阅读说明：本技术 关于风力涡轮机中的发电机的冷却的改进 (Improvements relating to cooling of generators in wind turbines ) 是由 P·蒙高 M·根杜斯 于 2020-01-08 设计创作，主要内容包括：在本发明的第一方面中,提供了一种用于风力涡轮机的发电机,所述发电机限定了中心发电机轴线。发电机包括定子支撑框架和可移除地附接到定子支撑框架的环境调节模块。环境调节模块包括由模块壳体支撑的热交换器和鼓风机。环境调节模块还包括与热交换器相关联的流体接口连接件,流体接口连接件可释放地连接到与热交换器相关联的流体供应系统,以及与鼓风机相关联的电接口连接件,电接口连接件可释放地连接到与鼓风机相关联的供电系统。(In a first aspect of the invention, a generator for a wind turbine is provided, the generator defining a central generator axis. The generator includes a stator support frame and an environmental conditioning module removably attached to the stator support frame. The environmental conditioning module includes a heat exchanger and a blower supported by the module housing. The environmental conditioning module also includes a fluid interface connection associated with the heat exchanger that is releasably connectable to a fluid supply system associated with the heat exchanger, and an electrical interface connection associated with the blower that is releasably connectable to a power supply system associated with the blower.)

1. A generator (24) for a wind turbine (1), the generator defining a central generator axis, the generator (24) comprising:

a stator support frame (38); and

an environmental conditioning module (44) removably attached to the stator support frame (38), wherein the environmental conditioning module (44) comprises:

a heat exchanger (58) and a blower (60) supported by a module housing (62);

a fluid interface connection (76) associated with the heat exchanger (58), the fluid interface connection (76) being releasably connectable to a fluid supply system associated with the heat exchanger (58); and

an electrical interface connection (82) associated with the blower (60), the electrical interface connection (82) being releasably connectable to an electrical supply system associated with the blower (60).

2. The generator (24) of claim 1, wherein the environmental conditioning module (44) includes a plurality of separable subassemblies including at least:

a heat exchanger subassembly (64); and

a blower sub-assembly (66), wherein at least one of the sub-assemblies is independently separable from the environmental conditioning module (44) with the environmental conditioning module (44) attached to the stator support frame (38) in situ.

3. The generator (24) of claim 2, wherein at least one of the subassemblies includes an electric motor (63) for driving the blower (60), wherein the electric motor (63) is independently detachable from the environmental conditioning module (44) with the environmental conditioning module (44) attached in situ to the stator support frame (38).

4. The generator (24) of claim 3, wherein the electric motor (63) forms part of the blower sub-assembly (66).

5. The generator (24) according to any one of the preceding claims, wherein the heat exchanger (58) forms at least a portion of an outer surface (86) of the module housing (62).

6. The generator (24) of claim 5, wherein the heat exchanger (58) is substantially planar, and wherein the environmental conditioning module (44) is positioned on the stator support frame (38) such that the heat exchanger (58) forms a portion of a radially innermost surface (86) of the module housing (62) relative to the central generator axis.

7. The generator (24) according to any one of the preceding claims, wherein the module housing (62) includes an access cover (72), wherein the access cover (72) is removable or openable to provide access to the interior of the module housing (62).

8. The generator (24) according to any one of the preceding claims, wherein the module housing (62) forms at least a portion of an outer surface (70) of the generator (24).

9. The generator (24) according to any one of the preceding claims, wherein the generator (24) is substantially cuboidal in shape defining six faces, wherein a first face (46) of the generator (24) is located at a drive end (48) of the generator (24), and wherein a second face (50) is located at an opposite non-drive end (52) of the generator (24), and wherein at least one environmental conditioning module (44) is located substantially at an apex (54) of the generator (24), extending substantially between the first face (46) and the second face (50).

10. The generator (24) of claim 9, wherein the environmental conditioning module (44) is located substantially at each apex (54) of the generator (24), extending substantially between the first and second faces (46, 50).

11. The generator (24) according to any one of the preceding claims, wherein the heat exchanger (58) is a liquid-to-air heat exchanger (58) and the blower (60) comprises a fan.

12. The generator (24) of claim 11, wherein the fan (60) is a centrifugal fan disposed within the module housing (62) such that an axis of rotation of the fan (60) is substantially parallel to the central generator axis.

