Wind Turbine Generator Assembly for Precise Air Gap Control
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Solution Overview
Problem
Manufacturing wind turbine generators is complex due to the high weight and size of components, particularly in controlling the air gap size between the stator and rotor, which often deviates from design specifications due to manufacturing tolerances.
Innovation Solution
A method involving optical measurements to determine the inner radii of the rotor house and bearing assembly, positioning magnet modules to achieve a circular shape, and calculating the minimum inner radius to accurately assemble the stator and rotor components, ensuring the air gap size adheres to design requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional assembly methods are used for generator components, then manufacturing process is simpler, but air gap size control precision deteriorates
Solution Approach 1:
The patent applies preliminary action by performing optical measurements and calculating optimal magnet module positions before the actual assembly process. The system determines the precise positioning of magnet modules on the rotor house based on pre-calculated data, ensuring that when components are assembled, the air gap size already meets design specifications without requiring complex real-time adjustments during assembly.
Solution Approach 2:
The patent replaces traditional mechanical measurement and adjustment methods with optical measurement systems and computational algorithms. Instead of using physical gauges and manual positioning to control air gap size, the system uses optical fields to measure component geometries and computational methods to determine optimal magnet module positions, thereby improving precision while managing complexity.
2Manufacturing precision
If manufacturing tolerances are relaxed for easier production, then ease of manufacture improves, but air gap size adherence to specifications deteriorates
Solution Approach 1:
The patent applies parameter changes by using optical measurement systems to precisely determine the actual geometric parameters of rotor house inner surfaces and magnet module dimensions. Based on these measured parameters, the system calculates optimized positioning arrangements that compensate for manufacturing tolerances. This allows components to be manufactured with standard tolerances while still achieving precise air gap control through adjusted positioning parameters.
3Manufacturing precision
If more measurement and calculation steps are added to control air gap size, then manufacturing precision improves, but productivity deteriorates
Solution Approach 1:
The patent performs measurements and calculations in advance before the actual assembly process. Optical measurements of component geometries and calculations of optimal magnet module positions are completed beforehand, allowing the physical assembly to proceed quickly without interruptions for measurements or adjustments. This separates the precision-determining steps from the time-consuming assembly steps.
Solution Approach 2:
The patent creates a digital model or copy of the physical components through optical measurement. This virtual representation contains all necessary geometric information for calculating optimal positions, eliminating the need to repeatedly handle physical components for measurement purposes during assembly, thereby speeding up the manufacturing process while maintaining precision.
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
This method allows for precise assembly of wind turbine generators, reducing manufacturing tolerances and ensuring the air gap size meets design specifications, thereby improving the accuracy and reliability of the generator assembly.
Implementation Method 1
determining, using optical measurements, plural first inner radii of an assembly comprising a rotor house and a bearing across a circumference
Data Source
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AI summary
It is described a method of assembling a generator (1) for a wind turbine (50), the method comprising: determining (RBMS) plural first inner radii (r1) of an assembly comprising a rotor house (6) and a bearing (5); measuring (IMIC) heights (h) of plural magnet modules (9); determining positions of the plural magnet modules (9) at the rotor house (6); calculating second inner radii (r2) of the rotor house-bearing assembly and determining a minimum second inner radius; measuring geometry information (FSMS) of a first mounting surface (3) and/or a second mounting surface (4) of a stator base structure (2); mounting (FSAC) plural stator segments (8) at the stator base structure (2), in order to obtain a stator assembly; coupling the rotor house-bearing assembly (5, 6) with the stator assembly (2, 8, 7); mounting (MMIC) the magnet modules (9) at the rotor house (6).