Generator Terminal Insulator Assembly After Brazing
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Solution Overview
Problem
The existing assembly process of generators risks damaging insulators due to overheating during the brazing of terminals to the stator winding, requiring costly and time-consuming un-brazing and replacement.
Innovation Solution
The terminal assembly is designed with an insulator that can be installed after the terminal is brazed to the stator winding, using retaining rings to secure the insulator in place, thereby avoiding direct exposure to heat during the brazing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulator is installed before the terminal is brazed to the stator winding, then the insulator is in place during assembly, but the insulator is damaged due to overheating from the brazing process
Solution Approach 1:
The terminal is brazed to the stator winding before the insulator is installed. This reverses the conventional sequence where the insulator would be installed first, thereby protecting the insulator from thermal damage during the brazing process while ensuring the terminal is already securely attached to the stator winding
2Reliability
If the insulator is installed after the terminal is brazed, then the insulator is protected from heat damage, but the insulator installation becomes more complex
Solution Approach 1:
The assembly process is segmented into distinct phases: first brazing the terminal to the stator winding, then separately installing the insulator. This segmentation allows each component to be prepared and assembled independently, reducing thermal interference and simplifying the overall manufacturing process despite the reversed sequence
3Productivity
If the insulator is damaged during brazing, then assembly continues, but costly and time-consuming un-brazing is required to replace the insulator
Solution Approach 1:
By brazing the terminal to the stator winding before installing the insulator, the terminal connection is established and secured in advance. This preliminary action ensures that the terminal cannot be accidentally damaged during insulator installation, eliminating the need for costly un-brazing operations and allowing straightforward insulator replacement if needed
Data Source
AI summary
A terminal assembly of an electric machine includes an electric machine housing including a terminal opening defined in the electric machine housing. A conductive terminal extends through the terminal opening, from an inside of the electric machine housing to an outside of the electric machine housing. An insulator is located at the terminal. The insulator is positioned between the terminal and a housing wall of the terminal opening. The insulator is sized and configured for installation into the terminal opening after installation of the terminal in the terminal opening.