13. The generator (24) according to any one of the preceding claims, wherein the environmental conditioning module (44) further comprises a temperature sensor and an electrical interface connection (82) associated with the temperature sensor, the electrical interface connection (82) being releasably connectable to an electrical supply system associated with the temperature sensor.

14. A method of cooling a generator (24) for a wind turbine (1), the generator (24) having the features of any of the preceding claims, the method comprising:

operating the generator (24); and

operating the blower (60) of the environmental conditioning module (44) such that air (98, 102) from an interior (56) of the generator (24) is drawn through the heat exchanger (58) into the module housing (62) and then returned to the interior (56) of the generator (24).

15. The method of claim 14, wherein airflow through the environmental conditioning module (44) forms a closed loop such that at least a portion of the air (100) returned to the interior (56) of the generator (24) is drawn back into the module (44).

16. A wind turbine (1) comprising a wind turbine tower (2), a nacelle (4) rotatably coupled to the tower (2), a rotating hub (8) mounted to the nacelle (4) and a plurality of wind turbine blades (10) coupled to the hub, wherein the nacelle (4) comprises a generator (24) according to any of claims 1 to 13.

Technical Field

The present invention relates generally to generators for wind turbines, and more particularly to cooling apparatus for such generators.

Background

In modern commercial scale wind turbines, ensuring that the power generation components are adequately cooled is a particular challenge. For example, a generator located in the nacelle of a wind turbine generates a large amount of heat energy due to the high current flowing through the field windings. Space in the nacelle is limited, and it is therefore challenging to ensure that there is sufficient space in the nacelle and in the generator set for an adequate cooling system.

It is known to implement one or more heat exchangers in the nacelle of a wind turbine. Such a heat exchanger may be located within the stator as in EP3054569a1 or mounted to the generator housing as in WO2017207537a 1. Access to such generator heat exchangers may be limited in the assembled nacelle, which may make maintenance work on the heat exchangers problematic. In some heat exchangers, the design may be such that the entire heat exchanger must be disassembled from the generator in order to service the individual components, which further complicates maintenance work.

Alternatively, the heat exchanger may be located in the nacelle remote from the generator and connected to the generator by piping to provide cooling to the generator components. Such pipes can be cumbersome and must be designed into the architecture of the entire nacelle, compromising space for other components.

It is in this context that the present invention has been developed.

Disclosure of Invention

In a first aspect of the invention, a generator for a wind turbine is provided, the generator defining a central generator axis. The generator includes a stator support frame and an environmental conditioning module removably attached to the stator support frame. The environmental conditioning module includes a heat exchanger and a blower supported by the module housing. The environmental conditioning module further includes: a fluid interface connection associated with the heat exchanger, the fluid interface connection being releasably connectable to a fluid supply system associated with the heat exchanger; and an electrical interface connection associated with the blower, the electrical interface connection being releasably connectable to a power supply system associated with the blower.

The environmental conditioning module may also include a plurality of separable subassemblies including at least one heat exchanger subassembly and a blower subassembly. At least one of the subassemblies is independently separable from the environmental conditioning module with the environmental conditioning module attached to the stator support frame in situ.

At least one of the subassemblies may include an electric motor for driving the blower, and the electric motor may be independently separable from the environmental conditioning module with the environmental conditioning module attached to the stator support frame in situ. The electric motor may form part of a blower sub-assembly.

The heat exchanger may form at least a portion of an outer surface of the module housing. Furthermore, the heat exchanger may be substantially planar and the environmental conditioning module may be positioned on the stator support frame such that the heat exchanger forms a portion of a radially innermost surface of the module housing relative to the central generator axis.

The module housing may include an access cover. The access cover may be removable or openable to provide access to the interior of the module housing. The module housing may form at least a portion of an outer surface of the generator.

The generator may be substantially cuboidal in shape, defining six faces. The first face of the generator may be located at a driving end of the generator and the second face may be located at an opposite, non-driving end of the generator. The at least one environmental conditioning module may be located substantially at an apex of the generator, extending substantially between the first and second faces. The environmental conditioning module may be located substantially at each apex of the generator, extending substantially between the first and second faces.

