Generator Injection Tool

Abstract

A generator injection tool is provided. The generator injection tool injects an adhesive into a generator including a rotor located within a stator having a stator vent. There is a gap between the stator and the rotor. The generator injection tool includes a first carriage sized to fit within the gap, a tube, a first motor, a controller, and an adhesive supply. An end of the tube is movable between a first position outside the stator vent and a second position within the stator vent. The first motor can move the tube between the first position and the second position. The controller can selectively activate the first motor to position the end of the tube within the stator vent. The adhesive supply moves adhesive through the end of the tube and injects a portion of the adhesive into the stator vent.

Description

[Technical field]

[0001] Turbogenerators and other large high voltage generator motors traditionally use components called side ripple springs between the coil and the side walls of the core slot to hold the coil in place and reduce the effects of vibration. Due to different friction coefficients between the components, the side ripple springs tend to move with the coil as it expands or contracts. If there is a mismatch in the friction coefficients between the components, the side ripple springs may not return to their original position and may move longitudinally. The longitudinal movement of the side ripple springs is commonly referred to as migration. If the end of the side ripple spring moves axially and contacts the side of the coil, at which point the coil insulation begins to wear. When this happens, a ground fault can occur because the stator coil has a conductive path to earth. Current solutions to this problem include disassembly of the generator, including removal of the rotor, and bonding the side ripple springs to the stator core by applying adhesive by hand, or rebuilding the stator components. To reduce disassembly, it is preferable to inject the adhesive without removing the rotor from the stator. [Background technology]

[0002] The generator injection tool is used to inject adhesive into a generator including a rotor disposed within a stator having a gap therebetween. The stator includes a stator tube. The generator injection tool includes a first carriage sized to fit within the gap, a tube guide mounted on the first carriage, a tube partially supported by the tube guide, a first motor coupled to the tube guide, a controller, and an adhesive supply. The tube includes a first end and a second end, the second end being movable between a first position where the second end is outside the stator tube and a second position where the second end is located within the stator tube. The first motor is capable of moving the tube between the first position and the second position. The controller is capable of selectively activating the first motor to position the second end of the tube at the second position within the stator tube. The adhesive supply is operable to move adhesive through the tube from the first end to the second end and to inject a portion of the adhesive into the stator tube when the tube is in the second position.

[0003] A method of injecting adhesive into a stator tube in a stator including a rotor while the rotor is positioned within the stator, comprising the steps of: positioning a first carriage so as to be disposed in a gap between the stator and the rotor and positioned radially inside the stator tube of the stator; guiding a tube into the stator tube to a first position by a tube guide attached to the first carriage; and driving the tube guide by a first motor to inject a predetermined amount of adhesive from an external source through the tube from a first nozzle attached to the end of the tube at the first position.

[0004] To easily identify the discussion of a particular element or act, the most significant digit or digits of a reference number refer to the figure number in which that element is first introduced. [Brief description of the drawings]

[0005] [Figure 1]FIG. 1 shows a partial cross-sectional perspective view of a generator including a stator and a rotor. [Diagram 2] FIG. 2 shows a perspective view of the stator core step iron area with the generator injection tool attached. [Diagram 3] FIG. 3 shows a perspective view of the generator injection tool. [Figure 4] FIG. 4 shows a perspective view of a nozzle attached to an adhesive tube. [Diagram 5] FIG. 5 shows a partial top view of the stator. [Figure 6] FIG. 6 shows a perspective view of a generator cleaning tool. [Figure 7] FIG. 7 shows a flow chart of a method according to one embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0006] Before any embodiment of the invention is described in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

[0007] In this disclosure, a generator injection tool and method are presented to provide a controlled application of adhesive between the stator tube wall and the side ripple spring to facilitate bonding while the rotor is installed in the stator. Additionally, a generator cleaning tool is presented to allow cleaning and inspection of the generator while the rotor is installed in the stator.

[0008] 1 shows a generator 100 that includes a rotor 102 supported for rotation about a longitudinal or central axis 116. The rotor 102 is disposed within a stator 104 and cooperates with the stator 104 to define an annular air gap 112. The stator 104 is typically housed within a housing 114 that protects the stator 104 from the external environment.

