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NEW STATOR CORE MANUFACTURING CONCEPTIONS

by Prof. Dr.-Ing. Friedrich Klinger

INNOWIND Forschunggesellschaft mbH 66115 Saarbrcken, Germany f.klinger@wind-energy-research.de

Content

1. Direct Drive generators in wind turbines 2. Punching and stacking by slinky concept 3. Manufacturing steps for the stator core 4. Concepts for automated stacking 5. Manufacturing 3000 wind turbines per year

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CWIEME BERLIN 2011

Direct Drive Generators

- Generators with outer rotor

Vensys 90

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Direct Drive Generators

Generators with inner rotor

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CWIEME BERLIN 2011

Direct Drive Generators

Generators with outer rotor

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CWIEME BERLIN 2011

Direct Drive Generators

Lamination stack

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CWIEME BERLIN 2011

Punching and stacking by slinky concept

slinky machine

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CWIEME BERLIN 2011

Punching and stacking by slinky concept

lamination for outer rotor

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CWIEME BERLIN 2011

Punching and stacking by slinky concept

lamination for inner rotor

Origin: The Switch

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CWIEME BERLIN 2011

Punching and stacking by slinky concept

punching and stacking machine

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CWIEME BERLIN 2011

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Punching and stacking by slinky concept

slinky machine with lift

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Manufacturing steps for the stator core

procedure of stator production

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CWIEME BERLIN 2011

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Manufacturing steps for the stator core

sheet segment with support structure

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CWIEME BERLIN 2011

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Manufacturing steps for the stator core

sheet segment band

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CWIEME BERLIN 2011

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Manufacturing steps for the stator core

Segment for inside stator

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CWIEME BERLIN 2011

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Manufacturing steps for the stator core

axial fixation of the stack

simplified lamination

Claming element
e.g. cup spring

Pressure plate 10mm

Profile
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Bar
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CWIEME BERLIN 2011

Concepts for automated stacking of segments

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Manufacturing 3000 wind turbines per year

Stator data and stacking time

Air gap diameter: Number of slots: Segments per layer: Core axial length: Total number of segments: Time per cycle: Number of robots: Number of parallel segments per robot and cycle: Netto stacking time: Time for pressing and other: Total time:

5200mm 384 24 1200mm 24 x 1200mm/0,5mm = 57600 2s/cycle 2 4 2 x 57600/(4x2) = 14400s = 4h 4h 8h

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CWIEME BERLIN 2011

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Manufacturing 3000 wind turbines per year

layout for stacking unit

Automated stacking in 8 hours. 6 automated stacking stations are needed to manufacture 3000 stators per year, 250 working days and 2 shifts

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CWIEME BERLIN 2011

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Automatic Stator core stacking

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Automatic Stator core stacking

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CWIEME BERLIN 2011

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Automatic Stator core stacking

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CWIEME BERLIN 2011

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