Design And Manufacturing Process Of Large-size Doubly-fed Wind Power Generator

Driven by renewable energy law and a series of national policies, the capacity ofwind power installation growing rapidly, the equipment manufacturers also developingrapidly, wind power industry has been forming gradually. Nowadays for wind powergenerator, but the mainly used are two: Doubly-fed Wind Power Generator andpermanent-magnet synchronous wind power generator. At present, Doubly-fed WindPower Generator is the most popular generator in wind turbine, because of mutualtechnology and high reliability. Due to the special application of wind turbines, highmaintenance costs and fierce competition, requirements for structure design andmanufacture process of wind power generator is more and more high. Therefore, in orderto realize the wind generator series products of high quality, efficient development andproduction, continuously improve the Doubly-fed Wind Power Generator design andmanufacturing technology level will have important practical significance. In this paper,for the1.5MW Doubly-fed Wind Power Generator, using the basic theory of motordesign and manufacturing technology and finite element analysis method, to explorethe structure of its analytical and numerical design method and improve thetraditional manufacturing process of the NC machining and clamp method, the mainworks can be concluded as the following:(1)Review on the research status of wind power generation, windturbine, Doubly-fed Wind Power Generator technology at home and abroad. Describesthe basic working principle, focus on the analysis of internal electromagnetic relationshipand power characteristics of the generator, and consider power distribution insuper-synchronous and sub-synchronous conditions, lay the theoretical foundation for thesubsequent design analysis.(2)Integrated design method for Doubly-fed Wind Power Generator. Select the methodfor poles, air gap length and slot type electromagnetic parameters. Make thesimulation analysis of the shaft fit and the rotor strength by using ANSYS software. Theresults of analytical and numerical calculations were compared and analyzed to ensurethe reliable design of generator structure.(3)Improvement of the manufacturing process of Doubly-fed Wind Power Generator.Based on traditional process design, NC machining method was established byusing improved rotor coil forming process numerical control equipment. Design theunique process of stator turning and lifting process, to ensure the production of high quality, high efficiency.In summary, this paper provides the effective ways to improve the1.5MW Doubly-fed Wind Power Generator’s structure design and manufacturing processlevel, also provides a important reference for large similar generator.