Classifications

• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K7/00—Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
  • H02K7/18—Structural association of electric generators with mechanical driving motors, e.g. with turbines
  • H02K7/1807—Rotary generators
  • H02K7/1823—Rotary generators structurally associated with turbines or similar engines
  • H02K7/183—Rotary generators structurally associated with turbines or similar engines wherein the turbine is a wind turbine
  • H02K7/1838—Generators mounted in a nacelle or similar structure of a horizontal axis wind turbine
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
  • F03D—WIND MOTORS
  • F03D80/00—Details, components or accessories not provided for in groups F03D1/00 - F03D17/00
  • F03D80/80—Arrangement of components within nacelles or towers
  • F03D80/82—Arrangement of components within nacelles or towers of electrical components
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
  • F03D—WIND MOTORS
  • F03D9/00—Adaptations of wind motors for special use; Combinations of wind motors with apparatus driven thereby; Wind motors specially adapted for installation in particular locations
  • F03D9/20—Wind motors characterised by the driven apparatus
  • F03D9/25—Wind motors characterised by the driven apparatus the apparatus being an electrical generator
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
  • H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K19/00—Synchronous motors or generators
  • H02K19/16—Synchronous generators
  • H02K19/26—Synchronous generators characterised by the arrangement of exciting windings
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K19/00—Synchronous motors or generators
  • H02K19/16—Synchronous generators
  • H02K19/38—Structural association of synchronous generators with exciting machines
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K3/00—Details of windings
  • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
  • H02K3/18—Windings for salient poles
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
  • F03D—WIND MOTORS
  • F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
  • F03D1/06—Rotors
  • F03D1/065—Rotors characterised by their construction elements
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
  • Y02E10/00—Energy generation through renewable energy sources
  • Y02E10/70—Wind energy
  • Y02E10/72—Wind turbines with rotation axis in wind direction

Definitions

• the present invention relates to a forming coil of a rotor of a synchronous generator of a gearless wind turbine. Moreover, the present invention relates to a generator with such a forming coil and the present invention relates to a wind turbine with such a generator. Moreover, the present invention relates to a method of manufacturing a forming coil.
• Wind turbines are known and have a generator. Modern and robust wind turbines use a gearless concept, in which the generator of the aerodynamic rotor of the wind turbine is driven directly without the interposition of a transmission. Such a generator is also referred to as a generator of a gearless wind turbine. Such generators are characterized by large air gap diameter. Such air gap diameters can reach values of up to 10 m, as is the case, for example, with an ENERCON type E-126 wind energy plant. Air gap diameters of 4 to 5 m are common in gearless wind turbines. In addition, such generators gearless wind turbines are multi-pole and can be designed in particular as a ring generator, in which the electrically and magnetically active elements are substantially present only in an annular region around the air gap around.
• a field winding must be provided for each rotor pole or pole piece in order to generate the magnetic field via a corresponding electrical excitation.
• Such a generator or such a synchronous machine can also be referred to as a separately excited generator or a separately excited synchronous machine.
• the term "rotor" is referred to below as the rotor of the generator. Unless otherwise stated.
• the described externally excited concept can also be complicated in that the pole shoes with their windings are immersed in a corresponding insulation bath for insulation, which is often carried out in such a way that the entire, fully assembled rotor is submerged.
• the insulation thus applied regularly hampers the transport of heat and thus the dissipation of heat, it is also complicated to immerse such a complete rotor in a corresponding insulation bath.
• the invention is therefore based on the object to address at least one of the problems mentioned.
• a solution is to be proposed which is less expensive and / or more thermally efficient, in particular heat can dissipate better.
• a preformed coil according to claim 1 is proposed. It is thus proposed a form coil of a rotor of a synchronous generator of a gearless wind turbine for arrangement around a pole piece defining a central axis.
• This use of a forming bobbin on a pole piece of a rotor implies that this involves a separately excited synchronous generator.
• the forming coil is thus to be arranged around the pole piece. In this arrangement, the forming coil is then the excitation winding of this pole piece and generates a magnetic field, which is guided in the pole piece and runs substantially parallel to a center axis of the pole piece.
• the forming coil has several turns and is composed of sheets.
• the turns are thus composed of sheets.
• coils are each composed of sheets. This can be achieved, among other things, that These sheets of each turn are flat against each other and thereby an improved temperature transport can be carried out to adjacent sheets, if different temperatures occur in the layer direction.
• a temperature transport can take place comparatively well within each of a sheet, because temperature-insulating gaps are not there.
• a heat transfer can take place particularly directly radially outward.
• these sheets are layered in the axial direction of the pole piece, ie in the axial direction with respect to the center axis of the pole piece.
