Stator Lamination Segment Mounting for Faster Wind Turbine Assembly
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Solution Overview
Problem
The assembly of stator lamination stacks in wind turbine generators is time-consuming and prone to errors, such as welding pimples being overlooked, which can lead to short circuits, and the two-sided welding hinders settling compensation, causing the lamination stack to sag.
Innovation Solution
A segment sheet design with radial sections featuring recesses for a positive connection to profiled strips on the stator support ring, allowing for simplified mounting and automated assembly, eliminating the need for threading and reducing the risk of sagging through radial fixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If segment sheets are threaded onto nesting rods simultaneously on three adjacent rods, then the stator lamination stack can be formed, but the assembly process becomes time-consuming
Solution Approach 1:
The invention extracts the nesting rods from the assembly process and replaces them with profiled strips that are directly fixed to the stator support ring. This eliminates the time-consuming threading operation while maintaining the structural integrity and positioning functionality of the original system.
Solution Approach 2:
The profiled strips are pre-fixed to the stator support ring before the segment sheets are installed. This preliminary action allows the segment sheets to be directly placed and secured without requiring threading operations, significantly reducing assembly time.
2Strength
If two-sided welding is used to secure pressure plate segments to the stator support ring, then structural strength is improved, but welding pimples may be overlooked causing short circuits
Solution Approach 1:
The invention replaces the welding process with a mechanical connection system using profiled strips with retaining protrusions and corresponding recesses in the segment sheets. This substitution eliminates the risk of welding defects while maintaining structural strength through the mechanical interlocking mechanism.
3Stability of the object's composition
If two-sided welding of pressure plate segments is performed, then the stator lamination stack is secured, but settling compensation is hindered causing sagging
Solution Approach 1:
The invention introduces a dynamic element through the movable retaining protrusions that can shift within their respective recesses. This allows the segment sheets to accommodate settling movements while maintaining their positional stability, preventing sagging without requiring welding.
4Ease of manufacture
If profiled strips are used for positive connection, then assembly is simplified and automated, but additional components are introduced
Solution Approach 1:
The profiled strips serve multiple functions: they provide structural support, enable positive connection through retaining protrusions, allow for settling compensation through movable connections, and facilitate automated assembly. By consolidating these functions into a single component, the overall device complexity is reduced despite the introduction of new elements.
Data Source
AI summary
A segment sheet for a stator lamination stack of a generator of a wind turbine, wherein the segment sheet has the shape of a ring segment, having a first radial section, in which recesses are provided for receiving a stator winding, having a second radial section, which is arranged radially adjacent to the first section and which forms a segment of a magnetic yoke of the generator, and having a third radial section, which is arranged radially adjacent to the second section. The proposal is that the third radial section has at least two recesses arranged in an azimuthally spaced manner, which are designed for a positive connection to profiled strips arranged on a stator support ring.