Patent Application
20240204619
This application claims priority to EP Application No. 22213893.5, having a filing date of Dec. 15, 2022, the entire contents of which are hereby incorporated by reference.
The following relates to an electric generator for a wind turbine, comprising a stator and a rotor having two axial ends opposed to each other, wherein a liquid cooling arrangement for cooling the stator by guiding a cooling liquid through the stator is provided.
An electric generator comprises the stator and the rotor, wherein the rotor rotates relative to the stator about an axial direction. The electric generator can be a permanent-magnet generator with a plurality of permanent magnets and an electric circuit which is constituted by a plurality of stator windings forming coils. The rotation of the rotor causes a change of the magnetic field in the wires of the stator windings which in turn cause an electric current in the electric circuit. Assuming that the electric generator is provided in a wind turbine, the wind-driven rotation of the rotor causes the rotation of the rotor and, hence, the electric current in the electric circuit which is used for energy or power generation.
Since the size of modern wind turbines become larger and larger, higher wind turbine output powers are generated. However, higher output powers result in higher torque densities in the electric generator which in turn cause higher operating temperatures in the stator and the rotor. Hence, it is essential to sufficiently cool these components, particularly the stator, since the stator- or wire windings are strongly affected by these high temperatures. To mitigate the temperature of the wire- or stator windings and also the temperature of the permanent magnets, air- and liquid cooling systems are disclosed in the state of the conventional art, particularly in EP 2 518 868 A1, EP 2 182 619 A1 and CN 110 676 980 A. In these cooling systems, a cooling liquid is guided through the stator.
An aspect relates to an improved cooling concept for an electric generator.
To solve this problem, according to embodiments of the present invention, the electric generator as described initially is characterized in that at least two side ports which are arranged at the two opposite axial ends of the stator and at least one central port which is arranged at an axial center of the stator are provided, wherein the liquid cooling arrangement comprises at least one fluid channel for leading the cooling liquid bidirectionally through the stator such that the cooling liquid either enters the stator through the side ports and leaves the stator through the central port or enters the stator through the central port and leaves the stator through the side ports.
Embodiments of the present invention are based on the idea that not the complete amount of the cooling liquid has to be guided through the entire axial length of the stator. According to embodiments of the present invention, a cooling liquid current is split into several branches, wherein each branch is guided through a respective part of the axial length of the stator. The fluid channel can be shaped such that at all axial positions of the stator, the cooling fluid of the respective branch passes this position only once, particularly to avoid a meander-like structure of the fluid channel. In summary, all axial parts of the stator can be flown through and, hence, cooled by at least one of the branches. The flowing direction of the cooling liquid within the branches can be opposite to each other such that the bidirectional flow is created. As a consequence, for each of the branches, the time span while the respective cooling liquid flows through the stator and the respective length of the flow path through the stator is decreased such that the temperature of the cooling liquid flowing through the stator is lower compared to the case where the cooling liquid flows through the entire axial length of the stator. Thus, the temperature difference between the cooling liquid and the stator is larger at all axial positions such that the energy or heat transfer from the stator to the cooling liquid is larger. Hence, the cooling efficiency is improved.
According to a first embodiment of the present invention, the cooling liquid enters the stator through the side ports and leaves the stator through the central port. In this embodiment, the side ports constitute an entrance port each and the central port constitutes an outlet port for the cooling fluid. In this embodiment, two cooling fluid currents or flows are provided, where each current is guided into the stator through the side ports. Regarding the axial direction, these two currents can have opposite flow directions which point towards each other. After flowing through the respective axial sections of the stator, these two currents can combine or unify and leave the stator through the central port.
According to a second embodiment of the present invention, the cooling liquid enters the stator through the central port and leaves the stator through the side ports. In this embodiment, the side ports constitute an outlet port each and the central port constitutes an entrance port for the cooling fluid. Also in this embodiment, two cooling fluid currents or flows are provided, where each current is guided into the stator through the central port or ports. Regarding the axial direction, these two currents can have opposite flow directions which point away from each other. The cooling fluid can be guided within one current and be split into at least two currents before, when or after entering the stator. After flowing through the respective axial sections of the stator, these two currents can leave the stator through the side ports.
