Generator Stator End Winding Coil Support Assembly
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Solution Overview
Problem
The existing methods for supporting generator stator end winding coils are labor-intensive, inconsistent, and time-consuming, particularly due to the manual application of glass banding, which makes it difficult to achieve consistent support and maintain mechanical strength, leading to potential system faults and degradation over time.
Innovation Solution
A support assembly and method that includes an outer support circumferentially disposed around the bottom end winding coils, with radially oriented studs threaded into inner braces to provide a controlled clamping force, allowing for precise and repeatable support of both top and bottom end winding coils without requiring disassembly of the rotor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual glass banding is used to support end winding coils, then the process can be applied to existing generators, but the labor intensity and inconsistency increase significantly
Solution Approach 1:
The support assembly is designed to be self-installing through the stator assembly, where the outer support fits over the stator core and the inner support is positioned within the coil assembly, eliminating the need for manual glass banding application and enabling consistent installation without disassembling the generator
2Adaptability or versatility
If manual glass banding is used to support end winding coils, then the process can be applied to existing generators, but the consistency and reliability decrease
Solution Approach 1:
The invention changes the support mechanism from manual tensioning of glass bands to a mechanical compression system where the outer support and inner support are positioned at predetermined locations, providing consistent and repeatable support parameters across all installations
3Strength
If additional banding and resin are applied to maintain support structures, then the mechanical strength can be maintained, but the maintenance time and complexity increase
Solution Approach 1:
The invention extracts the maintenance requirement from the support system by designing a pre-assembled support structure with predetermined outer and inner supports that provides long-term stable support without requiring periodic application of additional banding and resin
4Reliability
If a complex support structure with multiple components is used, then the mechanical strength and support reliability improve, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The support assembly is segmented into distinct outer support and inner support components with predetermined positions, where the outer support is circumferentially disposed around the stator core and the inner support is disposed within the coil assembly, simplifying the overall structure while maintaining reliability
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 solution provides a faster, less invasive, and more cost-effective way to maintain generator performance by ensuring consistent and predictable support of end winding coils, reducing labor costs and time, and allowing for retightening of the clamping force without rotor removal.
Implementation Method 1
The studs are configured to be tensioned to a required clamping force for supporting the end winding coils
Data Source
AI summary
An assembly and a method for supporting generator stator end winding coils are presented. The assembly includes an outer support circumferentially disposed on outer side of bottom end winding coils and inner braces disposed on inner side of top end winding coils and circumferentially spaced apart from each other. At least one inner brace is disposed along an axial direction of the top end winding coils. Studs are radially oriented and threaded into the inner braces from the outer support. The studs are tensioned and retightenable to a required clamping force for supporting the end winding coils. Filler layers are disposed between the top end wind coils and bottom end wind coils for supporting the clamping force.