Rotor assembly, electromechanical transducer and wind turbine

Abstract

A rotor assembly for an electromechanical transducer is provided. The rotor assembly comprises a mechanical support structure and a magnet arrangement having a first magnetic component part and a second magnetic component part. The first magnetic component part and the second magnetic component part are attached to the mechanical support structure and are arranged along an axial direction (Z) of the rotor assembly. With respect to the axial direction a first cross section of the first magnetic component part has a first shape and a second cross section of the second magnetic component part has a second shape being different from the first shape. It is further described an electromechanical transducer and a wind turbine, which are both equipped with such a rotor assembly.

Claims

1. A rotor assembly for an electromechanical transducer, the rotor assembly comprising: a mechanical support structure; and a magnet arrangement having: (i) a first magnetic component part; and (ii) a second magnetic component part, wherein the first magnetic component part and the second magnetic component part are attached to the mechanical support structure and are arranged along an axial direction of the rotor assembly, wherein with respect to the axial direction of the rotor assembly; (a) a first cross section of the first magnetic component part has a first shape; and (b) a second cross section of the second magnetic component part has a second shape being different from the first shape and wherein the first magnetic component part and/or the second magnetic component part have a gradually varying cross sectional shape along an axial and radially outer circumferential direction of the first and the second shapes, wherein the first shape is positioned next to the second shape and wherein the first and the second shapes are both on the same parallel axis in the axial direction of the rotor assembly, wherein the first shape is a first geometrically irregular shape and the second shape is a second geometrically irregular shape and wherein the first magnetic component part and the second magnetic component part are separate magnetic pieces.

2. The rotor assembly as set forth in claim 1, wherein the magnet arrangement comprises a mounting structure having a contour and the mechanical support structure comprises a complementary mounting structure having a complementary contour with respect to the contour, wherein the complementary contour is engaged with the contour.

3. The rotor assembly as set forth in claim 2, wherein the contour and/or the complementary contour is formed in a dove tail manner.

4. The rotor assembly as set forth in claim 1, wherein the first magnetic component and second magnetic component part form a magnet arrangement which is realized in a monolithic manner.

5. The rotor assembly as set forth in claim 1, wherein the magnet arrangement further comprises: at least one further magnetic component part, wherein the at least one further magnetic component part (a) is attached to the mechanical support structure, (b) is arranged along the axial direction with respect to the first magnetic component part and the second magnetic component part, and is located in between the first magnetic component part and the second magnetic component part, wherein with respect to the axial direction a third cross section of the at least one further magnetic component part has a third shape and the third shape is different at least from the second shape.

6. The rotor assembly as set forth in claim 5, wherein with respect to the second magnetic component part the magnet arrangement comprises a symmetry along the axial direction.

7. An electromechanical transducer comprising: a stator assembly and a rotor assembly as set forth in claim 1.

8. A wind turbine for generating electrical power, the wind turbine comprising: a tower, a nacelle which is arranged at a top end of the tower, a rotor which is arranged at a front end of the nacelle and which comprises at least one blade, and an electromechanical transducer as set forth in claim 7, wherein the electromechanical transducer is mechanically coupled with the rotor.

Description

BRIEF DESCRIPTION

(1) Some of the embodiments will be described in detail, with reference to the following figures, wherein like designations denote like members, wherein:

(2) FIG. 1 shows a wind turbine according to an embodiment of the present invention;

(3) FIG. 2 shows a rotor assembly in a representation, wherein the mechanical support structure of the rotor assembly is rolled out along a circumferential direction;

(4) FIGS. 3a, 3b, and 3c illustrate the engaging attachment of a magnetic component part into a slot of the mechanical support structure;

(5) FIG. 4 shows a magnet arrangement comprising three differently shaped magnetic component parts;

(6) FIG. 5a shows a magnet arrangement comprising two differently shaped magnetic component parts, FIGS. 5b and 5c illustrate the cancellation of cogging torque and torque ripple for the magnet arrangement shown in FIG. 5a;

(7) FIGS. 6a, 6b, and 6c show magnet arrangements exhibiting an axial symmetry with five magnetic component parts, four magnetic component parts, and three magnetic component parts, respectively;

(8) FIGS. 7a and 7b show a magnet arrangement having two respectively four magnetic component parts, wherein respectively two magnetic component parts are formed integrally by one magnet piece;

(9) FIGS. 8a and 8b show a magnet arrangement having three respectively six magnetic component parts, wherein respectively three magnetic component parts are formed integrally by one magnet piece;

(10) FIG. 9 shows four different geometries for a magnetic component part having a gradually varying cross section; and

(11) FIG. 10 shows two cross sectional shapes for a magnetic component part, which cross sectional shapes has a rounded edge resulting in a smooth bended surface of the respective magnetic component part.