The heat exchanger may be a liquid-to-air heat exchanger, and the blower may include a fan. The fan may be a centrifugal fan arranged within the module housing such that the axis of rotation of the fan is substantially parallel to the central generator axis.

The environmental conditioning module may also include a temperature sensor and an electrical interface connection associated with the temperature sensor, the electrical interface connection being releasably connectable to a power supply system associated with the temperature sensor.

In another aspect of the invention, a method of cooling a generator for a wind turbine having the features described above is provided. The method includes operating the generator and operating an air mover of the ambient cooling module such that air is drawn from an interior of the generator through the heat exchanger into the module housing and then returned to the interior of the generator. The air flow through the environmental conditioning module preferably forms a closed loop such that at least a portion of the air returning to the interior of the generator is drawn back into the module.

In another aspect of the invention, a wind turbine is provided comprising a wind turbine tower, a nacelle rotatably coupled to the tower, a rotating hub mounted to the nacelle, and a plurality of wind turbine blades coupled to the hub, wherein the nacelle comprises a generator as described above.

Drawings

Non-limiting examples of the present invention will now be described with reference to the accompanying drawings, in which:

FIG. 1 is a schematic perspective view of a horizontal axis wind turbine;

FIG. 2 is a schematic perspective view of functional components of a nacelle of a wind turbine;

FIG. 3 is a schematic perspective view of a portion of a generator and gearbox for a wind turbine;

FIG. 4 is a schematic cross-sectional view of a generator;

FIG. 5 is a schematic perspective exploded view of the generator;

FIG. 6 is a schematic exploded view in plan view orientation of the generator;

FIG. 7 is a schematic perspective view of an environmental conditioning module of the generator;

FIG. 8 is a schematic perspective view of the environmental conditioning module with the access cover removed, an

FIG. 9 is a schematic view of the air flow within the environmental conditioning module and between other components of the generator.

Detailed Description

Reference will now be made in detail to the present embodiments of the present invention, many of which will be discussed in detail in order to provide a thorough understanding of the inventive concepts defined in the claims. It will be apparent, however, to one skilled in the art that the present invention may be practiced without these specific details and that, in some instances, well known methods, techniques and structures have not been described in detail so as not to unnecessarily obscure the present invention.

To place embodiments of the present invention in a suitable environment, reference is first made to fig. 1, which shows a typical Horizontal Axis Wind Turbine (HAWT)1, in which a generator for a wind turbine according to embodiments of the present invention may be implemented. Although this particular image depicts an onshore wind turbine 1, it will be understood that equivalent features will also be found on an offshore wind turbine. Furthermore, although the wind turbine is referred to as a "horizontal axis", those skilled in the art will appreciate that for practical purposes the axis is typically slightly inclined to prevent contact between the rotor blade and the wind turbine tower in the event of strong winds.

The wind turbine 1 includes a tower 2, a nacelle 4 rotatably coupled to a top of the tower 2 by a yaw system 6, a rotating hub 8 mounted to the nacelle 4, and a plurality of wind turbine rotor blades 10 coupled to the hub 8. The nacelle 4 and the rotor blades 10 are turned by the yaw system 6 and directed into the wind direction.

The nacelle 4 houses many of the functional components of the wind turbine 1, including the generator, gearbox, drive train and rotor brake assembly, as well as converter equipment for converting the mechanical energy of the wind into electrical energy for provision to the grid power distribution system. Referring to FIG. 2, the nacelle 4 may include a shaft housing 20, a gearbox 22, and a generator 24. The main shaft extends through the shaft housing 20 and is supported on bearings (not shown). The main shaft is connected to and driven by the hub 8 and provides an input drive to the gearbox 22. The gearbox 22 steps up the rotational speed of the low speed spindle via internal gears (not shown) and drives the gearbox output shaft. The gearbox output shaft in turn drives a generator 24 that converts the rotation of the gearbox output shaft into electrical power. The power generated by the generator 24 may then be converted by other components (not shown) as needed before being supplied to the appropriate consumers (e.g., a grid power distribution system). So-called "direct drive" wind turbines are also known which do not use a gearbox 22. Thus, the gearbox 22 may be considered optional.

