solution Approach 1:
A common busbar structure is introduced as an intermediary component that receives cabling from both groups of winding segments. This busbar system allows flexible connection and distribution of electrical connections without requiring complex cable routing between converters and segments, significantly reducing the space required near the stator.
Solution Approach 2:
The electrical connections are reorganized from a distributed cable routing approach to a centralized busbar approach, effectively changing the dimensional arrangement of connections from radial (requiring space around the stator) to a more compact configuration that reduces spatial requirements near the stator.
3Device complexity
If winding segments are connected to a single frequency converter for simplified operation, then device complexity is reduced, but the machine loses redundancy and experiences imbalance and vibration when the converter fails
Solution Approach 1:
The stator winding segments are divided into two separate groups, with each group connected to its own frequency converter. This segmentation allows independent operation of each converter, providing redundancy while maintaining relatively simple connection configurations for each group.
Data Source
Figure 1~2
Figure 3
AI summary
A stator of a rotating electrical machine, a rotating electrical machine and a method of manufacturing a stator. The stator comprises multiple of winding segments adapted to produce multiple of phase systems, at least one mounting box for receiving cabling from the winding segments, wherein the multiple of phase systems are formed of winding segments which are divided evenly in the circumference of the stator. The at least one mounting box comprising bus bars for multiple of phase systems, and each of the multiple of phase systems is connectable to a corresponding frequency converter in the at least one mounting box.