Generator Stator Wedge Preload Measurement Device
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Solution Overview
Problem
Current methods for measuring stator wedge preload in generators are inaccurate, non-repeatable, and difficult to apply in situ, particularly due to the creep and wear of stator wedges and resilient members, which can lead to loose stator bars during generator operation.
Innovation Solution
A measurement device comprising a force application device with an actuator and a sensor to measure displacement, connected to a controller that collects data on the applied force and displacement, allowing for precise and repeatable preload measurements by correlating force and displacement data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If stator wedge tapping method is used to measure preload, then measurement can be performed, but measurement precision and repeatability are poor
Solution Approach 1:
The patent replaces the traditional mechanical tapping method with an electromagnetic actuator system. The actuator applies controlled forces to the stator wedge while sensors measure displacement, eliminating the need for manual hammering and acoustic evaluation. This substitution provides precise, repeatable measurements through electronic control and digital data collection.
Solution Approach 2:
The patent introduces sensors as intermediary devices between the actuator and the stator wedge. These sensors measure displacement caused by applied forces and transmit data to a controller, serving as a mediator that converts mechanical deformation into measurable electrical signals for accurate preload determination.
2Reliability
If manual tapping method is used, then operator can assess preload, but repeatability is poor due to varying tap location and force
Solution Approach 1:
The patent employs a dynamic measurement system where the actuator can apply forces at multiple locations and the sensors can detect displacement from different positions. The controller systematically varies measurement parameters to gather comprehensive data, enabling repeatable results regardless of slight variations in probe placement or measurement orientation.
Solution Approach 2:
The system incorporates feedback through sensors that continuously monitor displacement and transmit data to the controller. The controller processes this feedback information to determine preload status, allowing for automatic adjustment and verification of measurements, which ensures high repeatability and reduces dependence on operator skill.
3Productivity
If in situ measurement is required, then generator operation can be monitored, but measurement accessibility is limited
Solution Approach 1:
The measurement system is divided into modular components: an actuator module, a sensor module, and a control module. This segmentation allows the devices to be inserted and positioned independently within the generator structure, enabling in situ measurements without requiring complete disassembly of the generator assembly.
Solution Approach 2:
The measurement device is designed with multi-functional capabilities to handle various measurement scenarios within the generator. The actuator can apply forces in different directions, the sensors can measure displacement at multiple points, and the controller can process various types of data, making the system universally applicable for monitoring stator wedge preload in different operational conditions.
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
The solution provides specific, accurate, and repeatable preload measurements, enabling efficient in situ monitoring and maintenance of generators by ensuring stator bars remain securely in place.
Implementation Method 1
an actuator operable to apply a force to the stator wedge
Implementation Method 2
a sensor operable to measure displacement of the stator wedge
Data Source
AI summary
A measurement device for a generator and a method for measuring stator wedge preload are disclosed. The generator includes a stator and a rotor, the stator including a stator wedge. The measurement device includes a force application device, the force application device including an actuator operable to apply a force to the stator wedge. The measurement device further includes a sensor operable to measure displacement of the stator wedge. The measurement device further includes a controller in communication with the force application device and the sensor and configured to collect data associated with the force and the displacement.