Monolithic Wind Turbine Generator Frame for Air Gap Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Large wind turbine rotating electric machines face challenges in achieving a small, constant air gap as diameter increases, requiring complex and heavy frames that are difficult to assemble and maintain, while also needing to be lightweight and efficient.
Innovation Solution
A tubular structure with an annular flange and ring, formed in one piece, that supports active segments and minimizes air gaps through concentric machining and bolted connections, allowing for easy assembly and maintenance, and features radial arms to transmit forces without increasing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the diameter of the rotating electric machine is increased to achieve higher power, then the power output is improved, but the air gap becomes difficult to maintain at a small and constant size
Solution Approach 1:
The stator is divided into multiple modular segments that can be assembled around the rotor. Each segment is manufactured separately with precise dimensions, and the modular design allows for better control of the air gap across the entire large-diameter machine, solving the difficulty of maintaining uniform air gap in large-scale machines
Solution Approach 2:
The frame, tubular structure, and annular flange are merged into a single integrated component formed in one piece. This integration ensures perfect concentricity between the cylindrical face and annular seat, guaranteeing a small and uniform air gap across the entire large-diameter rotor assembly
2Manufacturing precision
If a rigid frame structure is used to maintain small air gaps, then the manufacturing precision is improved, but the weight of the machine increases
Solution Approach 1:
The frame, tubular structure, and annular flange are combined into a single monolithic component formed in one piece. This integration eliminates the need for multiple heavy fastening components and assembly hardware, reducing overall weight while maintaining the rigidity and concentricity required for small air gaps
Solution Approach 2:
The use of advanced casting processes allows the creation of a lightweight yet highly rigid structure with optimized material distribution. The single-piece construction can incorporate material only where structurally necessary, reducing weight while maintaining the precision required for uniform air gap
3Manufacturing precision
If complex frame structures are used to ensure rigidity and concentricity, then the manufacturing precision is improved, but the ease of manufacture deteriorates
Solution Approach 1:
The frame, tubular structure, and annular flange are merged into a single component formed in one piece through advanced casting processes. This eliminates the need for complex assembly operations involving multiple parts, fasteners, and alignment procedures, while still achieving perfect concentricity between the cylindrical face and annular seat
Solution Approach 2:
The adoption of modern casting technologies enables the production of complex geometries with high precision directly in the casting process. This parameter change in manufacturing methodology allows for intricate single-piece structures to be produced efficiently without requiring subsequent complex assembly operations
4Ease of manufacture
If traditional multi-component frame structures are used, then the ease of manufacture is improved, but the reliability deteriorates due to assembly errors in concentricity
Solution Approach 1:
The frame, tubular structure, and annular flange are integrated into a single monolithic component. This eliminates all interfaces and connections between these components, completely removing the source of assembly errors related to concentricity. The perfect concentricity is built-in through the single-piece construction rather than achieved through assembly precision
Data Source
AI summary
A frame of a rotating electric machine of a wind turbine extends about an axis of rotation, and has a tubular structure having a cylindrical face and configured to support a plurality of active segments along the cylindrical face; an annular flange configured to connect the rotating electric machine to a main frame of a wind turbine; and a ring having an annular seat for a bearing; and wherein the tubular structure, the annular flange, and the ring are formed in one piece.