國立虎尾科技大學 |

Additive Manufacturing for Wind Turbine Generators : = How Safety, Hybrid Approaches, and Advanced Cooling Come Together to Create High-Power Density Generators.

Record Type:	Language materials, manuscript : Monograph/item
Title/Author:	Additive Manufacturing for Wind Turbine Generators :/
Reminder of title:	How Safety, Hybrid Approaches, and Advanced Cooling Come Together to Create High-Power Density Generators.
Author:	Hayes, Austin C.
Description:	1 online resource (329 pages)
Notes:	Source: Dissertations Abstracts International, Volume: 85-06, Section: B.
Contained By:	Dissertations Abstracts International85-06B.
Subject:	Energy. -
Online resource:	click for full text (PQDT)
ISBN:	9798381165470

Additive Manufacturing for Wind Turbine Generators : = How Safety, Hybrid Approaches, and Advanced Cooling Come Together to Create High-Power Density Generators.
Hayes, Austin C.

Additive Manufacturing for Wind Turbine Generators :How Safety, Hybrid Approaches, and Advanced Cooling Come Together to Create High-Power Density Generators. - 1 online resource (329 pages)

Source: Dissertations Abstracts International, Volume: 85-06, Section: B.

Thesis (Ph.D.)--University of Colorado at Boulder, 2023.

Includes bibliographical references

As engineers, we are oftentimes eager to apply our knowledge about physical phenomena or use the newest technology to solve a problem. However, many times we forget to take a step back and ask the simple questions "Is this safe" or "Just because I can...should I do this?" This thesis discusses the use of additive manufacturing (AM) for high power density generators. First, we ask the questions "What emission concerns exist for additive manufacturing?" and "Should we use additive manufacturing to create these generators?" Chapter 1 offers an introduction to the variety of topics covered in the thesis including air quality, additive manufacturing, wind turbine generators, and two phase cooling. In chapter 2, the powder type was varied in a powder binder jetting printer and airborne particle emissions recorded. The powder types included two powders for space manufacturing and one for hybrid AM of large metal generators. In order to create large direct drive generators using AM, large, scalable commercial printers are needed. Therefore, understanding emissions from commercial additive manufacturing machines is important. Industrial health concerns for operators depends on the printer technology used and multiple printer types were measured in this study. In chapter 3, the use of AM for generators such as its ability to create large, lightweight, and metallic parts was explored. Hybrid AM with powder binder jetting and casting was selected for its ability to maintain high complexity of AM with the cost of traditional casting. Lightweighting was explored using triply periodic minimal surfaces (TPMS) structures optimized to the generator loading conditions. An automated lattice generation software was created for direct drive wind turbine generators resulting in a 34% rotor structural mass savings. This technique was extended to the stator allowing an automated optimization technique for lightweighting of the entire generator structural mass. One of the greatest barriers for decreasing the size of wind turbine generators is maintaining adequate cooling. Increasing the current density by 6x has the potential of reducing generator mass by 70% and generator diameter by 60%. In chapter 4, advanced cooling methods were investigated to improve the maximum current density in the stator. Simulated results were found to agree with experimental and analytical findings. Understanding of the fundamental heat transfer phenomenon in complex flows holds potential for improving heat transfer. Additive manufacturing enables complex flow modifiers to be printed which can enhance flow boiling performance. In chapter 5, two of such modifiers were explored. First, a printed jet impingement manifold offset to the flow direction to reduce pressure drop. Second, a radially fed jet impingement with tapered subdivision manifold with individual inlet and outlet fluidic routing to reduce pressure drop. In chapter 6, application of additive manufacturing was extended to a parabolic flight campaign to develop an understanding of extrusion printing under altered gravity conditions. In chapter 7, I discuss CU's "Triple E Initiative" an outreach program for K-12 students developed by myself and Vani Sundaram designed to maximize impact on students while seamlessly integrating research content in the classroom. This initiative was comprised of in-classroom teaching and a science fair at CU.