DETAILED DESCRIPTION

(12) The illustration in the drawing is schematically. It is noted that in different figures, similar or identical elements or features are provided with the same reference signs or with reference signs, which are different from the corresponding reference signs only within the first digit. In order to avoid unnecessary repetitions elements or features which have already been elucidated with respect to a previously described embodiment are not elucidated again at a later position of the description.

(13) FIG. 1 shows a wind turbine 100 according to an embodiment of the invention. The wind turbine 100 comprises a tower 120, which is mounted on a non-depicted fundament. On top of the tower 120 there is arranged a nacelle 122. In between the tower 120 and the nacelle 122 there is provided a yaw angle adjustment device 121, which is capable of rotating the nacelle 122 around a non-depicted vertical axis being aligned with the longitudinal extension of the tower 120. By controlling the yaw angle adjustment device 121 in an appropriate manner it can be made sure, that during a normal operation of the wind turbine 100 the nacelle 122 is always properly aligned with the current wind direction. However, the yaw angle adjustment device 121 can of course also be used to adjust the yaw angle to a position, wherein the nacelle 122 is intentionally not perfectly aligned with the current wind direction. Such a situation might occur if the wind driving the wind turbine is so strong that there is a risk of damaging a component of the wind turbine 100.

(14) The wind turbine 100 further comprises a rotor 110 having three blades 114. In the perspective of FIG. 1 only two blades 114 are visible. The rotor 110 is rotatable around a rotational axis 110a. The blades 114, which are mounted at a hub 112, extend radially with respect to the rotational axis 110a. Of course, also a rotor having a different number of blades may be used for the wind turbine.

(15) In between the hub 112 and a blade 114 there is respectively provided a blade adjustment device 116 in order to adjust the blade pitch angle of each blade 114 by rotating the respective blade 114 around a non-depicted axis being aligned substantially parallel with the longitudinal extension of the blade 114. By controlling the blade adjustment device 116 the blade pitch angle of the respective blade 114 can be adjusted in such a manner that at least when the wind is not so strong a maximum wind power can be retrieved from the available wind power. However, the blade pitch angle can also be intentionally adjusted to a position, in which only a reduced wind power can be captured. This might be the case if the wind driving the wind turbine 100 is so strong that there is a risk of damaging in particular the rotor 110 of the wind turbine 100.

(16) As can be seen from FIG. 1, within the nacelle 122 there is provided an optional gear box 124. The gear box 124 may be used for converting the number of revolutions of the rotor 110 into a higher number of revolutions of a shaft 125, which is coupled in a known manner to an electromechanical transducer 130. The electromechanical transducer is a generator 130.

(17) Further, a brake 126 is provided in order to stop the operation of the wind turbine 100 or to reduce the rotational speed of the rotor 110 for instance (a) in case of an emergency, (b) in case of too strong wind conditions, which might harm the wind turbine 100, and/or (c) in case of an intentional saving of the consumed fatigue life time and/or the fatigue life time consumption rate of at least one structural component of the wind turbine 100.

(18) The wind turbine 100 further comprises a control system 128 for operating the wind turbine 100 in a highly efficient manner. Apart from controlling for instance the yaw angle adjustment device 121 the depicted control system 128 is also used for adjusting the blade pitch angle of the rotor blades 114 in an optimized manner.

(19) In accordance with basic principles of electrical engineering the generator 130 comprises a stator assembly 140 and a rotor assembly 150. The stator assembly 140 comprises a plurality of coils for generating electrical current in response to a time alternating magnetic flux. The rotor assembly 150 comprises a plurality of magnet arrangements which are shaped along an axial direction of the generator 130. This axial direction corresponds to the orientation of the rotational axis 110a. By shaping the magnet arrangements along the axial direction a cogging torque and/or torque ripples which occur when the generator 130 is in operation can be reduced.