• they are layered exclusively in this axial direction of the pole piece, so in each plane have only one sheet and not several sheets side by side.
• heat in each layer can also be dissipated radially outward to the radially outer edge of the shaping coil. As a result, the temperature transport and thus a cooling process can be made favorable.
• the metal sheets are designed such that the preformed coil has enlarged surfaces compared to planar surfaces, in particular corrugated or ribbed surfaces through beveled edges of the metal sheets and / or through different widths of adjacent metal sheets.
• This relates to surfaces which are remote from the pole piece, that are directed radially outward relative to the pole piece or its central axis. These surfaces may also be referred to as exterior surfaces. In particular, this may relate to surfaces which together form a substantially circumferential outer shell surface of the shaping coil. In this area, therefore, the sheets may be provided with bevelled edges. Now, if these sheets with the chamfered edges stacked or layered to form the forming coil, these beveled edges put together to form a corrugated surface.
• sheets of different widths can be provided, in particular with alternately different widths. If these are stacked on each other, thus every second sheet is present and thereby forms a rib structure or rib shape and thus there a ribbed surface. In both cases exemplified, the result is an increased overall outer surface area of the forming coil. Especially when added to the fact that each sheet extends from the pole piece through to this corrugated or ribbed surface, heat can be relatively easily transported there and are easier to radiate on this enlarged surface. It is also contemplated that a structure is provided in which a cooling medium such as an air flow flows along these corrugations or ribs, thereby to carry away the heat there.
• a cooling medium such as an air flow flows along these corrugations or ribs
• the forming coil each have a turn or a half turn of a sheet metal and these sheets are assembled to the plurality of turns of the forming coil.
• half a turn consists of or is provided from a sheet
• it is preferably proposed that such a sheet is approximately L-shaped. This has the particular advantage that such sheets can be punched out with very little waste.
• two identical L-shapes can be folded into a rectangle or punched out in a rectangular shape.
• a sheet metal can be prepared in layers or levels of two sheets are prepared.
• Such a sheet can thus be formed substantially from a flat sheet.
• punch out the corresponding sheets from a large overall sheet or cut out for example by laser cutting.
• L-shaped sheets they can be cut out with very little waste.
• These individual sheets then only need to be connected. This can be done, for example, by welding or soldering, and in both of these examples mentioned, this also results in a compound with high electrical conductivity.
• a positive connection can be provided, for example, a so-called dovetail connection, in which one of two parts to be connected has an approximately dovetailed extension and the other part has a dovetail-shaped recess corresponding thereto.
• the sheets are thus so specially cut or punched that this cut-out or punched shape is adapted to the pole piece, which is to surround the form of coil and thus in each case the relevant turn.
• the fact that this turn is placed around this pole piece does not take place in that the material is bent around this pole piece, but this shape is punched out and no longer needs to be bent. This also makes it possible, virtually any Any shape around this pole piece around.
• these turns made of sheets can also be designed and placed tightly around sharp edges. Problems that might arise when bending around such sharp corners or edges in the material are avoided as a result of the principle.
• the sheets are made of aluminum. Aluminum has a lower conductivity than copper but weighs less.
• the rotor or its pole pieces with the form of coils which can also be referred to as Polschuhspulen be slightly increased in its design.
• a rotor could be created, which behaves electrically similar to a rotor with copper coils in a slightly smaller space.
• Such a construction with aluminum would then nevertheless be lighter than the comparable copper solution with a smaller construction volume.
• it would be expected that such an aluminum solution would also be less expensive than the comparatively described copper solution.
• the situation can be improved even though aluminum conducts less well than copper.
• the sheets are made of copper, especially to exploit the good conductivity of copper.
• the mold coil is characterized in that it has been dipped for isolation in a bath with an insulating varnish, in particular without the pole piece and without other winding body.
• an insulating varnish in particular without the pole piece and without other winding body.
• this without pole piece can have a high mechanical stability. It can thus be immersed for isolation in a bath with an insulating varnish, without being placed on the pole piece. In particular, this dive is possible without the entire rotor must be dipped.
• This dipping, in particular separate dipping of the coil form is also to be considered, namely the fact that the insulating varnish wets the sheets of the form coil uniformly everywhere and covered uniformly after solidification.
• the mold coil is immersed in a slightly spread state by at least a small distance between the metal planes is achieved, so that the insulating varnish also passes between the sheets.
• a generator is also proposed, which is provided for a gearless wind turbine and has a rotor with form coils, which are formed as described above in connection with at least one embodiment.
• a wind turbine with such a synchronous generator is also proposed.