Electronic reproduction.
Ann Arbor, Mich. :
ProQuest,
2024

Mode of access: World Wide Web

ISBN: 9798381165470Subjects--Topical Terms:

784773
Energy.
Subjects--Index Terms:

Additive manufacturingIndex Terms--Genre/Form:

554714
Electronic books.

Additive Manufacturing for Wind Turbine Generators : = How Safety, Hybrid Approaches, and Advanced Cooling Come Together to Create High-Power Density Generators.
LDR:04900ntm a22003977 4500 001 1143686
005 20240517104630.5
006 m o d
007 cr mn ---uuuuu
008 250605s2023 xx obm 000 0 eng d
020 $a 9798381165470
035 $a (MiAaPQ)AAI30811122
035 $a AAI30811122
040 $a MiAaPQ $b eng $c MiAaPQ $d NTU
100 1 $a Hayes, Austin C. $3 1468455
245 1 0 $a Additive Manufacturing for Wind Turbine Generators : $b How Safety, Hybrid Approaches, and Advanced Cooling Come Together to Create High-Power Density Generators.
264 0 $c 2023
300 $a 1 online resource (329 pages)
336 $a text $b txt $2 rdacontent
337 $a computer $b c $2 rdamedia
338 $a online resource $b cr $2 rdacarrier
500 $a Source: Dissertations Abstracts International, Volume: 85-06, Section: B.
500 $a Advisor: Whiting, Gregory L.;Vance, Marina.
502 $a Thesis (Ph.D.)--University of Colorado at Boulder, 2023.
504 $a Includes bibliographical references
520 $a As engineers, we are oftentimes eager to apply our knowledge about physical phenomena or use the newest technology to solve a problem. However, many times we forget to take a step back and ask the simple questions "Is this safe" or "Just because I can...should I do this?" This thesis discusses the use of additive manufacturing (AM) for high power density generators. First, we ask the questions "What emission concerns exist for additive manufacturing?" and "Should we use additive manufacturing to create these generators?" Chapter 1 offers an introduction to the variety of topics covered in the thesis including air quality, additive manufacturing, wind turbine generators, and two phase cooling. In chapter 2, the powder type was varied in a powder binder jetting printer and airborne particle emissions recorded. The powder types included two powders for space manufacturing and one for hybrid AM of large metal generators. In order to create large direct drive generators using AM, large, scalable commercial printers are needed. Therefore, understanding emissions from commercial additive manufacturing machines is important. Industrial health concerns for operators depends on the printer technology used and multiple printer types were measured in this study. In chapter 3, the use of AM for generators such as its ability to create large, lightweight, and metallic parts was explored. Hybrid AM with powder binder jetting and casting was selected for its ability to maintain high complexity of AM with the cost of traditional casting. Lightweighting was explored using triply periodic minimal surfaces (TPMS) structures optimized to the generator loading conditions. An automated lattice generation software was created for direct drive wind turbine generators resulting in a 34% rotor structural mass savings. This technique was extended to the stator allowing an automated optimization technique for lightweighting of the entire generator structural mass. One of the greatest barriers for decreasing the size of wind turbine generators is maintaining adequate cooling. Increasing the current density by 6x has the potential of reducing generator mass by 70% and generator diameter by 60%. In chapter 4, advanced cooling methods were investigated to improve the maximum current density in the stator. Simulated results were found to agree with experimental and analytical findings. Understanding of the fundamental heat transfer phenomenon in complex flows holds potential for improving heat transfer. Additive manufacturing enables complex flow modifiers to be printed which can enhance flow boiling performance. In chapter 5, two of such modifiers were explored. First, a printed jet impingement manifold offset to the flow direction to reduce pressure drop. Second, a radially fed jet impingement with tapered subdivision manifold with individual inlet and outlet fluidic routing to reduce pressure drop. In chapter 6, application of additive manufacturing was extended to a parabolic flight campaign to develop an understanding of extrusion printing under altered gravity conditions. In chapter 7, I discuss CU's "Triple E Initiative" an outreach program for K-12 students developed by myself and Vani Sundaram designed to maximize impact on students while seamlessly integrating research content in the classroom. This initiative was comprised of in-classroom teaching and a science fair at CU.
533 $a Electronic reproduction. $b Ann Arbor, Mich. : $c ProQuest, $d 2024
538 $a Mode of access: World Wide Web
650 4 $a Energy. $3 784773
650 4 $a Sustainability. $3 793436
650 4 $a Mechanical engineering. $3 557493
653 $a Additive manufacturing
653 $a Air quality
653 $a Direct drive generators
653 $a Optimization
653 $a Wind turbine
655 7 $a Electronic books. $2 local $3 554714
690 $a 0791
690 $a 0640
690 $a 0548
710 2 $a ProQuest Information and Learning Co. $3 1178819
710 2 $a University of Colorado at Boulder. $b Mechanical Engineering. $3 1178880
773 0 $t Dissertations Abstracts International $g 85-06B.
856 4 0 $u http://pqdd.sinica.edu.tw/twdaoapp/servlet/advanced?query=30811122 $z click for full text (PQDT)