The axial direction of the stator can be defined by the axis or direction about the rotor is rotating. The stator can be cylindrical or hollow-cylindrical in shape, wherein the longitudinal direction of the respective cylinder can define the axial direction. A radial direction can be defined as the direction pointing radially outwards from the axial direction. A circumferential direction can be defined as the direction pointing tangentially away from the radial direction, i.e., into the direction in which a point which rotates about the axial direction is moving.
The axial end of the stator can consist of the outermost axial part of the stator and particularly the part of the stator which is immediately adjacent to the outermost axial part. If the stator is cylindrical or hollow-cylindrical in shape, the outermost axial part is one of the axial front faces of the stator. The axial center of the stator can consist of the middle axial section of the stator. The axial center can be defined as the part of the stator which is arranged between the axial ends.
The generator can comprise a housing, wherein the stator and the rotor are arranged within the housing. While the stator is non-rotating, the rotor can rotate about the axial direction. The stator can comprise a stator body which can be carried by a, particularly cylindrical shaped, stator support structure. The stator body can have a segmented structure comprising several, exemplarily six, segments. The stator body can comprise a stator yoke and a plurality of teeth which protrude into the radial direction and/or which can be evenly spaced along the circumferential direction. Two adjacent teeth can laterally delimit a slot each, wherein the stator windings for realizing the coils are arranged within the slots. The windings can comprise end-windings having particularly a curved shape to connect the windings arranged in two adjacent slots. The rotor can comprise a plurality of permanent magnets which arranged, particularly evenly spaced, along the circumferential direction.
The liquid cooling arrangement can constitute a closed system. In an embodiment, the cooling liquid circulates in a cooling circuit, particularly comprising a pump for circulating the cooling liquid and at least one chiller unit, e.g., a heat exchanger and/or a condenser and/or an evaporator to cool the cooling fluid before it is again guided through the stator. The cooling circuit splits up into several separate branches before or within the stator.
The at least one fluid channel or at least the part of the at least one fluid channel which is arranged in the stator can consist of at least one pipe or of at least one duct. The at least one pipe or the at least one duct is made of one single piece, which is particularly connected with further elements, e.g., at least one stub, constituting or being connected with the respective port. The pipe or duct can be made of a material with a high thermal conductivity, e.g., a metal like steel or the like.
The at least one fluid channel or at least the part of the at least one fluid channel which is arranged in the stator can be constituted by at least one hollow section of the stator. Openings of the surface of the stator leading into the hollow section can constitute the respective ports.
The fluid channel has a longitudinal direction, wherein the fluid flowing through the fluid channel flows along the longitudinal direction. Hence, the longitudinal direction can be defined by the flow path of the cooling liquid flowing through the respective fluid channel. The longitudinal direction can be linear and/or bent and/or can even comprise angles. If the longitudinal direction is linear or straight, particularly over the entire length of the fluid channel, the longitudinal direction of the fluid channel can be the axial direction of the stator.
At least one of the longitudinal ends of the at least one fluid channel or at least one stub which is connected with one of the longitudinal ends of at least one the fluid channel can constitute the respective side port. Additionally, or alternatively, a longitudinal center of the at least one fluid channel or a lateral opening arranged at the longitudinal center, respectively, can be connected with at least one stub which constitutes the respective central port. The longitudinal end and/or the stub can protrude from the surface of the stator, wherein the longitudinal end and/or the stub can be connected with a connection pipe of the liquid cooling arrangement. The connection pipe, which can also be a, particularly flexible, tube or hose, can be a part of the cooling circuit and can lead to the pump and/or the chiller unit. The connection pipe can be made of a plastic or metallic material and can be particularly constituted by a bendable metal- or PTFE-hose. The connection pipe can be connected to the fluid channel, e.g., the pipe or duct, by a connection means like a hose clamper and/or can be plugged on the longitudinal end of the pipe.