• a method for producing a forming coil according to claim 9 is also proposed. Accordingly, first the sheets, in particular two sheets are cut or punched out of a large sheet. These sheets are then connected to one or more turns, depending on the form in which the sheets present and in what number. In particular, so many sheets are punched or cut out so that the complete winding of the shaping coil can be produced. For example, for a 20-turn coil form wound coil, it is possible to punch or cut 40 L-shaped sheets. These L-shaped sheets are then gradually assembled and bonded, such as welded or soldered, to thereby form this composite winding. In particular, in this example, two L-shaped sheets are connected in a single step to form a turn.
• the first and fortieth plates differ from the remaining 38 plates, because these two plates must be provided with appropriate connections. Otherwise, it can also be assumed that the complete winding essentially forms the shaping coil. Here, linguistically, a distinction is made between these two elements, above all because the winding can also constitute an intermediate state to the finished shaping coil, e.g. one without insulation varnish.
• a method is also proposed for producing a pole piece provided with a shaping coil. Accordingly, first of all, a forming coil is produced or provided according to at least one of the described embodiments. The production can be carried out according to a described manufacturing method thereto according to at least one of the embodiments. The mold coil is then placed or pushed onto the pole piece and the thus assembled mold coil with pole piece is then filled, in particular with synthetic resin.
• synthetic resin can be used, which is otherwise used for diving or filling of coils or transformers. As a result, this form of coil can be fixed well and firmly and in a comparatively simple manner on the pole piece. This solves the problem that there is no tight connection by conventional winding.
• a mold coil made of aluminum is used and this can be well secured by the manufacturing or bonding method described. It also takes into account the fact that aluminum expands more strongly with temperature than copper and incidentally also significantly stronger than the core on which it is to sit on the pole piece.
• the shaping coil be dimensioned so that it can be loosely placed on the pole shoe with a certain amount of play or can be pushed open. Again, the different coefficients of expansion is taken into account and this slightly larger dimensioning of the forming coil, a correspondingly slightly larger gap between the forming coil and pole piece. This is then filled with resin in the manner described and correspondingly more resin is used, which can thus possibly provide a compensation which might be necessary due to the said different temperature coefficients.
• Figure 1 shows a wind turbine in a perspective view.
• Figure 2 shows schematically two L-shaped sheets for a forming coil.
• FIG. 3 shows a shaping coil or a winding of a shaping coil made of metal sheets according to FIG. 2 in a perspective and schematic representation.
• FIGS. 4 and Figure 5 illustrates different corrugated surfaces in a side view to illustrate the contours.
• FIG. 6 shows a part of a winding of a shaping coil in a perspective view
• FIG. 7 shows a section of a generator arranged in a nacelle.
• FIG. 1 shows a wind energy plant 100 with a tower 102 and a nacelle 104.
• a rotor 106 with three rotor blades 108 and a spinner 110 is arranged on the nacelle 104.
• the rotor 106 is set in rotation by the wind in rotation and thereby drives a generator in the nacelle 104 at.
• FIG. 2 shows a top view of two L-shaped sheets 2. These two L-shaped sheets 2 can have an identical shape and are connected to one another at the connecting seam 4 to form a turn 3. This also overlaps can be avoided from one to the next turn.
• the two L-shaped sheets 2 can be connected to other sheets, namely in a higher or lower position or plane for producing a forming coil, which is not shown here in Figure 2.
• FIG. 4 shows schematically a finished winding 8, which is composed of eight layers and thus 16 L-shaped sheets 2 according to Figure 2.
• the winding 8 thus essentially already forms a forming coil.
• FIG. 4 shows four layers of a winding 8 'in a side view, which corresponds to a view from the right onto the winding 8 according to FIG.
• no connection seam 4 is shown in FIG. 4 and, moreover, not in FIG. Figure 4 is intended to illustrate the outer surface 10 by showing its contour.
• This outer surface 10 is formed from edges of the individual sheets 2 ', which has a curved edge 12 by a pressing operation.
• the layers of these sheets 2 'with their curved edges 12 leads to the illustrated corrugated surface 10, of which the contour is shown in Figure 4 by the selected perspective.
• FIG. 4 also shows a section of a winding 8 ', and between these two windings 8' an air channel 14 is formed whose side walls are shaped by the contour of the outer surfaces 10. It has thus been achieved on the one hand, that the surface of the outer surface 10 is increased by the curved edges 12 and also that results in an air duct 14 with guide grooves or grooves.
• FIG. 5 shows an alternative embodiment of the sheets 2 ". These sheets 2" have cut edges 16, which thus also lead to an outer surface 18 with an enlarged surface.
• FIG. 6 shows, in a perspective view, a part of a winding 68 which is composed of five L-shaped metal sheets 62 at connecting seams 64, respectively.