[0009] The rotor 102 includes rotor windings 110 disposed about the rotor 102 and operable to generate a magnetic field when energized.

[0010] The stator 104 includes a plurality of laminations 106 that are stacked along a central axis 116 to define a stator core. An insulating layer 108 is typically disposed between each lamination 106 and acts to inhibit unwanted electrical flow between the laminations 106. Each lamination 106 is formed to define a plurality of radially extending teeth such that adjacent teeth cooperate to define longitudinally extending core slots 202 in which the stator windings are located.

[0011] FIG. 2 shows a generator injection tool 300 positioned on the step iron section 206 of the stator core. The stator core has a stator core bore 212 aligned with the central axis 116 including a stator bar 204 having a straight bore section 208 with the step iron section 206 near one axial end of the stator. The straight bore section 208 has a generally constant diameter along the axial direction, while the step iron section 206 has a stepped diameter increase along the axial direction outside of the adjacent straight bore section 208. The stator core includes core slots 202 extending axially along the central axis 116. Radial stator tubes 214 extend at a 90 degree angle to the core slots 202 to allow for cooling flow to cool the stator 104. The generator injection tool 300 is positioned radially inward of at least one of the core slots 202. In one embodiment, the generator injection tool 300 includes a first handle 210 for manually positioning the generator injection tool 300 within the air gap 112, along the step iron portion 206, and radially inward of at least one of the core slots 202. The generator injection tool 300 may be held securely to the step iron portion 206 by magnetic forces. A borescope port 216 allows for attachment of a camera for observing and photographing the stator tube 214.

[0012] FIG. 3 shows a perspective view of the generator injection tool 300. The generator injection tool 300 includes a first carriage 304, a tube guide 302, a tube 306, a controller 308, and an adhesive supply 310. The first carriage 304 provides a structure for mounting and support of the other components of the generator injection tool 300. The contour of the bottom surface (not shown) of the generator injection tool 300 contacts and aligns with the geometry of the step iron portion 206. In one embodiment, the bottom surface of the generator injection tool 300 may include a slot guide, or a portion of the first carriage 304 that protrudes from the bottom surface and fits within the core slot 202. In some configurations, the first carriage 304 and other components of the generator injection tool 300 may be additively manufactured to reduce the total number of parts and allow for the formation of shapes and cavities not possible with conventional manufacturing techniques.

[0013] The tube guide 302 is mounted to a first carriage 304 and driven by a first motor 312. The tube guide 302 guides an adhesive-carrying tube 306 into the stator tube 214. A second motor 314 mounted to the first carriage 304 moves the tube guide 302 and tube 306 axially along the central axis 116 within a carriage slot 316 in the first carriage 304 to reach another position within an adjacent stator tube 214.

[0014] A tube 306 carrying adhesive includes a first end and a second end. The first end is attached to an adhesive supply 310 and the second end is movable between a first position outside the stator tube 214 and a second position within the stator tube 214. The tube 306 extends through a tube guide 302 of the first carriage 304 from one side of the first carriage 304 through the first carriage structure to the other side. A first motor 312 is controlled via a controller 308 to move the second end between the first and second positions. A nozzle 402 (shown in FIG. 4) is attached to the second end for dispensing adhesive into the stator tube 214.

[0015] The first motor 312 and the second motor 314 are controlled via a controller 308. Each of the first motor 312 and the second motor 314 may be a DC gear motor driven by the controller 308. The controller 308 controls, via the first motor 312, the speed at which the tube 306 is guided into the stator tube 214 and the depth to which the tube 306 is positioned within the stator tube 214. The controller 308 also controls, via the second motor 314, the axial positioning of the tube 306 to a further position within the adjacent stator tube 214.

[0016] An encoder 318 is also mounted to the first carriage 304. By being attached to a gear 322 disposed on the tube guide 302, the encoder 318 relates the rotational motion of the gear 322 to the linear motion of the tube 306 to determine the position of the second end of the tube 306 within the stator tube 214.

[0017] In the illustrated configuration, the first carriage 304 further includes a plurality of permanent magnets 320 at various positions on the first carriage 304 that engage with the step iron portion 206 to stationary the first carriage 304 on the step iron portion 206 during operation.

