Generator Winding Repair via Segmented Partial Coil Replacement
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Solution Overview
Problem
Existing methods for repairing windings in generators, especially in large or hard-to-access wind turbines, require removing the rotor or substituting entire stator sectors, which is cumbersome and inefficient, particularly in offshore installations.
Innovation Solution
A method involving cutting existing windings into two parts to allow for easy removal and replacement with a substitute partial coil, where incomplete turns are connected using conductor portions, enabling the winding to be repaired without disassembling the rotor from the stator, and a kit comprising incomplete turns and connectors for this purpose.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the rotor is removed from the stator to replace windings, then the windings can be replaced, but the maintenance becomes very difficult and cumbersome
Solution Approach 1:
The winding is divided into two separate parts: the first part remains in the slot and the second part is removed and replaced. This segmentation allows the winding to be replaced without removing the entire rotor from the stator, making maintenance much easier and less cumbersome while still achieving complete winding replacement.
Solution Approach 2:
The second part of the winding is extracted from the slot and replaced with a new winding part. This extraction approach allows the defective portion to be removed and replaced independently, avoiding the need to disassemble the entire rotor-stator assembly for maintenance.
2Ease of repair
If a complete sector of the stator is substituted to replace a coil, then the coil can be replaced, but a part of the generator is substituted requiring precise air gap adjustment
Solution Approach 1:
Instead of substituting a complete stator sector, the invention segments the winding into two parts and only replaces the second part. This localized replacement approach maintains the original stator structure and positioning, eliminating the need for complex air gap adjustments that would be required if an entire sector were replaced.
Solution Approach 2:
Only the necessary portion of the winding (the second part) is extracted and replaced, rather than extracting and replacing an entire stator sector. This minimizes the scope of replacement and preserves the original generator geometry, avoiding subsequent air gap adjustment requirements.
3Ease of operation
If the winding is cut into two parts, then the substitute partial coil can be slid on the tooth, but the winding structure becomes more complex
Solution Approach 1:
The winding is segmented into two parts with a specific configuration where the first part remains in the slot and the second part extends outward. This segmentation enables the second part to be independently installed by sliding it onto the tooth, simplifying the installation process despite the divided structure.
Solution Approach 2:
The first part of the winding is nested within the slot structure, while the second part extends outward for connection. This nesting arrangement allows the winding to be divided into manageable sections that can be installed separately, with the first part providing a foundation for the second part.
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 1e~1f
AI summary
Method of repairing a winding in a generator, the generator having a generator rotor and a generator stator, wherein the generator rotor and/or stator comprises a plurality of windings, the windings comprising a stack of turns of a conductor around a tooth (11), wherein the method comprises cutting the winding on a side of the tooth (11) to separate the winding in two parts; removing the two parts of the winding from the tooth (11); sliding a substitute partial coil (20) on the tooth (11), the substitute partial coil (20) comprising a stack of incomplete conductor turns (201,202,203) having a first end (20d) and a second end (20e), said first and second end positioned on the same side of the tooth (11); and connecting the second ends of each incomplete turn (201,202,203) with a first end of the next incomplete turn using a plurality of conductor portions (30,301,302). The disclosure further relates to a kit for making a substitute coil.