Yokeless Stator Modules for Wind Turbine Generators
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Solution Overview
Problem
Conventional wind turbines face challenges with large generator sizes due to the need for high power ratings, leading to increased material mass, space occupation, and costly cooling methods, particularly in land-based applications where transportation and assembly are complicated by large diameters.
Innovation Solution
The development of modular-pole, double-sided or single-sided radial-flux electrical machines with yokeless stators, which allow for a smaller overall size, reduced material usage, and more efficient cooling, enabling higher power ratings without increasing the generator's diameter or axial length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the generator diameter is increased to achieve higher power ratings, then the power output is improved, but the transportation and assembly become more difficult
Solution Approach 1:
The stator is divided into multiple modular stator tooth modules that can be independently manufactured and assembled. Each module contains a portion of the stator teeth and windings, allowing the generator to be constructed in sections that are easier to transport and assemble while maintaining the required power output capability
2Power
If the axial length of the generator is increased to achieve higher power ratings, then the power output is improved, but the frame structure becomes more complex and costly
Solution Approach 1:
The stator core is segmented into multiple modular units arranged axially, with each module containing stator teeth and windings. This modular approach allows the required power rating to be achieved through axial stacking of standardized modules rather than requiring a single complex long-stator design, simplifying the overall frame structure
Solution Approach 2:
The modular stator tooth modules are designed as universal components that can be used in different configurations and positions within the generator. This universality reduces the variety of unique parts required, simplifying the frame structure and reducing manufacturing complexity compared to custom-designed sections
3Strength
If a stator yoke is used to mechanically link the poles, then the structural integrity is improved, but the material mass and space occupation increase
Solution Approach 1:
The traditional continuous stator yoke is removed and replaced with individual stator tooth modules that are mechanically linked through alternative means such as end plates and radial bracing. This extraction of the yoke eliminates the excessive material mass while maintaining structural integrity through more efficient load-path design
Solution Approach 2:
Instead of using a continuous yoke throughout the entire stator, structural reinforcement is applied locally only where needed to maintain integrity. The modular design allows strengthening at critical junction points while leaving other areas with minimal material, optimizing the strength-to-weight ratio
4Stability of the object's composition
If the stator yoke is used to fix the stator to the frame, then the mechanical stability is improved, but the inner airgap diameter is reduced
Solution Approach 1:
The stator yoke that was occupying space in the airgap region is removed and replaced with a mounting system that attaches the modular stator teeth directly to the frame through end plates and radial support structures. This extraction restores the airgap diameter while maintaining mechanical stability through the alternative mounting arrangement
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 configuration results in cost-effective wind turbines with increased power ratings, reduced weight, and simplified transportation and assembly, while maintaining or enhancing power output and torque production.
Implementation Method 1
electrical machines, i.e. generators and motors, are devices that transform mechanical power into electrical power, and vice-versa
Data Source
Figure 1
Figure 2~3
Figure 4a~4b
AI summary
An electrical machine comprising a rotor (16) and a stator (22) is provided. The stator (22) includes a plurality of stator tooth modules (40) configured for radial magnetic flux flow. The stator tooth modules (40) include at least one end plate (39), and the end plates have extensions (42) for mounting onto a stator frame (50). The stator (22) is concentrically disposed in relation to the rotor (16) of the electrical machine.