End Winding Support for Electric Generator Rotor Coils
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Solution Overview
Problem
Electric generator rotor coils face strain due to high rotational speeds and vibrations, particularly at the ends where additional support is needed to prevent breakage and ensure retention in high-temperature, possibly lubricating oil environments, which existing support methods inadequately address.
Innovation Solution
The implementation of end winding supports with specific geometries, including grooves and shim support features, to securely hold the coil in place across the rotor core ends, providing structural integrity and insulation while allowing coolant flow, and using spring clips for conductive connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional support pieces are provided at the ends of the rotor core, then the coil retention and service life are improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The end winding support is divided into multiple functional segments: a support body portion for structural retention, groove features for coil positioning, and shim support features for adjustable positioning. This segmentation allows each feature to address specific retention requirements without over-complicating the overall structure.
Solution Approach 2:
The support structure incorporates localized features at specific positions: grooves are positioned where the coil requires retention, and shim support features are located where positioning adjustment is needed. This local quality approach provides enhanced support only where required rather than uniformly throughout the entire structure.
2Duration of action of moving object
If the support structure is made more robust to handle high temperatures and vibrations, then the service life is improved, but the weight and material usage increase
Solution Approach 1:
The end winding support utilizes a thin-walled structure with strategic reinforcement features rather than a uniformly thick robust design. The groove features and shim support areas provide localized strength where needed while maintaining overall lightweight construction through thinner walls in non-critical areas.
Solution Approach 2:
The support structure employs composite construction combining different material properties: the support body portion provides structural framework, while groove features and shim support areas provide localized reinforcement. This composite approach achieves robust performance at critical locations without uniformly increasing weight throughout the entire component.
3Reliability
If the end winding support provides comprehensive coil retention, then the reliability under strain is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The groove features are designed to self-align with the coil structure during assembly, and the shim support features automatically provide positioning through the shim installation process. This self-service mechanism reduces the need for high-precision manual alignment and machining while ensuring reliable coil retention under operational strain.
Solution Approach 2:
The shim support features provide pre-positioning capability that cushions against manufacturing tolerances. By allowing adjustment through shims before final assembly, the design compensates for variations in groove positioning and ensures reliable coil retention without requiring extremely tight manufacturing precision on all features.
Data Source
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AI summary
An end winding support for an electric generator includes a pair of winding lead supports 202 formed on opposite sides of a winding slot 204 and separated by an upper slot width. Each of the winding lead supports includes a winding channel routed between a lead coupling port and the winding slot. The winding slot includes a base support 210 and a pair of alignment members 212 that define a transition between the base support and the winding lead supports. A lower slot width is defined along the base support between the alignment members and a ratio of the upper slot width to the lower slot width is between 1.024 and 1.053.