Generator Housing Alignment Hardware for Consistent Stator Gap
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Solution Overview
Problem
Conventional engine-driven generators face challenges in achieving consistent stator-to-rotor gap length due to manufacturing variations and require labor-intensive varnish processes, leading to increased costs and complexity in machining and assembly.
Innovation Solution
The implementation of a mechanical attachment system using tapered stud and nut hardware for aligning and securing the stator assembly to the generator housing, simplifying the attachment process and ensuring consistent gap length, while allowing for thicker varnish layers without extensive secondary processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional machining and assembly methods are used for generator housings, then manufacturing precision can be achieved, but the process becomes labor-intensive and complex
Solution Approach 1:
The patent introduces an intermediary mechanical attachment system with tapered stud and nut hardware that mediates between the stator assembly and generator housing. This intermediary mechanism simplifies the direct connection process, enabling precise alignment and consistent gap length without requiring complex machining operations on the housings themselves.
Solution Approach 2:
The patent changes the geometric parameters of the attachment hardware by using tapered surfaces instead of conventional flat or threaded-only connections. The tapered studs and nuts provide self-aligning characteristics that automatically establish the correct orientation and spacing, reducing the need for precise pre-machining of the housing mounting surfaces.
2Strength
If conventional attachment methods are used for the stator assembly, then secure mounting is achieved, but the varnish process becomes labor-intensive and costly
Solution Approach 1:
The patent performs preliminary alignment and positioning actions through the tapered attachment hardware before the varnish application process. The mechanical attachment system pre-establishes the correct stator position and orientation, allowing the varnish to be applied more efficiently without requiring extensive secondary processing or repositioning after varnishing.
3Manufacturing precision
If precise alignment is achieved through conventional methods, then consistent gap length is obtained, but manufacturing costs increase
Solution Approach 1:
The tapered stud and nut hardware acts as an intermediary alignment mechanism that provides precise positioning without requiring expensive precision machining of the generator housing mounting surfaces. The self-aligning geometry of the tapered components achieves high alignment precision while keeping the housing manufacturing relatively simple and cost-effective.
Data Source
AI summary
An example engine-driven generators includes: a stator assembly having first mounting holes; a first generator housing configured to couple the stator assembly to an engine, and having second mounting holes; first stator alignment hardware configured to align the first mounting holes of the stator assembly with corresponding ones of the second mounting holes of the first generator housing; stator securing hardware configured to secure the stator assembly in cooperation with the first stator alignment hardware; first locating faces configured to mate with mating faces of corresponding ones of the second mounting holes to locate the first mounting holes with the second mounting holes; and first housing securing hardware configured to secure the first generator housing to the stator assembly.