(20) FIG. 2a shows a rotor assembly 250 in a representation, wherein a mechanical support structure 252 of the rotor assembly 250 is rolled out along a circumferential direction a of the rotor assembly 250. The rotor assembly 250 comprises a plurality of slots 254, which are oriented along an axial direction Z of the rotor assembly 250. This means that the slots 254 are not skewed. The rotor assembly 250 comprises a plurality of magnet arrangements 260. According to the embodiment described here each magnet arrangement 260 comprises three magnetic component parts 270, which can be inserted along an insertion direction 280 into the respective slot 254. As can be seen from FIG. 2, in one slot the magnetic component parts 270 are inserted with their north pole N at the upper side and in the neighboring slot the magnetic component parts 270 are inserted with their south pole S at the upper side.

(21) FIGS. 3a, 3b, and 3c illustrate the engaging attachment of a magnetic component part 270 into a slot 254 of the mechanical support structure 252.

(22) As can be seen from FIG. 3a, according to the embodiment described here the magnetic component part 270 comprises a base element or base plate 372. At the base element or base plate 372 there is attached, e.g. by means of an appropriate glue, a magnet piece 374. The magnet piece 374 is a permanent magnet (PM) such as for instance a rare earth PM. In accordance with embodiments of the invention the magnet piece 374 has a cross sectional shape having the form of an irregular quadrangle.

(23) As can be seen from FIG. 3b, according to the embodiment described here the slot 254 comprises two undercuts 354a which are formed within the mechanical support structure 252.

(24) As can be seen from FIG. 3c, when inserting the magnetic component parts 270 into respective slot 254, the edges of the base plate 372 engage with the two undercuts 354a.

(25) In the following there will be described several geometric configurations for magnet arrangements which, when being attached to a mechanical support structure of a rotor assembly, yield a reduced cogging torque and/or reduced torque ripples when the rotor assembly is in operation.

(26) FIG. 4 shows in a perspective view a magnet arrangement 460 comprising three differently shaped magnetic component parts, a first magnetic component part 470a, a second magnetic component part 470b and a third magnetic component part 470c. In connection with the perspective view the axial direction Z of the magnet arrangement 460, the circumferential direction a and the radial direction r of the not depicted corresponding rotor assembly are indicated.

(27) In FIG. 4 the three magnetic component parts are numbered with 1, 2, and 3. Due to the different geometries of the three magnetic component parts 470a, 470b, and 470c (the respective cross sections are indicated on the right side of this Figure) the magnet arrangement 460 consisting of the three magnetic component parts 470a, 470b, and 470c comprises a shape variation or a shaping along the axial direction Z. Such a shape variation leads to a reduction of cogging torque and/or torque ripples even if there is no skewing of the magnetic component parts 470a, 470b, and 470c.

(28) FIG. 5a shows a magnet arrangement 560 in accordance with another embodiment of the invention. The magnet arrangement 560 comprises two differently shaped magnetic component parts, a first magnetic component part 570a and a second magnetic component part 570b. Again, due to the different geometries of the two magnetic component parts 570a and 570b (the respective cross sections are indicated on the right side of this Figure), the magnet arrangement 560 consisting of the two magnetic component parts 570a and 570b comprises a shape variation along the axial direction Z.

(29) FIGS. 5b and 5c illustrate the cancellation of cogging torque and torque ripple for the magnet arrangement shown in FIG. 5a. As can be seen from FIG. 5b, as a function of the rotor position or the rotor angle the cogging torque caused by the first magnetic component part 570a (denominated with 1) is in anti-phase with the cogging torque caused by the second magnetic component part 570b (denominated with 2). Therefore, these two cogging torques cancel each other. The resultant cogging torque, which is a superposition of the two cogging torques, shows no dependency on the rotor position and is depicted in FIG. 5b as a straight line. As can be seen from FIG. 5c, the same holds for the total torque.

