Research and development for optimization of generator design
Modern highly utilized power plant generators suffer strain from multi-physical effects
The challenge is not just the combination of high thermal and mechanical stresses, but also their occurrence together with electromagnetic, high voltage and ventilation topics.
In the field of electromagnetics, the focus lies on highly precise prediction of the electromagnetic and thermal data to optimize generator parameters, efficiency and size.
Besides assuring high-level winding performance, the insulation technology concentrates on higher voltage levels up to 30 kV, on insulation systems for higher temperature classes, and on improved heat transfer between winding and stator core.
Cooling optimization needs precise ventilation design tools, including heat transfer calculations with modern CFD (computational fluid dynamics) and CHT (conjugate heat transfer) methods.
Bearing loads of up to of several tens of thousands of MN require combined investigations of thermal, mechanical and oil flow influences using FSI (fluid structure interaction) methods.
In the mechanics sector, the main R&D focuses are on new and improved design concepts, precise vibration and noise analysis, as well as thermo-mechanical effects in consideration of the huge generator dimensions and tremendous centrifugal forces.
Turbogenerators for gas and thermal power plant applications have special requirements due to their high rotor speed, their rotor dynamics, and hydrogen as cooling fluid if required for intense heat transfer.
Actual market demands require highly dynamic generators for energy storage and grid stabilization, thus special concepts are necessary with variable speed motor generators for pumped storage applications.