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Title: Structural Mass Saving Potential of a 5-MW Direct-Drive Generator Designed for Additive Manufacturing

Abstract

As wind turbine blade diameters and tower height increase to capture more energy in the wind, higher structural loads results in more structural support material increasing the cost of scaling. Weight reductions in the generator transfer to overall cost savings of the system. Additive manufacturing facilitates a design-for-functionality approach, thereby removing traditional manufacturing constraints and labor costs. The most feasible additive manufacturing technology identified for large, direct-drive generators in this study is powder-binder jetting of a sand cast mold. A parametric finite element analysis optimization study is performed, optimizing for mass and deformation. Also, topology optimization is employed for each parameter-optimized design.The optimized U-beam spoked web design results in a 24 percent reduction in structural mass of the rotor and 60 percent reduction in radial deflection.

Authors:
 [1];  [1];  [1];  [2]
  1. National Renewable Energy Laboratory (NREL), Golden, CO (United States)
  2. Rochester Institute of Technology
Publication Date:
Research Org.:
National Renewable Energy Lab. (NREL), Golden, CO (United States)
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE), Wind and Water Technologies Office (EE-4W)
OSTI Identifier:
1409001
Report Number(s):
NREL/PO-5000-70322
DOE Contract Number:
AC36-08GO28308
Resource Type:
Conference
Resource Relation:
Conference: Presented at WindTech 2017, International Conference on Future Technologies in Wind Energy, 24-26 October 2017, Boulder, Colorado
Country of Publication:
United States
Language:
English
Subject:
17 WIND ENERGY; 24 POWER TRANSMISSION AND DISTRIBUTION; additive manufacturing; direct-drive generator; topology optimization; structural design

Citation Formats

Sethuraman, Latha, Fingersh, Lee J, Dykes, Katherine L, and Hayes, Austin. Structural Mass Saving Potential of a 5-MW Direct-Drive Generator Designed for Additive Manufacturing. United States: N. p., 2017. Web.
Sethuraman, Latha, Fingersh, Lee J, Dykes, Katherine L, & Hayes, Austin. Structural Mass Saving Potential of a 5-MW Direct-Drive Generator Designed for Additive Manufacturing. United States.
Sethuraman, Latha, Fingersh, Lee J, Dykes, Katherine L, and Hayes, Austin. Thu . "Structural Mass Saving Potential of a 5-MW Direct-Drive Generator Designed for Additive Manufacturing". United States. doi:. https://www.osti.gov/servlets/purl/1409001.
@article{osti_1409001,
title = {Structural Mass Saving Potential of a 5-MW Direct-Drive Generator Designed for Additive Manufacturing},
author = {Sethuraman, Latha and Fingersh, Lee J and Dykes, Katherine L and Hayes, Austin},
abstractNote = {As wind turbine blade diameters and tower height increase to capture more energy in the wind, higher structural loads results in more structural support material increasing the cost of scaling. Weight reductions in the generator transfer to overall cost savings of the system. Additive manufacturing facilitates a design-for-functionality approach, thereby removing traditional manufacturing constraints and labor costs. The most feasible additive manufacturing technology identified for large, direct-drive generators in this study is powder-binder jetting of a sand cast mold. A parametric finite element analysis optimization study is performed, optimizing for mass and deformation. Also, topology optimization is employed for each parameter-optimized design.The optimized U-beam spoked web design results in a 24 percent reduction in structural mass of the rotor and 60 percent reduction in radial deflection.},
doi = {},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Thu Nov 09 00:00:00 EST 2017},
month = {Thu Nov 09 00:00:00 EST 2017}
}

Conference:
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