• the winding 68 and the partial winding 68 of Figure 6 is also shown slightly spread. In this position, this partial winding 68 can be dipped well in a bath of insulating varnish. However, this is illustrated only illustratively and preferably, such an insulation dipping process is proposed only for a complete winding, so if more sheets 62 are still added.
• FIG. 7 shows a generator 130 schematically in a side view. It has a stator 132 and a rotatably mounted electrodynamic rotor 134 and is fastened with its stator 132 via a journal 136 to a machine carrier 138.
• the stator 132 has a stator support 140 and stator lamination stacks 142 which form stator poles of the generator 130 and are secured to the stator support 140 via a stator ring 144.
• the electrodynamic rotor 134 has rotor pole shoes 146, which form the rotor poles and are mounted rotatably about the axis of rotation 152 on the axle journal 136 via a rotor carrier 148 and bearing 150.
• the stator lamination packages 142 and rotor pole shoes 146 only separate a narrow air gap 154, which is a few mm thick, in particular less than 6 mm, but has a diameter of several meters, in particular more than 4 m.
• the stator laminations 142 and the rotor pole shoes 146 form each ring and are also annular, so that the generator 130 is a ring generator.
• the electrodynamic rotor 134 of the generator 130 rotates together with the rotor hub 156 of the aerodynamic rotor, of which lugs of rotor blades 158 are indicated.
• a forming coil of composite sheets is proposed. This form of coil can also be referred to as a pole shoe coil.
• such Polschuhspulen of half or whole turns which are cut from sheets, composed by suitable connection technology.
• Welding, such as friction stir welding, and soldering, for example, are particularly suitable as a joining technique, because in this way the necessary electrically conductive connection can be produced.
• a significant advantage of the invention is to provide improved cooling of the pole piece coils as compared to such wire wound coils. This is achieved in particular by the fact that in each turn of the proposed solution the heat can flow directly to the coil surface.
• cut sheet metal coils can be produced in any two-dimensional geometries and therefore do not require bending gradients. Whereby otherwise wound coils with respect to the heat flow could have similar advantages as the solution proposed here.
• the coils can be given a suitable contour for cooling by means of suitable cutting tools or a suitable after-treatment.
• the coils can be cut obliquely at the outer edge, so that superimposed turns on the outer surface of the coil creates a serrated surface.
• the thus enlarged surface leads to an increased heat transfer to the cooling medium, which is usually air between the poles.
• the individual turns of sheet metal can for example be pressed into a shape such that a cooling lug or cooling rib of suitable geometry is produced at the outer edges.
• a better cooling of the coils is achieved by the invention particularly. Due to the very good heat flow within the conductor material, ie within the sheets of a turn from inside to outside, the heat generated can be given off directly at the coil surface.

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• Engineering & Computer Science (AREA)
• Power Engineering (AREA)
• Life Sciences & Earth Sciences (AREA)
• Sustainable Energy (AREA)
• Sustainable Development (AREA)
• Combustion & Propulsion (AREA)
• Chemical & Material Sciences (AREA)
• Mechanical Engineering (AREA)
• General Engineering & Computer Science (AREA)
• Manufacturing & Machinery (AREA)
• Manufacture Of Motors, Generators (AREA)
• Windings For Motors And Generators (AREA)
• Iron Core Of Rotating Electric Machines (AREA)
• Insulation, Fastening Of Motor, Generator Windings (AREA)
• Connection Of Motors, Electrical Generators, Mechanical Devices, And The Like (AREA)

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• 2015
  • 2015-05-07 DE DE102015208553.8A patent/DE102015208553A1/de not_active Withdrawn
• 2016
  • 2016-04-29 BR BR112017023531A patent/BR112017023531A2/pt not_active Application Discontinuation
  • 2016-04-29 CN CN201680026468.5A patent/CN107580746A/zh active Pending
  • 2016-04-29 JP JP2017557989A patent/JP2018516052A/ja active Pending
  • 2016-04-29 KR KR1020177034995A patent/KR20180003592A/ko not_active Application Discontinuation
  • 2016-04-29 CA CA2983220A patent/CA2983220A1/en not_active Abandoned
  • 2016-04-29 US US15/571,466 patent/US20180131251A1/en not_active Abandoned
  • 2016-04-29 EP EP16719408.3A patent/EP3292615A1/de not_active Withdrawn
  • 2016-04-29 WO PCT/EP2016/059628 patent/WO2016177640A1/de active Application Filing
  • 2016-05-05 UY UY0001036669A patent/UY36669A/es not_active Application Discontinuation
  • 2016-05-06 AR ARP160101303A patent/AR104782A1/es unknown
  • 2016-05-06 TW TW105114204A patent/TW201707350A/zh unknown

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