The gearbox 22 and generator 24 may be coupled together in an integrated unit. One end of such an integrated unit is shown in fig. 3 to 5 as a specific example. In these figures, the generator 24 is shown coupled to the gearbox 22, which is shown only in partial view. The generator 24 and the gearbox 22 are separate subassemblies that themselves have been coupled together to form a relatively compact, single assembly. A portion of the gearbox 22 is shown on the right hand side of the figure, and the generator 24 is shown on the left hand side of the figure.

Referring first to the gearbox 22, the gearbox housing 30 is generally cylindrical in form and is oriented such that its main axis of rotation is horizontal in the orientation of the drawing. The cylindrical configuration of the gearbox housing 30 depends on the particular type of gearbox 22 used in the illustrated embodiment, which is a planetary gearbox. As is known to those skilled in the art, a planetary gearbox includes a series of planet gears arranged around a central sun gear and collectively disposed within a surrounding ring gear. The ratio of the number of teeth between the ring gear, the planet gears and the sun gear determines the gear ratio of the gearbox. For the sake of clarity, the details of the gearbox 22 will not be described in further detail herein, as the gearbox 22 is not the main subject of the present invention. Suffice it to say that other gearbox configurations may be used, although it is presently envisaged that the planetary gearbox provides an elegant solution adapted to the extent of the wind turbine nacelle 4.

Turning now to the generator 24, the output shaft of the gearbox 22 is engaged with the rotor 32 of the generator 24. Thus, the main axis of the gearbox output shaft defines the axis of rotation of the generator 24.

The generator 24 in the illustrated embodiment is an IPM (interior permanent magnet) machine having an outer stator 34 surrounding a rotor 32. The stator 34 includes a stator core 36. As best shown in fig. 4, the stator core 36 includes a plurality of sheets 40 stacked in the axial direction of the generator 24. An excitation winding 42 made of an electrically conductive material, such as copper, is wound around the sheets 40 of the stator core 36. Electric current is induced in the field windings 42 of the stator core 36 by the fluctuating magnetic field caused by magnets attached to the rotor 32, which in use is rotated by wind driving the rotor blades 10. Although the examples described herein refer to an interior permanent magnet machine, it should be understood that in other examples, other types of generators 24 may be used, for example, the generator 24 may include a rotor 32 having electromagnets rather than permanent magnets.

As discussed by way of background, the high current flowing through the stator field winding 42 results in the release of a large amount of thermal energy due to inherent resistance in the field winding 42. The efficiency of the generator 24 is directly related to the temperature of critical generator components such as the stator core 36 and its field windings 42. To provide cooling to the generator components, at least one Environmental Conditioning Module (ECM)44 is removably attached to the stator support frame 38.

Referring now to the schematic exploded views of the integrated gearbox 22 and generator 24 shown in fig. 5 and 6, the generator 24 in this example includes four environmental conditioning modules 44. Although four environmental conditioning modules 44 are depicted in this example, it will be understood that any number of one or more environmental conditioning modules 44 may be incorporated into the generator 24 without departing from the scope of the present invention as defined in the appended claims.

Each of the environmental conditioning modules 44 of the generator 24 is located radially outward of the stator 34 relative to the central generator axis. In the particular example described herein, the generator 24 is substantially cubical in shape, defining six faces. A first face 46 of the generator 24 is located at a drive end 48 of the generator 24, i.e., the end of the generator 24 closest to the gearbox 22, and a second face 50 is located at an opposite, non-drive end 52 of the generator 24. The plurality of vertices 54 theoretically extend substantially between the first face 46 and the second face 50 of the generator 24, and the at least one ECM44 is located substantially at such vertices 54 of the generator 24. In this example, the generator 24 includes four vertices 54 extending between the first and second faces 46, 50, and the environmental conditioning module 44 is located substantially at each of the vertices 54. It should be appreciated that although each of the vertices 54 of the generator 24 in this example includes the ECM44, in some examples, only one vertex 54 of the generator 24 may include the ECM 44.

In this example, the location of the four environmental conditioning modules 44 optimizes airflow within the generator 24 and reduces the volumetric space requirements of the generator 24 within the nacelle 4. Implementing the environmental conditioning module 44 in the generator 24 results in a closed loop cooling system in which air is circulated within an interior 56 of the generator 24. This eliminates pumping losses and other inefficiencies of known cooling systems implemented outside of the generator 24.