[0018] 2, a borescope can be placed through the borescope port 216 to position the camera within the stator tube 214. The camera allows a technician to visually inspect the stator tube 214 to more precisely position the nozzle 402. Light emitting diodes on the borescope illuminate the desired area within the generator. The camera is operable to capture an image of the stator tube 214.

[0019] FIG. 4 shows a perspective view of a nozzle 402 attached to a second end of a tube 306. The nozzle 402 is positioned within the stator tube 214 and dispenses adhesive as described above. The adhesive is dispensed through at least one orifice 404 in the nozzle 402. The nozzle end 408 is contoured to form the adhesive into a desired shape within the stator tube 214. This desired shape may be a two fillet pattern as shown in FIG. 5. In some cases, a spring positioning tab 406 is used to apply a force to the nozzle 402 to maintain pressure against a side ripple spring 502.

[0020] Figure 5 shows a top view of a portion of the stator 104 illustrating the desired location of adhesive within the stator tube 214. A side ripple spring 502 in the form of a wave spring is shown positioned within the stator tube 214 in Figure 5. Two fillet patterns 504 of adhesive are shown between the stator bar 204 and the side ripple spring 502. To form the two fillet patterns 504 in the correct locations, the nozzle 402 of the generator injection tool 300 is positioned at a desired location within the stator tube 214 by the controller 308. A predetermined amount of adhesive is pumped through the tube 306 and dispensed by the nozzle 402 in the correct location. The predetermined amount of adhesive creates the two fillet patterns 504 that have the ability to bond the side ripple spring 502 to the stator bar 204 without clogging the cooling flow into the stator tube 214.

[0021] 6 shows a perspective view of the generator cleaning tool 600 positioned on the step iron portion 206 of the stator core. Similar to the generator injection tool 300, the generator cleaning tool 600 includes a second carriage 604 that provides a structure for mounting and support of other components of the generator cleaning tool 600. The contour of the bottom surface (not shown) of the generator cleaning tool 600 contacts and aligns with the shape of the step iron portion 206. In one embodiment, the generator cleaning tool 600 includes a second handle 602 for manually positioning the generator cleaning tool 600 along the step iron portion 206 and radially inward of at least one of the core slots 202 and within the air gap 112. In some constructions, the second carriage 604 and other components of the generator cleaning tool 600 may be additively manufactured to reduce the total number of parts and to allow for the creation of shapes and cavities not possible with conventional manufacturing techniques.

[0022] Also similar to the first carriage 304, the second carriage 604 includes a plurality of permanent magnets 606 that engage the step iron portion 206 to secure the second carriage 604 in a stationary position on the step iron portion 206. The second carriage 604 also includes a tube spray adapter 608 coupled to the second carriage 604. The tube spray adapter 608 serves as a mounting for at least one spray tube. The at least one spray tube is attached and then removed as needed. In one embodiment, each spray tube extends from the tube spray adapter 608 to a pump and from the tube spray adapter 608 through the second carriage 604 to the stator tube 214. The pump sprays a fluid onto the stator tube 214 to clean and degrease the stator tube 214.

[0023] Additionally, the second carriage 604 includes at least one port 610 such that a borescope can be positioned to allow positioning of a camera within the stator tube 214 through one of the ports 610. The camera allows a technician to visually inspect the stator tube 214 and step iron portion 206. A light emitting diode on the borescope illuminates the area. The camera is operable to capture images of the stator tube 214 and / or step iron portion 206.

[0024] 7 is a flow chart illustrating a method 700 of injecting adhesive into a stator tube 214 in a stator 104 of a generator 100 while the rotor 102 is positioned within the stator 104. In block 702, the method 700 positions a first carriage 304 such that the first carriage 304 is located within the air gap 112 between the stator 104 and the rotor 102 and radially inward of the stator tube 214 of the stator 104. In block 704, the method 700 guides a tube 306, driven by a first motor 312, into the stator tube 214 by a tube guide 302 attached to the first carriage 304 to a first location. In block 706, the method 700 injects a predetermined amount of adhesive from an external adhesive source 310 through the tube 306 and from a first nozzle 402 attached to a nozzle end 408 of the tube 306 to the first location.

[0025] In operation, a user places the generator injection tool 300 and / or generator cleaning tool 600 in the air gap 112 between the rotor 102 and the stator 104. The permanent magnets 320 magnetically engage the step iron 206 and hold the generator injection tool 300 / generator cleaning tool 600 in place when gravity cannot hold the tool in place.

