Wind Turbine Generator Power Take-Off Module Design
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Solution Overview
Problem
Existing wind turbine generators face challenges in efficient assembly, maintenance, and space optimization due to complex cable connections and the need for multiple cables, which complicate manufacturing, transportation, and in-situ maintenance.
Innovation Solution
The design features a generator with power take-off modules having offset interfaces located within the housing corners, allowing for efficient cable routing and easy access, along with removable panels for maintenance, and the use of flexible connections to accommodate thermal expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If bus rings with multiple cables are used to connect windings to power take-off, then electrical power can be conveyed from multiple windings, but the number of cables and connections increases significantly
Solution Approach 1:
The patent combines multiple cable connections into a single integrated power take-off module. The module integrates multiple bus ring connections (for multiple windings) and multiple power take-off cables into one unified component assembly, thereby reducing the total number of separate connections and simplifying the overall system architecture.
Solution Approach 2:
The power take-off module is designed as a multi-functional component that handles multiple electrical connections simultaneously. It can connect to multiple bus rings (from different windings) and provide multiple power take-off cable connections, making it a universal interface that replaces numerous individual connection points.
2Reliability
If power take-off cables are permanently attached during manufacture, then electrical connections are established, but assembly becomes complicated and time consuming
Solution Approach 1:
The patent segments the power take-off system into a separate, modular power take-off module that can be manufactured and tested independently. This module includes the connection interfaces for both bus rings and power take-off cables, allowing it to be assembled as a discrete unit and then integrated into the generator, thereby simplifying the overall assembly process while maintaining connection reliability.
Solution Approach 2:
The power take-off module is prepared in advance as a pre-assembled unit with all necessary electrical connections and insulation already in place. This preliminary preparation allows the module to be installed as a single component, reducing assembly complexity and time while ensuring that all electrical connections are properly established before the generator is put into service.
3Power
If a large number of cables are routed from bus ring to exterior, then electrical power can be transferred, but space within generator housing is consumed
Solution Approach 1:
The patent employs a nested arrangement where multiple power take-off cables are bundled and routed together through a single dedicated opening in the generator housing. The cables are organized in a compact, space-efficient manner within the housing, with insulation and support structures nested around them, thereby minimizing the volume occupied by the cable assembly while maintaining full electrical power transfer capability.
4Ease of operation
If generator is transported with cable ends exposed, then electrical connections can be made, but transportation becomes difficult due to delicate flying ends
Solution Approach 1:
The patent extracts the delicate cable ends from the generator housing and concentrates them into a single, protected location at the power take-off module. The cables are routed through a dedicated opening and positioned in a way that allows them to be easily accessed and connected after installation, while their exposed ends are minimized and protected during transportation, reducing the risk of damage.
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 design simplifies the assembly and maintenance process, reduces the complexity and cost of manufacturing, and enhances packaging efficiency within the nacelle, while allowing for easier transportation and reduced risk of errors.
Implementation Method 1
a bus ring for conveying electrical power from the one or more multi-phase windings to one or more power take-off modules
Implementation Method 2
electric current is induced in each winding by the action of a rotating magnetic field in the vicinity of the windings
Data Source
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AI summary
The invention relates to a generator for a wind turbine comprising a housing of substantially cuboidal form within which is mounted a stator. The stator has one or more multi-phase windings and a bus ring is provided for conveying electrical power from the windings to power take-off modules. One end of the power take-off modules are connected to the bus ring, and the other end of the modules have a plurality power take-off interfaces for connection to power take-off cables. The distal ends of the power take-off modules are located in the corners of the cuboidal generator housing.