slinky lam stacks
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NEW STATOR CORE MANUFACTURING CONCEPTIONSby Prof. Dr.-Ing. Friedrich Klinger
INNOWIND Forschunggesellschaft mbH66115 Saarbrücken, Germany
f.klinger@wind-energy-research.de
CWIEME BERLIN 2011 224. May 2011
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
CWIEME BERLIN 2011 324. May 2011
Direct Drive Generators - Generators with outer rotor
Vensys 90
CWIEME BERLIN 2011 424. May 2011
Direct Drive Generators – Generators with inner rotor
CWIEME BERLIN 2011 524. May 2011
Direct Drive Generators – Generators with outer rotor
CWIEME BERLIN 2011 624. May 2011
Direct Drive Generators – Lamination stack
CWIEME BERLIN 2011 724. May 2011
Punching and stacking by slinky concept – slinky machine
CWIEME BERLIN 2011 824. May 2011
Punching and stacking by slinky concept – lamination for outer rotor
CWIEME BERLIN 2011 924. May 2011
Origin: The Switch
Punching and stacking by slinky concept – lamination for inner rotor
CWIEME BERLIN 2011 1024. May 2011
Punching and stacking by slinky concept – punching and stacking machine
CWIEME BERLIN 2011 1124. May 2011
Punching and stacking by slinky concept – slinky machine with lift
CWIEME BERLIN 2011 1224. May 2011
Manufacturing steps for the stator core – procedure of stator production
CWIEME BERLIN 2011 1324. May 2011
Manufacturing steps for the stator core – sheet segment with support structure
CWIEME BERLIN 2011 1424. May 2011
Manufacturing steps for the stator core – sheet segment band
CWIEME BERLIN 2011 1524. May 2011
Manufacturing steps for the stator core – Segment for inside stator
CWIEME BERLIN 2011 1624. May 2011
simplified lamination
Pressure plate 10mm
BarProfile
Claming element e.g. cup spring
Manufacturing steps for the stator core – axial fixation of the stack
CWIEME BERLIN 2011 1724. May 2011
Concepts for automated stacking of segments
CWIEME BERLIN 2011 1824. May 2011
Manufacturing 3000 wind turbines per year – Stator data and stacking time
Air gap diameter: 5200mmNumber of slots: 384Segments per layer: 24Core axial length: 1200mmTotal number of segments: 24 x 1200mm/0,5mm = 57600
Time per cycle: 2s/cycleNumber of robots: 2Number of parallel segmentsper robot and cycle: 4Netto stacking time: 2 x 57600/(4x2) = 14400s = 4hTime for pressing and other: 4h
Total time: 8h
CWIEME BERLIN 2011 1924. May 2011
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
CWIEME BERLIN 2011 2024. May 2011
Automatic Stator core stacking
CWIEME BERLIN 2011 2124. May 2011
Automatic Stator core stacking
CWIEME BERLIN 2011 2224. May 2011
Automatic Stator core stacking
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