The electric generator according to embodiments of the present invention can be characterized in that the cooling liquid enters the stator through the side ports along the axial direction or the radial direction and leaves the stator through the central port along a radial direction. Alternatively, the cooling liquid can enter the stator through the central port along the radial direction and leaves the stator through the side ports along the axial direction or the radial direction. These configurations can be realized by respective shapes of the fluid channels and/or components which are connected with the fluid channels, particularly the stubs. If the cooling liquid leaves or enters the stator through the side ports along the axial direction, the side ports can be arranged on the outermost axial part of the stator. If the cooling liquid leaves or enters the stator through the side ports and/or the central port along the radial direction, the respective port can be arranged on a circumferential side of the stator.
In a possible embodiment of the electric generator according to the present invention, the fluid channel comprises two longitudinal ends which constitute or communicate with one of the side ports arranged at opposite axial ends of the stator each, wherein the fluid channel comprises a longitudinal center section which constitutes or communicates with the at least one central port. In this embodiment, at least one fluid channel which can be the or a pipe or duct extends through the entire axial length of the stator, wherein the longitudinal ends of this fluid channel constitute or communicate with the side ports. In the longitudinal center section of the fluid channel, particularly in the middle of the fluid channel, the central port can be arranged. The central port can be constituted by a lateral opening of the fluid channel or by a stub which is connected to the fluid channel. In this embodiment, both branches of the liquid cooling arrangement are guided within the same fluid channel.
The electric generator according to embodiments of the present invention can be characterized in that at least one first fluid channel and at least one second fluid channel and at least two central ports are provided. In this embodiment, the first fluid channel and the second fluid channel, which are particularly pipes or ducts, comprise two longitudinal ends each. One of the longitudinal ends of each of the fluid channels communicates with one of the side ports and the other longitudinal end constitutes or communicates with one of the central ports. Hence, in this embodiment, at least two fluid channels are provided, wherein each of the fluid channels constitute or communicate with one of the side ports and one of the central ports. In this embodiment, the branches of the liquid cooling arrangement are guided within several fluid channels. One of the longitudinal ends of the respective fluid channel can be connected with the central port by an elbow stub.
If the at least one first fluid channel and the at least one second fluid channel and the at least two central ports are provided, the longitudinal directions of the fluid channels can extend collinearly along the axial direction. In this embodiment, each fluid channel extends over a certain axial part of the stator. Particularly, the fluid channels comprise equal lengths such that the flow paths of the cooling liquid of the branches are equal in length.
Alternatively, the longitudinal directions of the fluid channels can extend offset to each other with respect to a radial direction and/or a circumferential direction. In this embodiment, the longitudinal directions of the fluid channels are shifted along the radial direction and/or the circumferential direction. Hence, the fluid channels are not collinearly with respect to each other. Particularly, the longitudinal directions of the fluid channels can extend along the axial direction. In this case, the longitudinal directions of the fluid channels are parallel to the axial direction but are shifted along the radial direction and/or the circumferential direction.
It is desired that the first fluid channel and the second fluid channel overlap each other with respect to the axial direction. In this embodiment, the axial sections of the stator in which one of fluid channels is located can intersect. Hence, the cooling effect of the respective part of the stator where the fluid channels overlap each other is enhanced.
The fluid channels can extend through the stator at least partially along an inclined direction with respect to the axial direction. In this embodiment, there is an angle between the longitudinal direction of the fluid channel and the axial direction, wherein this angle is greater than 0° and less than 90°, particularly greater than 5° and less than 20°, exactly 10°. Assuming that the stator is a hollow component, particularly with the shape of a hollow cylinder, one of the longitudinal ends can be located at one of the outermost axial parts of the stator and the other longitudinal end can be arranged at or in the hollow space of the stator.
