Interlocking Wedge System for Stator Coil Locking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing generator stator wedge systems lack an effective mechanism to securely lock stator coils in place within the stator core, leading to potential movement and uneven distribution of radial loads.
Innovation Solution
A locking wedge system comprising an outer wedge with a tapered surface and an inner locking wedge with a corresponding recess, along with an interlocking mechanism and a locking member, is used to securely position and lock the stator coil within the stator core, utilizing a triangular protrusion and oval recess configuration for interlocking, and featuring ears for radial vent engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a locking mechanism is added to secure stator coils in the stator core, then the reliability of the stator coil positioning is improved, but the device complexity increases
Solution Approach 1:
The locking mechanism is nested within the wedge structure itself. The locking protrusion on the outer wedge fits into the locking recess on the inner wedge, creating an integrated locking feature that does not require separate external locking components. This nesting approach improves reliability while minimizing additional complexity.
Solution Approach 2:
The locking function is merged with the wedge structure. The outer wedge and inner wedge are designed with complementary locking features (protrusion and recess) that combine the securing function with the existing wedge components, eliminating the need for separate locking devices and reducing overall system complexity.
2Productivity
If multiple wedge segments are used to hold stator coils, then the productivity of coil installation is improved, but the ease of operation for assembly and disassembly deteriorates
Solution Approach 1:
The locking protrusion and recess are pre-configured in the wedge segments before assembly. When the wedges are installed, the locking features automatically engage without requiring additional manual intervention or complex alignment procedures, maintaining ease of operation while enabling secure multi-segment construction.
Solution Approach 2:
The wedge system is divided into multiple segments (outer wedge and inner wedge) that can be independently positioned and assembled. Each segment has simplified locking features that engage automatically, allowing efficient assembly of multiple segments while maintaining ease of operation through modular design.
3Strength
If a locking mechanism with interlocking features is implemented, then the strength of the wedge system is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The locking protrusion and recess are designed with asymmetric geometries that provide inherent alignment guidance. The triangular locking protrusion fits into a corresponding recess with specific angular orientation, creating self-aligning features that reduce sensitivity to manufacturing tolerances while maintaining strong locking capability.
Solution Approach 2:
The locking features utilize geometric parameters (angles, dimensions of protrusion and recess) that are optimized to provide adequate locking strength while accommodating reasonable manufacturing tolerances. The tapered surfaces and interlocking geometry are designed with parameter ranges that balance strength requirements with manufacturability.
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 system effectively inhibits stator coil movement, evenly distributes radial loads, and allows for easy installation and disassembly without damage, ensuring secure and efficient operation.
Implementation Method 1
an outer wedge including a first tapered surface, an inner locking wedge positioned on the slot layer, the inner locking wedge including a second tapered face that interfaces with the first tapered face
Implementation Method 2
an interlocking mechanism to couple the outer wedge to the inner locking wedge
Implementation Method 3
a locking member configured to lock the inner locking wedge to the stator core
Data Source
AI summary
A locking wedge system for securing a stator coil in a slot of a stator core includes a slot layer positioned on the stator coil to inhibit movement of the stator coil within the slot, an outer wedge including a first tapered surface, an inner locking wedge positioned on the slot layer, the inner locking wedge including a second tapered face that interfaces with the first tapered face, a locking member configured to lock the inner locking wedge to the stator core, and an interlocking mechanism to couple the outer wedge to the inner locking wedge.