Lightweight design of rotor structure of large capacity outer rotor permanent magnet wind generator

ZHANG Kun1, YU Shen-bo1, ZHAI Feng-chen1, LU Hua-xing2, LIU Wei2
(1.College of Mechanical Engineering, Shenyang University of Technology, Shenyang 110870, China;
2.Research Institute of Science and Technology Co.,Ltd., State Power Investment Group, Beijing, 100029, China)

Abstract: Aiming at the problems that the weight of the outer rotor structure of 3 MW permanent magnet wind generator was large, which increased the load of the unit and affectd the safety of the unit, the load characteristics and stress deformation of the outer rotor structure of the wind generator unit were studied. The rotor lightweight method combined with topology optimization, multiobjective sensitivity analysis and response surface optimization was proposed. By using the method of variable density, the optimization model of rotor with minimum deformation energy was established, and the preliminary topology optimization design of the rotor model was carried out. The parametric modeling of the rotor model was carried out, and the structural size parameters which had great influence on the rotor structure were determined by sensitivity analysis. Combining with the response surface optimization method, the optimal parameters were selected to achieve the optimal structural design goal of the rotor. The results indicate that under the condition that the structural strength and deformation meet the requirements, the overall weight loss of the structure is 4 799 kg, which accounts for 26.5% of the total weight.

Key words: wind turbines; topology optimization; sensitivity analysis; response surface optimization; lightweight design