(30) In this respect it is mentioned that the magnet arrangements 460 and 560 shown in the FIGS. 4 and 5a are not symmetrical along the axial direction. This may cause an axial force acting on the rotor assembly when the rotor assembly is in operation. In order to eliminate this axial force, the magnet arrangement should be designed in such a manner that it comprises a symmetry along the axial direction. Examples for axially symmetric magnet arrangement are elucidated in the following with respect to the FIGS. 6a, 6b, and 6c.

(31) FIG. 6a shows an axially symmetric magnet arrangement 660a consisting of five magnetic component parts. FIG. 6b shows an axially symmetric magnet arrangement 660b consisting of four magnetic component parts. FIG. 6c shows an axially symmetric magnet arrangement 660c consisting of three magnetic component parts.

(32) FIG. 7a shows a magnet arrangement 760a comprising two differently shaped magnetic component parts which are formed integrally or monolithically within a single magnet piece. FIG. 7b shows a magnet arrangement 760b having four magnetic component parts. Respectively two magnetic component parts of the four magnetic component parts are formed integrally or monolithically by one single magnet piece. As can be seen from the FIGS. 7a and 7b, both of the two magnet arrangements 760a and 760b have no symmetry along the axial direction. As has already been mentioned above, this may lead to an axial force acting on the respective rotor assembly when being operated in a rotary electric machine.

(33) FIG. 8a shows a magnet arrangement 860a having three magnetic component parts which are formed integrally or monolithically within a single magnet piece. FIG. 8b shows a magnet arrangement 860b having six magnetic component parts. Respectively three magnetic component parts of the six magnetic component parts are formed integrally or monolithically by one single magnet piece. As can be seen from the FIGS. 8a and 8b, both of the two magnet arrangements 860a and 860b exhibit a symmetry along the axial direction. As a result of this axial symmetry there is no axial force acting on the respective rotor assembly when being operated in a rotary electric machine.

(34) According to the embodiments described above each magnetic component part has a constant cross section along the axial direction Z. As a consequence, each magnet arrangement comprises at least two magnetic component parts each with a different cross section which has several sections of different cross-sections. This applies both for the embodiments where each magnet arrangement comprises separate magnetic component part and for the embodiments where different magnetic component parts are formed integrally. However, the embodiment of the invention and its positive effects (i.e. the reduction of cogging torque and/or torque ripples) may also be achieved with magnetic component parts having gradually varying cross section along the axial direction Z.

(35) FIG. 9 shows four different magnetic component parts, a magnetic component part 970a, a magnetic component part 970b, a magnetic component part 970c, and a magnetic component part 970d. All these magnetic component parts have a gradually varying cross section along the axial direction.

(36) According to the embodiments described above the cross section of the magnetic component parts is always formed by straight lines. However, the cross section can have many other shapes.

(37) FIG. 10 shows as an example two magnetic component parts 1070a and 1070b, which both have a cross sectional shape with a rounded edge on their upper side. This rounded edge results in a smooth bended surface of the magnetic component part 1070a and 1070b, respectively.

(38) The new design for the magnet arrangement described in this document may provide inter alia the following advantages:

(39) (A) The cogging torque and torque ripple of a rotary electric machine can be reduced without skewing the positions of the magnetic component parts. Hence, the new design can be easily implemented.

(40) (B) An axial force acting on the rotor assembly can be removed by symmetrically arranging magnetic component parts of different shapes along the axial direction. Thereby, the magnetic component parts may be arranged at the same angular position of the rotor assembly (i.e. there is no need for skewing the magnetic component parts). Hence, a rotor assembly taking benefit from the new design is much easier to manufacture. In particular, the slots which are used to fix the magnetic component part can be straight respectively can be oriented parallel to the axial direction.
(C) There is no need to employ the skewing technique to reduce cogging torque and/or torque ripple. Since the skewing technique reduces the so called back electromagnetic force (back-EMF) the efficiency for an electromechanical transducer having a skewed arrangement of the magnetic component parts is reduced due to the skewing. On the contrary, the new design proposed in this document has less influence on the efficiency because all axial magnetic component parts are at the same circumferential position.

(41) It should be noted that the term comprising does not exclude other elements or steps and the use of articles a or an does not exclude a plurality. Also elements described in association with different embodiments may be combined. It should also be noted that reference signs in the claims should not be construed as limiting the scope of the claims.