Interpole Coil Replacement on Integral-Core DC Motor Frames
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Solution Overview
Problem
DC machines with integral interpole coil cores are difficult to repair due to limited rebuild options, often requiring entire re-winding or being deemed unrepairable, leading to high costs and inefficiencies.
Innovation Solution
A retainer is mounted to the field frame to secure the interpole coil in place, using a stand-off to position and retain the new interpole coil, which is then resin-coated and cured, allowing for individual coil replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If interpole coil cores are integrally formed with the field frame, then structural strength and manufacturing simplicity are improved, but repairability deteriorates
Solution Approach 1:
The invention segments the interpole coil assembly by introducing a retainer component that can be independently removed from the field frame. This allows the interpole coil to be separated and replaced without affecting the integral field frame structure, thereby enabling repairability while maintaining the structural integrity of the original design.
2Reliability
If entire re-winding is performed for integral cores, then reliability is improved, but loss of time and cost increase
Solution Approach 1:
The invention extracts the interpole coil from the integral field frame structure by using a removable retainer. This allows only the failed coil to be removed and replaced, rather than requiring complete re-winding of all coils, significantly reducing downtime and cost while maintaining system reliability.
3Ease of operation
If retainer with stand-off is used to position coil, then ease of assembly is improved, but device complexity increases
Solution Approach 1:
The invention introduces a retainer with stand-off as an intermediary component between the field frame and the interpole coil. This simple mechanical element provides positioning and retention functions, making assembly easier while adding minimal complexity to the overall system.
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
Enables repair of individual interpole coils, reducing time and cost by transforming the motor into a repairable state, avoiding the need for complete re-winding.
Implementation Method 1
The insulation of the new interpole coil is resin coated and cured
Data Source
AI summary
A method of replacing a failed interpole coil on a DC motor field frame having integral interpole coil cores. The failed interpole coil is removed from the interpole coil core of the field frame. A new interpole coil, separate from the corresponding interpole coil core, is wound to replace the failed interpole coil, the new interpole coil including conductor turns and insulation. A retainer is mounted to the field frame at an axial end thereof, the retainer having a body portion extending radially inward with a width configured to fit within an interior dimension of the new interpole coil. The retainer has a stand-off projecting from the body. The new interpole coil is assembled in a radial direction onto the corresponding interpole coil core such that the new interpole coil is positioned by the stand-off. The insulation of the new interpole coil is resin coated and cured.