In an embodiment of the electric generator according to the present invention, an air gap is arranged between the stator and the rotor, wherein at least one air cooling arrangement for guiding air through the air gap is provided. In this embodiment, the air cooling arrangement and the liquid cooling arrangement constitute a hybrid cooling arrangement where air as well as the cooling liquid is used as a cooling means. Hence, a system is realized where a cooling effect for the stator as well as for the rotor is realized. Cooling the rotor might be necessary, since the permanent magnets of the rotor can be heated during the energy production. The air gap can have a width in the order of millimeters.
The air cooling arrangement and the liquid cooling arrangement can work independently from each other. However, the air cooling arrangement and the liquid cooling arrangement can be linked by a heat exchanger such that heat can be transferred from the air to the cooling liquid and/or vice versa.
The air cooling arrangement can be an open system where air from an environment of the wind turbine is guided through the air gap and then emitted into the environment again by a fan. Alternatively, the air cooling arrangement can constitute a closed system, i.e., a circuit where the air is circulated. A fan for moving the air can be provided as well as a chiller unit in the air cooling arrangement.
At least two air side ports which are arranged at the opposite axial ends of the air gap can be provided, wherein the air enters the air gap through one of the air side ports and leaves the air gap through the other air side port. In this embodiment, air enters the air gap, regarding the axial direction, from the one side and leaves the air gap on the other side. Hence, a unidirectional air flow through the air gap can be realized. The stator and the rotor can be arranged within a housing of the electric generator. The area in the housing which is located at the outermost axial part of the stator and of the rotor can constitute the air side port.
In another embodiment of the present invention, at least two air side ports which are arranged at the opposite axial ends of the air gap and at least one air central port which is arranged at an axial center of the air gap are provided, wherein the air either enters the air gap through the air side ports and leaves the air gap through the air central port or enters the air gap through the air central port and leaves the air gap through the air side ports. In this embodiment, the air current is split into several branches, wherein each branch is guided through a respective part of the axial length of the air gap. The flowing direction of the air within the branches can be opposite to each other. Hence, a bidirectional air flow can be created in the air gap.
In an embodiment, the stator comprises at least one air duct which extends through the stator along the radial direction, wherein the air central port communicates with the air gap by the air duct. Particularly, the stator can comprise a plurality of axial portions which are arranged along the axial direction, wherein the portions are separated from each other by the at least one air duct. The air ducts can be distributed, particularly evenly, along a certain axial part of the stator, particularly over the complete axial length of the stator. The air can enter or leave the air gap via the air ducts. In this embodiment, the air additionally flows through the stator and causes an additional cooling effect regarding the elements of the stator, particularly the stator- or wire windings.
The electric generator according to embodiments of the present invention can comprise a distributed stator winding. In this embodiment, each coil or winding is housed or arranged in different slots which are not adjacent to each other. Having the distributed stator winding, the coil- or winding temperatures are expected to be higher on the axial ends than in axial center. Hence, in this embodiment, the cooling liquid enters the stator through the side ports and leaves the stator through the central port. The same holds true for the air of the air cooling arrangement.
Alternatively, the electric generator according to embodiments of the present invention can comprise a concentrated stator winding. In this embodiment, each coil or winding is wound around one tooth or, in other words, housed in two adjacent slots. Having the concentrated generator winding, the coil- or winding temperatures are expected to be higher in the axial center than on the axial ends. Hence, in this embodiment, the cooling liquid enters the stator through the central port and leaves the stator through the side ports. The same holds true for the air of the air-cooling arrangement.
Additionally, embodiments of the present invention relate to a wind turbine, comprising at least one electric generator according to the foregoing description. All advantages and features which have been described with respect to the electric generator according to embodiments of the present invention can be applied to the wind turbine according to embodiments of the present invention and vice versa.