As shown in the exploded views of fig. 5 and 6, environmental conditioning module 44 is a modular subassembly that is independently removable from generator 24. The ECM44 includes a heat exchanger 58 and a blower 60 supported by a module housing 62. In this particular example, the blower 60 includes a centrifugal fan driven by an electric motor 63 (shown in FIG. 7). Each environmental conditioning module 44 additionally includes all required auxiliary connections for the components housed in the ECM 44. In this manner, ECM44 may be removed from generator 24 as a complete unit without requiring complex and time consuming disassembly of generator 24.

Environmental conditioning module 44 includes a plurality of separable subassemblies, wherein at least one of the subassemblies is independently separable from ECM44 with ECM44 attached to stator support frame 38 in situ. In this example, the ECM44 includes the heat exchanger subassembly 64 and the blower subassembly 66, as will be described in more detail below with reference to fig. 7 and 8. In this example, blower subassembly 66 is located at drive end 48 of generator when ECM44 is attached to generator 24. However, it will be appreciated that in some examples, blower sub-assembly 66 may likewise be located at an opposite end of ECM44, i.e., at non-drive end 52 of generator 24, or any other suitable location.

Each ECM44 is attached to the stator support frame 38 by mechanical fastening devices (not shown). The fastening devices may, for example, include nut and bolt assemblies to form compression joints that secure the ECM44 to the stator support frame 38 via the mounting flange 68 of the ECM 44. Notably, environmental conditioning module 44 is attached to stator support frame 38 by non-permanent fastening means that enable ECM44 to be simply detached and reattached, and in some examples, a sealing gasket (not shown) may be included between ECM mounting flange 68 and a corresponding outer surface 70 of generator 24. With the ECM44 assembled to the stator support frame 38, the module housing 62 forms at least a portion of an outer surface 70 of the generator 24.

Fig. 7 shows a schematic perspective view of the environmental conditioning module 44. The module housing 62 includes a removable access cover 72 to provide access to the interior of the module housing 62 for maintenance. In an alternative example, the access cover 72 may be attached to the module housing 62 by a hinge and may open to provide access to the interior of the module housing 62 for maintenance. When attached to the generator 24, the base portion 74 of the ECM44 is located radially inward of the access cover 72 relative to the central generator axis. The heat exchanger 58 forms part of the base portion 74 of the module housing 62, as shown in more detail in fig. 8. In the present example, the removable cover portion 72 defines at least a portion of the outer surface 70 of the generator when the ECM44 is attached to the stator support frame 38 in situ.

A fluid interface connection 76 associated with the heat exchanger 58 extends from an end plate 78 of the module housing 62. When attached to the generator 24 as shown in fig. 3, the fluid interface connection 76 extends from the end plate 78 in a direction substantially parallel to the central generator axis. The fluid interface connection 76 is releasably connectable to a fluid supply system (not shown) associated with the heat exchanger 58. A conduit 80 communicates with the fluid interface connection 76 for conveying cooling fluid to and from the heat exchanger 58 in use.

Electrical interface connections 82 associated with fan 60 are similarly provided external to end plates 78 of module housing 62 so that electrical connections may be made without disassembling ECM44 or generator 24. The electrical interface connector 82 is releasably connectable to a power supply system (not shown) associated with the fan 60. In some examples, ECM44 also includes a temperature sensor, and electrical interface connection 82 thus also includes a connection associated with the temperature sensor. Such an electrical interface connection 82 may be releasably connectable to a power supply system (not shown) associated with the temperature sensor. Internal electrical wiring (not shown) is provided to transfer power from the electrical interface connector 82 to the fan 60 and temperature sensor (if present).

In this example, electric motor 63 forms part of blower sub-assembly 66. The electric motor 63 is accessible from outside of the module housing 62 and is independently separable from the ECM44 with the ECM44 attached to the stator support frame 38 in situ. The electric motor 63 may thus be repaired or replaced in situ without requiring any disassembly of the generator 24 or the ECM44, while the remainder of the ECM44 is attached to the stator frame 38.

