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Title: Structural Optimization of a Direct-Drive Wind Turbine Generator Inspired by Additive Manufacturing

Abstract

This study explores the structural freedom and design opportunities of additive manufacturing for a 5-MW direct-drive generator for a wind turbine and compares it to more traditional spoke-arm designs using NREL's GeneratorSE. The work focuses on light-weighting the stator within the generator, complementing previous rotor work. The light-weighting approach uses complex geometries and lattice structures made possible by additive manufacturing to realize increased strength with reduced mass. By reducing the mass at the top of the tower, wind turbines face lower loading along with decreased cost and improved structural stability. Furthermore, an altered bedplate support location facilitates lighter stator designs by better load transfer. Design optimization suggests additive manufacturing has the potential to transform generator designs to realize light-weighting. Since these machines are large, simulation and modeling are essential first steps before future experimental validation.

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:
1471114
Report Number(s):
NREL/JA-5000-70973
DOE Contract Number:  
AC36-08GO28308
Resource Type:
Journal Article
Journal Name:
Procedia Manufacturing
Additional Journal Information:
Journal Volume: 26
Country of Publication:
United States
Language:
English
Subject:
17 WIND ENERGY; 42 ENGINEERING; additive manufacturing; light-weighting; direct drive generator; stator; wind turbine; simulation/modeling

Citation Formats

Sethuraman, Latha, Fingersh, Lee J, Dykes, Katherine, and Hayes, Austin. Structural Optimization of a Direct-Drive Wind Turbine Generator Inspired by Additive Manufacturing. United States: N. p., 2018. Web. doi:10.1016/j.promfg.2018.07.084.
Sethuraman, Latha, Fingersh, Lee J, Dykes, Katherine, & Hayes, Austin. Structural Optimization of a Direct-Drive Wind Turbine Generator Inspired by Additive Manufacturing. United States. doi:10.1016/j.promfg.2018.07.084.
Sethuraman, Latha, Fingersh, Lee J, Dykes, Katherine, and Hayes, Austin. Fri . "Structural Optimization of a Direct-Drive Wind Turbine Generator Inspired by Additive Manufacturing". United States. doi:10.1016/j.promfg.2018.07.084. https://www.osti.gov/servlets/purl/1471114.
@article{osti_1471114,
title = {Structural Optimization of a Direct-Drive Wind Turbine Generator Inspired by Additive Manufacturing},
author = {Sethuraman, Latha and Fingersh, Lee J and Dykes, Katherine and Hayes, Austin},
abstractNote = {This study explores the structural freedom and design opportunities of additive manufacturing for a 5-MW direct-drive generator for a wind turbine and compares it to more traditional spoke-arm designs using NREL's GeneratorSE. The work focuses on light-weighting the stator within the generator, complementing previous rotor work. The light-weighting approach uses complex geometries and lattice structures made possible by additive manufacturing to realize increased strength with reduced mass. By reducing the mass at the top of the tower, wind turbines face lower loading along with decreased cost and improved structural stability. Furthermore, an altered bedplate support location facilitates lighter stator designs by better load transfer. Design optimization suggests additive manufacturing has the potential to transform generator designs to realize light-weighting. Since these machines are large, simulation and modeling are essential first steps before future experimental validation.},
doi = {10.1016/j.promfg.2018.07.084},
journal = {Procedia Manufacturing},
number = ,
volume = 26,
place = {United States},
year = {2018},
month = {8}
}