Vertical Generator Assembly for Precise Rotor-Stator Alignment
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Solution Overview
Problem
Existing generator assembly methods require precise alignment of rotor and stator components in controlled environments, leading to challenges in transportation and assembly costs due to the generator's weight and the need for exact magnet alignment, which is difficult to achieve outside controlled facilities.
Innovation Solution
A vertical assembly system comprising separate first and second assembly elements with guiding means, hydraulic cylinders for alignment, and adjustable linear guides to ensure precise coaxial alignment of rotor and stator, allowing assembly at any location, including the wind turbine site.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If generator assembly is performed in controlled environments with precise alignment tools, then manufacturing precision is improved, but transportation cost and complexity increase due to generator weight
Solution Approach 1:
The assembly system is divided into separate modular components: a first assembly element connectable to the rotor, a second assembly element connectable to the stator, and guiding means for alignment. This segmentation allows the system to be transported in parts and assembled on-site, reducing transportation complexity while maintaining alignment precision through the guiding means.
Solution Approach 2:
The guiding means acts as an intermediary between the first and second assembly elements, providing precise alignment guidance during the assembly process. This intermediary component enables accurate rotor-stator alignment without requiring the entire assembly system to be transported as a complete unit, thus reducing transportation complexity while maintaining manufacturing precision.
2Manufacturing precision
If permanent magnets are aligned precisely after rotor and stator assembly, then manufacturing precision is improved, but assembly time increases due to sequential assembly steps
Solution Approach 1:
The guiding means is installed on the assembly elements before the actual rotor-stator assembly takes place. This preliminary setup ensures that the alignment infrastructure is already in place, allowing magnets to be aligned precisely during the assembly process without requiring additional time for separate alignment operations after assembly.
3Manufacturing precision
If guiding rings are installed temporarily for rotor-stator alignment, then manufacturing precision is improved, but ease of operation deteriorates due to difficulty in removing guiding rings
Solution Approach 1:
The guiding means is designed to be easily separable from the assembly elements after serving its alignment purpose. The guiding means can be removed from the first and second assembly elements without difficulty, unlike traditional guiding rings that are difficult to remove. This extraction capability maintains alignment precision during assembly while improving ease of operation during disassembly.
4Manufacturing precision
If assembled generator is transported to installation site, then manufacturing precision is maintained, but transportation cost increases due to excessive generator weight
Solution Approach 1:
Instead of transporting the complete assembled generator, the system segments the assembly process by transporting only the individual assembly elements and guiding means to the installation site. The rotor and stator are then assembled on-site using the guiding means, significantly reducing the weight that needs to be transported while maintaining assembly precision through the guiding alignment system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables flexible and precise assembly of generators directly at the installation site, reducing transportation costs and ensuring accurate alignment without excessive magnetic forces, with the system being reusable for multiple assemblies.
Implementation Method 1
the driving means comprises one or more hydraulic cylinders
Data Source
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AI summary
The invention relates to a system (2, 102) for assembling a generator (3, 103), preferably a permanently excited generator (3, 103) of a wind turbine, comprising a rotor (16, 116) and a stator (10, 110). According to the invention a vertical assembly device (4, 104) being connectable to the rotor (16, 116) and the stator (10, 110) is proposed, for guiding the rotor (16, 116) in parallel and coaxially aligned to the stator (10, 110) during assembly, the vertical assembly device (4, 104) comprising a first assembly element (26, 126) being connectable to the rotor (16, 116), a second assembly element (6, 106) being connectable to the stator (10, 110), and guiding means (28, 128) for guiding the first assembly element (26, 126) coaxially aligned to the second assembly element (6, 106).