Generator Connection Assembly Metal Rails Grounding
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Solution Overview
Problem
Existing high-speed generators face issues with impedance in the connection assembly, particularly due to the use of beryllium copper elements as rails, which can introduce undesirable effects on the transmitted DC voltage, and the plastic members in which spring clips sit may deform, reducing the compressed force holding the spring clips against the connections.
Innovation Solution
The connection assembly in the high-speed generator uses metal rails (aluminum) for both positive and negative rails, eliminating the need for a high impedance resistor by providing a direct ground connection, and incorporates metal spring clips and ceramic suppression resistors, with the negative rail making contact with the shaft to establish a ground connection, and the spring clips sitting in metal pockets to maintain a secure lock.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If beryllium copper elements are used as rails in the connection assembly, then electrical connection is established, but impedance is introduced that causes undesirable effects on the transmitted DC voltage
Solution Approach 1:
The patent removes the high impedance resistor from the connection assembly by establishing a direct ground connection through the negative rail to the shaft. This extraction of the impedance-introducing component eliminates the harmful impedance effect while maintaining the electrical connection function.
Solution Approach 2:
The patent changes the electrical resistance parameter of the connection assembly by using aluminum rails with lower impedance characteristics and establishing a direct ground path. This parameter change reduces the impedance from a high value (requiring suppression resistors) to a low value that eliminates the need for impedance management components.
2Ease of manufacture
If plastic members are used to hold spring clips, then structural support is provided, but the plastic may deform and reduce the compressed force holding the spring clips against the connections
Solution Approach 1:
The patent changes the material parameter of the spring clip from plastic to metal, which fundamentally alters the mechanical properties. Metal spring clips maintain their elastic properties and compressed force over time and temperature ranges where plastic would deform, thus maintaining reliable electrical connection force.
Solution Approach 2:
The patent employs a hybrid construction where metal spring clips are used within a housing structure, combining the advantages of metal (elasticity, force maintenance) with the manufacturing benefits of molded housing structures. This composite approach maintains connection reliability while preserving ease of manufacture.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances the reliability and efficiency of the DC voltage transmission to the main field winding by eliminating impedance issues and maintaining a consistent connection force, improving the overall performance of the high-speed generator.
Implementation Method 1
A rectifier assembly is in electric communication with the exciter rotor to receive AC current and rectify the AC current into a DC voltage
Implementation Method 2
The negative rail is in contact with the shaft to provide a ground connection
Data Source
AI summary
A rotor pack for a generator has an exciter rotor rotating with a shaft. A rectifier assembly is in electric communication with the exciter rotor to receive AC current and rectify the AC current into a DC voltage. Positive and negative busses extend from the rectifier assembly to a negative rail and a positive rail on a connection assembly. The negative rail is in contact with the shaft to provide a ground connection. The negative and positive rails are formed of a metal. The negative and positive rails are connected to a main field winding. A high speed generator is also disclosed.