Hexagonal Generator Collar Reduces End Turn Deflection

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Solution Overview

Problem

The end turn support in generators experiences deflection during operation, leading to fatigue and potential failure due to high-speed interactions with rotating components, which existing technologies have not adequately addressed.

Innovation Solution

A collar with a hexagonal outer periphery and an axially extending inner ledge is positioned on the generator shaft, fitting within the end turn support ring to reduce deflection, and is used in combination with an insulator to enhance stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the end turn support ring is used to support coil ends, then the generator structure is simplified and manufacturing is easier, but the end turn support experiences deflection during operation leading to fatigue and potential failure

Engineering Contradiction:

Improveease of manufactureVSAvoidreliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The collar acts as an intermediary component between the shaft and the end turn support ring. It is mounted on the shaft and provides additional support to the end turn support, thereby reducing deflection and stress without complicating the overall generator structure or manufacturing process

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The support function is segmented into two separate components: the original end turn support ring and the newly introduced collar. This segmentation allows each component to perform its specific function optimally - the ring provides structural support while the collar reduces deflection and stress concentrations

Inventive Principle:

Principle #1Segmentation

2Power

If high speed components rotate relative to the end turn support, then the generator operates at higher power output, but deflection increases causing fatigue and possible failure

Engineering Contradiction:

ImprovepowerVSAvoidreliability

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The collar provides beforehand cushioning by reducing stress concentrations and deflection in the end turn support ring before fatigue can occur. It acts as a protective measure that mitigates the harmful effects of high-speed operation before they lead to failure

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The collar converts the harmful dynamic stresses and deflections caused by high-speed rotation into beneficial stress distribution. By providing additional support and reducing deflection, it transforms the problematic high-speed conditions into acceptable operational parameters

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Data Source

PatentUS7855487B2Generator end turn stress reduction collar

Publication Date: 2010.12.21 HAMILTON SUNDSTRAND CORP

AI summary

A collar is to be positioned on a generator and includes an inner bore sized to be received on an outer periphery of a generator shaft. The collar has an outer periphery, which is generally hexagonal. The collar has an axially extending ledge to be received within an inner periphery of an end turn support in a generator.