Rotating Machine Coil Insulation Repair Method
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Solution Overview
Problem
Conventional methods for repairing the insulating layer of rotating electrical machine coils require large facilities and struggle to ensure dimensional accuracy and reliability of insulation performance, particularly due to the need for vacuum impregnation and complex processes.
Innovation Solution
A repair method that involves removing a portion of the existing insulating layer, applying a thinner first insulating layer, and then a second layer to achieve the original thickness, using a resin-rich insulation method that allows for on-site repairs without the need for large equipment, ensuring dimensional accuracy and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the whole bar or coil is impregnated in varnish using conventional methods, then the insulation performance is restored, but a large facility with vacuum impregnation equipment is required
Solution Approach 1:
The invention extracts the varnish impregnation process from the large-scale vacuum tank facility and performs it locally at the repair site. The varnish is applied directly to the specific damaged area of the bar or coil using simple application tools, eliminating the need for large vacuum impregnation facilities while still achieving proper varnish penetration and insulation restoration.
Solution Approach 2:
Instead of impregnating the entire bar or coil uniformly, the invention applies varnish only to the specific local area where insulation damage occurs. This localized approach reduces material consumption and eliminates the need for large facilities, as only the affected portion requires treatment to restore insulation performance.
2Manufacturing precision
If vacuum impregnation is used to ensure dimensional accuracy of the insulating layer, then the insulation property is improved, but the facility complexity increases
Solution Approach 1:
The invention uses pre-formed insulating layers (such as pre-impregnated tapes or pre-cured insulation pieces) that replicate the dimensional characteristics of the original insulation. These copied insulating layers are applied to the damaged area, ensuring dimensional accuracy matches the original design without requiring complex vacuum impregnation facilities to achieve proper curing and shaping.
3Reliability
If the insulating layer is sufficiently examined and processed to ensure dimensional accuracy, then the reliability is improved, but the manufacturing time and cost increase
Solution Approach 1:
The invention uses pre-impregnated insulating materials that have already been prepared with the correct varnish concentration and curing properties before application. This preliminary preparation eliminates the need for time-consuming on-site varnish mixing, multiple coating passes, and extended curing cycles, thereby reducing manufacturing time while maintaining reliable insulation performance through the use of pre-engineered materials.
Data Source
AI summary
A bar or coil includes a conductor arranged in a rotating electrical machine and an insulating layer having a predetermined insulation thickness disposed on a surface of the conductor. The repair method includes: extracting a part of the bar or coil as a repair target; removing the insulating layer in a part of the bar or coil as the repair target; disposing a first insulating layer in the part where the insulating layer is removed, the first insulating layer having an insulation thickness thinner than the predetermined insulation thickness; and disposing a second insulating layer on a surface of the first insulating layer to form an insulating layer after a repair where the first insulating layer and the second insulating layer are added, the insulating layer after the repair having a thickness of the predetermined insulation thickness.