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| Optimization Design of Stator Core Pipe for Evaporative Cooling Wind Generators Considering the Influence of Electromagnetic and Heat Transfer |
| Cheng Ziran1, Wang Yu2, Gao Jian1, Huang Shoudao1, Ruan Lin2,3 |
1. College of Electrical and Information Engineering Hunan University Changsha 410082 China;
2. Institute of Electrical Engineering Chinese Academy of Sciences Beijing 100190 China;
3. University of Chinese Academy of Sciences Beijing 100049 China |
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Abstract In recent years, with the rapid development of renewable energy, the capacity of wind generators has increased, and the problems of loss and heating are becoming more and more serious. Excessive operating temperatures will harm the safe operation of wind generators. Evaporative cooling technology can greatly improve the generator’s cooling efficiency. The whole system has many advantages, such as simple maintenance, safety, reliability, and more. Many scholars have researched electromagnetic and cooling performance analysis modeling and wind generator optimization. However, the influence of small changes in the stator’s local structure on electromagnetic performance and the contact thermal resistance on cooling performance is often ignored. Therefore, a collaborative optimization strategy of electromagnetic and cooling performance is proposed based on the electromagnetic and heat transfer sensitivity analysis of the design unit. Through experiments, the thermal contact resistance between the hollow cooling tube and the core interface is measured, and the heat transfer characteristics of the hollow cooling tube under the self-circulation characteristics of a small dip angle are analyzed. The optimization design of a 10 MW direct drive wind turbine is carried out.
Firstly, the influence of the stator core’s cooling pipe structure on electromagnetic and cooling performance of wind generators is analyzed based on the operating characteristics of wind generators and the element sensitivity method. Secondly, the heat transfer capacity and contact thermal resistance of hollow round copper pipe are analyzed and tested through the heat transfer experiment of self-circulating pipe with a small dip angle and the temperature rise experiment of contact thermal resistance. Thirdly, the optimization model of the stator core cooling structure is established. Finally, the optimization design of the stator core cooling structure is studied and verified by finite element analysis.
The self-recirculating cooling system with a small dip angle experiment shows that the critical heat flux of a 1 500 mm hollow copper tube is 8 303 W/m2 when the condenser height is 900 mm, and the inlet temperature of cooling water is 20℃. The variation trend of the convective heat transfer coefficient of the evaporative cooling medium with heat flux is revealed by experiments, and the standard deviation of the fitted curve is 2.05. The contact thermal resistance experiment shows that when the hole/shaft matching accuracy is H7/h7, the roughness of DW470-50 is Ra3.2 μm, the heat flux is 9 549 W/m2, the contact thermal resistance between the iron core and the hollow copper tube with the roughness of Ra1.6 μm, Ra3.2 μm, and Ra 6.4 μm is 7.644 8×10-5 m2·K/W, 8.901 5×10-5 m2·K/W, and 9.425 1×10-5 m2·K/W, respectively. Finally, evaporation cooling wind generators of three different configurations using stator core pipe structures are optimized based on the sensitivity analysis strategy.
The following conclusions can be drawn from the simulation analysis: (1) The established influence analysis model can analyze the influence of the stator cooling tube’s design elements on the electromagnetic and cooling performance of wind generators. (2) Based on the small-dip self-circulation test platform and the contact thermal resistance test platform, the relationship between the cooling performance of the core tube and the loaded heat flux is obtained. It shows that wind generators’ new evaporative cooling technology has good thermal conductivity. (3) The finite element simulation method verifies that the three optimization schemes can meet the requirements of electromagnetic and winding maximum temperature rise constraints.
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Received: 09 January 2023
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2024, Vol. 39 
