Generative Design and Additive Manufacturing Techniques on the Optimization of Multi-MW Offshore Direct-Drive Wind Turbine Electrical Generators

Abstract

New advances in structural optimization techniques and manufacturing methods, such as generative design (GD) and additive manufacturing (AM), are revolutionizing the capabilities to generate high-efficiency and lightweight models in comparison with conventional processes. This study addresses a structural optimization strategy for offshore wind turbine direct-drive generator structures using generative design (GD) and additive manufacturing (AM) techniques. The use of multi-objectives structural optimization processes using GD techniques allows for the exploration of a wide number of unconventional topologies on a tailored, fit-for-purpose strategy, and the implementation of AM methods makes possible the fabrication of complex designs with metallic and composite materials. GD and AM represent a revolution in the field of design optimization, offering flexibility and adaptability while collecting a vast amount of structural analysis data, crucial for a cost-effective approach in the early stages of design projects. The implementation of these techniques demonstrated over 7% weight reduction, a 40% increase in operational range, and a decrease in the cost of manufacturing.

Keywords

• offshore wind turbine
• direct-drive electrical generator
• structural optimization
• generative design
• additive manufacturing