The wind turbine can comprise a tower on which a nacelle is arranged and a hub with several, particularly three, blades. The hub can be rotated about the axial direction, wherein the respective rotation is driven by wind which interacts with the blades. The rotation of the hub can be transferred to the rotor of the electric generator by a main shaft which extends along the axial direction. The total height of the wind turbine can be in the order of tens or hundreds of meters. The output power of the wind turbine can be in the range of multi-Megawatts, particularly between 1 and 40 Megawatts. The wind turbine can be an onshore- or an offshore wind turbine.
Some of the embodiments will be described in detail, with reference to the following figures, wherein like designations denote like members, wherein:
The electric generator 7 comprises a housing 9, a stator 10 and a rotor 11, wherein the stator 10 and the rotor 11 are arranged within the housing 9. The stator 10 is non-rotating. The rotor 11 is connected with the main shaft 9 such that the rotation of the hub 4 is transferred to the rotor 11 which can also rotate about the axial direction 6.
The stator body 13 comprises a stator yoke 15 and a plurality of teeth 16 which protrude into a radial direction 17. The teeth 16 are evenly spaced along a circumferential direction 23. Two adjacent teeth 16 laterally delimit a slot 18 each. Within the slots 18, stator windings 19 for realizing coils are arranged. The windings 19 comprise end-windings 20 which have a curved shape and connect the windings 19 of several, particularly adjacent, slots 18. For separating the stator windings 19 from the air gap 12, wedges 21 are arranged at the radial ends of the slots 18.
The rotor 11 comprises a plurality of permanent magnets 22 which are arranged evenly spaced along the circumferential direction 23.
The electric generator 7 furthermore comprises a liquid cooling arrangement 24 for cooling the stator 10 by guiding a cooling liquid 25 through the stator 10. Details regarding a first concrete embodiment of the liquid cooling arrangement 24 are shown in
As can be seen in
In the embodiment of
Regarding the embodiment of
Regarding the embodiment of
Although in
With reference to
In contrast to the embodiment of
In the embodiment of
The air-cooling arrangement 33 comprises two air side ports 38 which are arranged at the opposite axial ends of the air gap 12. The air 37 enters the air gap 12 through one of the air side ports 38 and leaves the air gap through the other air side port 38. Hence, a unidirectional air flow through the air gap 12 is realized.
With reference to
In the embodiment of
The air-cooling arrangement 33 of
To realize the air flow between the air gap 12 and the air central port 40, these sections are connected via air ducts 41 which extend through the stator 10 along the radial direction 17. The stator 10 comprises a plurality of axial portions 42 which are arranged along the axial direction 6, wherein the portions 42 are separated from each other by the air ducts 41. The air ducts 41 are evenly distributed along the axial direction 6.
While this is not shown in the other figures, the air-cooling arrangement 33 which has been explained with the help of
Concretely, these directions are offset with respect to the circumferential direction 23. Additionally, or alternatively, these directions can be offset with respect to the radial direction 17. In the configuration of
As can be seen in
Regarding the production of the electric generator 7 according to embodiments of the present invention, in the following two concrete and exemplary methods are described. According to a first possible production method, the pipes constituting the fluid channels 30, 43, 44 can be inserted into the stator 10, particularly into the support structure 14 and/or into the stator yoke 15 using a shrink-fitting technique. This technique ensures a sufficient contact between the fluid channels 30, 43, 44 with other components of the stator 10 to allow for a sufficient heat transfer from the cooling liquid 25 to these components. This technique can be used for all embodiments which have been described before. According to a second possible production method, which particularly corresponds to the embodiment of
Although the present invention has been disclosed in the form of embodiments and variations thereon, it will be understood that numerous additional modifications and variations could be made thereto without departing from the scope of the invention.
For the sake of clarity, it is to be understood that the use of “a” or “an” throughout this application does not exclude a plurality, and “comprising” does not exclude other steps or elements.
| Number | Date | Country | Kind |
|---|---|---|---|
| 22213893.5 | Dec 2022 | EP | regional |
