Stator Slot Wedge Structure to Eliminate Finger End Plates
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Solution Overview
Problem
Existing electrical generators, particularly those in wind turbines, face inefficiencies due to expensive finger end plates and eddy-current losses, which affect mechanical support and Annual Energy Production (AEP).
Innovation Solution
A wedge design for stator teeth that provides mechanical support without finger end plates, featuring a 'T'-shaped structure with portions extending longitudinally and circumferentially to abut against multiple teeth, reducing eddy-current losses and enhancing coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If finger end plates are used to mechanically support stator teeth, then mechanical support is provided, but manufacturing cost increases and eddy-current losses occur
Solution Approach 1:
The invention merges the functions of the wedge and the end plate by extending the wedge longitudinally to provide mechanical support to the teeth, eliminating the need for separate finger end plates. This integration removes the source of eddy-current losses while maintaining structural support.
Solution Approach 2:
The invention extracts and removes the finger end plates from the stator assembly, replacing their function with the extended wedge structure. This elimination of the end plates directly eliminates the eddy-current losses they caused.
2Strength
If finger end plates are used to support stator teeth, then mechanical support is achieved, but manufacturing cost increases
Solution Approach 1:
The invention combines the support function into the wedge component itself, eliminating the need for separate end plate manufacturing. This reduces the total number of parts and manufacturing steps, thereby lowering manufacturing costs.
Solution Approach 2:
By removing the finger end plates from the design, the invention eliminates their associated manufacturing costs. The simplified structure requires fewer components and assembly steps.
3Reliability
If conventional wedges are used, then winding protection is provided, but mechanical support for teeth is insufficient
Solution Approach 1:
The wedge is segmented into multiple functional portions: a first portion for circumferential extension between teeth, a second portion for longitudinal abutment against tooth ends, and multiple wings for enhanced coupling. This segmentation allows each portion to perform its specific function optimally.
Solution Approach 2:
The wedge extends in multiple dimensions beyond the traditional design - circumferentially between teeth and longitudinally along the tooth ends. This multi-dimensional extension provides both winding protection and enhanced mechanical support simultaneously.
Data Source
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AI summary
Stator (20) for an electrical generator comprising: - a frame body (21) longitudinally extending along a longitu- dinal axis (Y) and including a stator yoke (22) and a plural- ity of teeth (33) radially protruding from the stator yoke (22) to respective tooth radial ends (38), each tooth extend- ing longitudinally between a first tooth longitudinal end (21a) and a second tooth longitudinal end (21b), - at least a wedges (40a-f). The wedge (40) comprises at least a first portion (41) and a second portion (42a-f), the first portion (41) and the second portion (42a-f) being shaped and dimensioned in such a way that, when the wedge (40) is attached to one of the tooth ra- dial ends (38), the first portion (41) extends longitudinally from one tooth longitudinal end (21a, 22a) and the second portion (42a-f) abuts against said one tooth longitudinal end (21a, 22a).