[0026] The generator injection tool 300 allows adhesive to be injected into the generator 100 while the rotor 102 is attached within the stator 104, avoiding disassembly. The first motor 312 and the second motor 314 can be operated to move the tube 306 to a desired location within the stator tube 214 before the adhesive is dispensed. The controller 308 can then operate the adhesive supply to pump a predetermined amount of adhesive to the desired location.

[0027] The generator cleaning tool 600 allows cleaning of the stator tubes 214 to be performed with the rotor 102 installed within the stator 104, avoiding disassembly. Using a low profile body that fits into the low clearance air gap 112 between the rotor 102 and stator 104, a second carriage aligns the stator tubes 214 and tubes to be cleaned. Additionally, the generator injection tool 300 and generator cleaning tool 600 can be used to guide a borescope through the borescope port 216 and port respectively to inspect the stator tube spaces.

[0028] Although illustrative embodiments of the present disclosure have been described in detail, it will be appreciated by those skilled in the art that various changes, substitutions, variations, and improvements therein can be made without departing from the spirit and scope of the disclosure in its broadest form.

Claims

1. 1. A generator injection tool for injecting adhesive into a generator including a rotor disposed within a stator having a stator tube, the rotor and the stator cooperating to define a gap; a first carriage sized to fit within the gap; a tube guide attached to the first carriage; a tube supported in part by the tube guide, the tube including a first end and a second end; a second end movable between a first position outside the stator tube and a second position in which the second end is located within the stator tube; a first motor coupled to the tube guide and operable to move the tube between the first position and the second position; a controller operable to selectively operate the first motor to position the second end of the tube at the second location within the stator tube; an adhesive source operable to move the adhesive through the tube from the first end to the second end when the tube is in the second position and to inject a portion of the adhesive into the stator tube; A generator injection tool having:

2. a second motor controlled via the controller, the second motor coupled to the first carriage and configured to axially move the tube within a slot in the first carriage such that the tube supplies the adhesive to a third location within an adjacent stator tube; The generator injection tool of claim 1 .

3. The generator injection tool of claim 1 , wherein the tube guide further comprises an encoder for determining a position of the tube within the stator tube.

4. The generator injection tool of claim 1 , further comprising a camera coupled to the first carriage and operable to capture an image of the stator tube.

5. The generator injection tool of claim 1 , further comprising a first handle attached to the first carriage for manually placing the first carriage within the gap.

6. The generator injection tool of claim 1 , further comprising a nozzle attached to the second end, the nozzle including an opening through which the adhesive is dispensed to the second location.

7. The generator injection tool of claim 6 , wherein the nozzle profile creates a two fillet pattern of the adhesive as the adhesive is dispensed at the second location.

8. 1. A method for injecting adhesive into a stator tube in a stator of a generator including a rotor disposed within the stator while the rotor is disposed on the stator, comprising: positioning a first carriage to be located in a gap between the stator and the rotor and radially inward of the stator tube of the stator; orienting a tube in the stator tube to a first position by a tube guide mounted to the first carriage and driven by a first motor; injecting a quantity of adhesive from an external source through the tube and into the first location through a first nozzle attached to the end of the tube; The method includes:

9. The method of claim 8 , wherein the orienting step further comprises determining a position of the tube within the stator tube utilizing an encoder attached to the tube guide.

10. 9. The method of claim 8, further comprising: moving the tube axially through a slot in the first carriage to the second location by a second motor mounted on the first carriage to inject the predetermined amount of adhesive at the second location and injecting the predetermined amount of adhesive at the second location.

11. Prior to the step of attaching the first carriage, the method further includes the step of positioning a second carriage in the gap between the stator and the rotor of the generator, the second carriage including a second tube having an end; The step of placing includes: positioning the second carriage radially inward of the stator tube of the stator; aligning the end of the second tube with the stator tube; and pumping a fluid through the second tube and into the stator tube from the end to clean the stator tube; The method of claim 8 , comprising:

12. removing the second tube; mounting a camera on an attachment on the second carriage; aiming the camera at the stator tube; inspecting the stator tube via the camera; The method of claim 11 , further comprising:

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