In some examples, the electric motor 63 is a variable frequency drive motor. In such an example, the total airflow within the generator 24 may be specifically controlled by individually controlling the variable frequency drives 63. The cooling profile within generator 24 may be adjusted by controlling variable frequency drives 63 of each ECM44 to reflect the different loss profiles associated with the lead and power connections. The variable frequency drive 63 may be controlled based on feedback from sensors in the ECM44 and the generator 24 (e.g., the temperature sensors described above).

Fig. 8 illustrates a schematic perspective view of the ECM44 with the access cover 72 removed to reveal the interior of the module housing 62 and the components included within the ECM 44. The heat exchanger subassembly 64 includes the liquid-to-gas heat exchanger 58. As noted above, the heat exchanger subassembly 64 includes a fluid connection in the form of a conduit 80. The conduit 80 extends from the heat exchanger 58 through a dividing wall 84 of the module housing 62 to the fluid interface connection 76.

As shown in fig. 8, the heat exchanger 58 is substantially planar and forms a portion of the outer surface 86 of the module housing 62. In a fully assembled generator 24, the ECM44 is attached to the stator support frame 38 such that the heat exchanger 58 forms a portion of the radially innermost surface 86 of the module housing 62 relative to the central generator axis.

The blower sub-assembly 66 may be separate from the heat exchanger sub-assembly 64 and may be separate from the heat exchanger sub-assembly while the remainder of the ECM44 is attached to the stator support frame 38. Blower subassembly 66 may be detached from heat exchanger subassembly 64 by moving blower subassembly 66 in the direction of arrow 88. With the ECM44 attached to the stator frame 38, the direction of arrow 88 is substantially parallel to the central generator axis, and the blower sub-assembly 66 may thus be decoupled from the heat exchanger sub-assembly 64 in the axial direction of the generator 24.

The fan 60 is disposed in the module housing 62 such that the axis of rotation of the fan is substantially parallel to the central generator axis when the ECM44 is attached to the stator frame 38. In use, the blower 60 is operated to draw air from the interior 56 of the generator 24 through the heat exchanger 58 and into the module housing 62. Air is drawn into the module housing 62 through the spaces 90 between the cooling fins 92 of the heat exchanger 58 before entering the blower sub-assembly 66 via the air inlet cone 94. The centrifugal fan 60 then discharges the cooling air that has been cooled by passing through the heat exchanger 58 through an aperture 96 in the module housing 62 to return the cooling air to the interior 56 of the generator 24, thereby forming a closed loop cooling system.

FIG. 9 is a schematic diagram illustrating a closed loop air flow path within one of the environmental conditioning modules 44 and through other components of the generator 24. The air flow paths are shown by arrows 98, 100, 102. As described with reference to fig. 9, warm air 98 heated by the rotor 32 and stator 34 of the generator 24 is drawn into the module housing 62 of the ECM44 by the blower 60. Air 98 is drawn into module housing 62 through heat exchanger 58, by which air 98 is cooled. Cooling air 100 is drawn into blower subassembly 66 through dividing wall 84.

Cooling air 100 is discharged from ECM44 to interior 56 of generator 24 via centrifugal fan 60 of blower sub-assembly 66. The cooling air 100 is directed to the radially inner components of the generator relative to the central generator axis. Thus, this arrangement results in a low pressure drop as the coolest air 100 exiting the ECM44 is directed to the innermost surface of the rotor 32. In use, rotation of the rotor 32 further facilitates air flow. The rotation of the rotor 32 results in a degree of self-pumping, wherein the air 100 in the interior region 56 is caused to flow outwardly in the radial direction Y through the stator 34 and through centrifugal force to the environmental conditioning module 44.

In examples where the rotor 32 includes permanent magnets, it is of particular interest to ensure that the generator components are adequately cooled, since magnets are particularly sensitive to heat and prolonged exposure to high temperatures can cause accelerated degradation thereof. In the arrangement schematically illustrated in fig. 9, the cooling air 100 exiting the ECM44 is incident on the rotor 32, and thus on any permanent magnets, while the air 100 is at a low temperature, i.e., before providing cooling to other generator components, such as the stator 34. After passing through the rotor 32 and any magnets attached to the rotor, the air 102 flows through the stator 34 of the generator 24 to provide cooling to the stator core 36 and associated stator windings 42.