Drive solutions for electric power generation
In power generation, the electric machine determines availability – and thus security of supply and operating costs. A breakdown here is more costly than elsewhere. This is precisely why the machine is rarely designed off the shelf.
Where ATE plays a key role in electric power generation
Generators & Electric Machines
Generators and motor-generator units, microturbines and high-speed generators, as well as rotor and stator systems for power generation modules.
Pumps, Fans & Auxiliary Systems
Drives for cooling water and boiler feed pumps, fans, blowers and compressors, as well as cooling units and other auxiliary drives.
Wind & Hydropower
Pitch and yaw drives for wind turbines, as well as electric drives for auxiliary systems in hydropower plants.
Microturbines & High-Speed Generators
Compact generator solutions for microturbines and applications requiring high rotational speeds and application-specific integration.
Customized Rotor & Stator Systems
Application-specific rotors, stators and windings tailored to the requirements of electric machines in power generation systems.
Special-Purpose Systems & Integrated Drive Solutions
Customized electric motors and drive components for specialized plant designs and auxiliary functions in power generation.
What makes the drive task challenging
Power generation plants often operate round the clock, over long periods and under high thermal loads. Four factors determine the design.
This is where the real impact lies: breakdowns result not only in repair costs but also in lost generation. A robust design, thermal reserves, a long service life and low maintenance requirements are key to the economic viability of the entire plant.
Maximum efficiency does not result from catalogue figures, but from the optimization of the load profile, operating point, inverter operation and thermal behaviour. ATE designs for real operating conditions, not just the rated point.
Compact systems require high speeds combined with high power density – and thus place high demands on rotor strength, balancing, heat dissipation and the cooling concept. The rotor, stator and cooling system are designed as an integrated whole.
Precision does not arise from mechanics alone. Thermal displacement, cooling design, bearing arrangements and power dissipation all influence dimensional accuracy and surface finish. ATE takes thermal behaviour into account right from the electromagnetic and mechanical design stages.
Standard motors function as long as power, speed, cooling, efficiency, installation space and interfaces remain within defined limits. In power generation, these limits are usually exceeded not individually, but collectively.
Continuous operation over long running times, high availability, high thermal loads, high speeds, customer-specific rotor-stator geometries and direct integration into generator or turbine units: this is when the electric machine becomes a bespoke development challenge. This is precisely where ATE provides support.
How ATE approaches such tasks
Clarify requirements
Motor or generator function, speed and torque range, power, load profile, continuous operation, environment, cooling concept, installation space, rotor strength, bearings, mains or inverter interface, and target unit numbers. The basis of any robust design.Machine design
Rotors, stators and windings – as synchronous or asynchronous machines, field-weakening designs, torque or direct drives, right through to generator assemblies and motor-generator units. Depending on the project, individual components or a complete machine.Consider integration
Shaft and bearing design, cooling, magnetic circuit, mains or inverter connection and mechanical interfaces are considered as part of the overall machine, not as afterthoughts.Preparing for implementation
From functional prototypes through performance measurement and validation to series production. Development and manufacturing under one roof.What goes into this
Customized generator components for a power generation module
Initial situation: An OEM is developing a compact power generation module with stringent requirements in terms of efficiency, continuous operation and installation space. Standard generators do not fully meet the thermal and mechanical requirements.
ATE solution: Customized rotors, application-specific stators and windings, electromagnetic design and thermal optimization, tailored to the cooling and bearing concept and to integration into the overall assembly.
Result: A solution tailored to the application, offering high efficiency, reliable continuous operation and seamless integration into the module.
FAQs
Tailoring drive solutions
Are you developing a generator, a microturbine, a pump or fan drive, or an energy generation module with specific requirements regarding efficiency, continuous operation, cooling or integration?
ATE supports you in the development of customized rotors, stators and electrical machines – from functional prototypes through to series production.
Call us on
+49 (0) 7561-98248-23
Send us a message to
r.zell(at)ate-system.de