Optical Fiber Resin Impregnation Detection Device for Rotating Machine Coils
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Solution Overview
Problem
Existing resin impregnation detection devices face challenges in detecting resin impregnation in narrow portions of coils for rotating machines due to their size and the presence of metal foreign materials, which hinder insertion and leave residues after impregnation.
Innovation Solution
A resin impregnation detection device utilizing an optical fiber with a Fiber Bragg Grating (FBG) sensor and a coating resin that softens upon contact with the resin, allowing detection through strain changes caused by compressive strain release, eliminating the need for metal foreign materials and enabling insertion into narrow spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional detection device with metal foreign materials is used, then detection function is provided, but the device cannot be inserted into narrow portions and leaves residues after impregnation
Solution Approach 1:
The invention extracts and removes the metal foreign material component from the detection device. The detection device is reconfigured to use only optical fiber and resin materials, eliminating metal parts that would leave harmful residues. This allows the device to be inserted into narrow portions without causing contamination.
Solution Approach 2:
The invention changes the material parameters of the detection device from metal-based to optical fiber and resin-based materials. This parameter change enables the device to meet both requirements: insertability into narrow portions and absence of harmful residues after impregnation.
2Strength
If the coating resin thickness is increased to protect the optical fiber, then mechanical strength is improved, but the device cannot be inserted into narrow spaces
Solution Approach 1:
The invention applies local quality by making the coating resin thickness position-dependent. The coating resin is made thinner at the tip portion where insertability is critical, while maintaining sufficient thickness at the shaft portion for mechanical strength. This localized variation in thickness resolves the contradiction between strength and insertability.
3Reliability
If the resin impregnation process time is extended to prevent unimpregnated portions, then insulation reliability is improved, but productivity is lowered
Solution Approach 1:
The invention implements feedback by using the optical fiber-based detection device to monitor resin impregnation in real-time. The detection device provides continuous feedback on the impregnation state, allowing the process to be stopped precisely when impregnation is complete. This eliminates the need for extended process times while ensuring complete impregnation, thus maintaining reliability while improving productivity.
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 device accurately detects resin impregnation without leaving foreign materials, ensuring precise detection and minimizing the thickness of the coating resin for easy insertion, thus enhancing productivity and preventing insulation breakdown.
Implementation Method 1
an optical fiber including at least one FBG sensor; and a coating resin, which is coated by applying a compressive strain to the FBG sensor when being cured
Implementation Method 2
the resin impregnation detection device is configured to detect impregnation with the resin by the FBG sensor, which is configured to detect, when the compressive strain applied to the FBG sensor is released during the softening, a change in a Bragg wavelength caused by the release of the compressive strain
Implementation Method 3
the coating resin includes a resin to be softened by contact with a detection target resin
Data Source
AI summary
A resin impregnation detection device configured to detect resin impregnation in a resin impregnation process for a coil insulation layer. The resin impregnation detection device can be inserted in a narrow portion, is capable of detecting impregnation with a liquid resin, and does not leave metal foreign materials other than an optical fiber in a product even after the resin impregnation. The resin impregnation detection device includes an optical fiber including an FBG sensor, and a coating resin, which coats the FBG sensor. The coating resin includes a resin to be softened by contact with a detection target resin. The FBG sensor is applied with a compressive strain caused by cure shrinkage of the coating resin or heat shrinkage thereof from a curing temperature to a normal temperature.