Optical Stator Wedge Inspection for Ripple Spring Tightness
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Solution Overview
Problem
Conventional methods for inspecting the tightness of retaining ripple springs in dynamoelectric machines are subjective, time-consuming, and inaccessible in many generators, leading to potential catastrophic failures due to vibration of stator coils.
Innovation Solution
A visual inspection apparatus and method using an optical device inserted into a stator core slot to obtain images of the retention assembly, measuring the distance between the wedging member and shim, calculating the remaining deflection of the ripple spring, and determining the load value using a known load versus deflection correlation, allowing for accurate assessment of ripple spring tightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional methods (manual tapping, depth gauge measurements, or physical displacement) are used to inspect ripple spring tightness, then inspection can be performed, but the methods are either subjective, time-consuming, require pre-formed test holes, or involve physical impact that may cause damage
Solution Approach 1:
The patent replaces mechanical inspection methods (manual tapping, depth gauges, physical displacement sensors) with an optical measurement system. The optical device captures images of the stator wedge surface, and image processing algorithms automatically measure wedge position and ripple spring compression, eliminating the need for physical contact or complex mechanical measurement apparatus.
Solution Approach 2:
The patent creates an optical copy (image) of the stator wedge and ripple spring assembly, then analyzes this copy to determine tightness measurements. This allows non-contact measurement by capturing visual information and processing it through image analysis algorithms, avoiding the need for physical measurement tools.
2Measurement precision
If pre-formed test holes are added to stator wedges to enable depth gauge measurements, then measurement becomes possible, but the generator must be rewound, which is time-consuming and costly
Solution Approach 1:
The patent extracts the measurement function from the physical structure by using optical imaging instead of requiring physical access holes. The system captures images through the existing stator wedge structure and uses image processing to measure ripple spring compression, eliminating the need to extract material (create test holes) or disassemble the generator for measurement.
Solution Approach 2:
The optical inspection system provides a universal measurement method that works on all generator types without requiring modifications such as pre-formed test holes. The system can inspect any stator wedge configuration by capturing optical images and processing them algorithmically, making the inspection method universally applicable across different generator designs.
3Ease of operation
If manual tapping of stator wedges is used to assess ripple spring tightness, then inspection is simple, but the results are extremely subjective and vary greatly between inspectors
Solution Approach 1:
The patent implements an automated feedback system where the optical device captures images, the processing system analyzes the images to measure wedge position and ripple spring compression, and the results are automatically displayed. This closed-loop system eliminates human subjectivity by providing objective, quantifiable measurements with clear pass/fail criteria based on predetermined thresholds.
Solution Approach 2:
The patent replaces the subjective mechanical tapping method with an optical measurement system that provides objective numerical measurements. Instead of relying on inspector experience and subjective interpretation of tap sounds, the system uses image processing to calculate precise measurements of wedge position and spring compression, eliminating inter-inspector variability.
4Measurement precision
If physical displacement of stator wedge is used to measure ripple spring compression, then indirect indication of compression is obtained, but the method involves impacting the wedge which may cause damage
Solution Approach 1:
The patent replaces the mechanical impact method with an optical measurement system that requires no physical contact or force application. The optical device captures images of the stator wedge in its natural position, and image processing algorithms measure the wedge position to determine ripple spring compression, completely eliminating impact forces that could damage fragile stator components.
Solution Approach 2:
The patent introduces light as an intermediary to transfer measurement information without physical contact. Instead of mechanically impacting the wedge to induce displacement, the system uses optical fields to capture the wedge position and translates this visual information into measurement data, avoiding all harmful mechanical forces.
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
This approach provides a precise, non-invasive, and efficient method to assess ripple spring tightness, reducing the risk of stator coil vibration and extending the operational life of dynamoelectric machines by identifying potential issues before they cause failure.
Implementation Method 1
an optical device for obtaining at least an image of the retention assembly, the optical device being insertable into a slot between two stator core laminations and directable toward a side view of the retention assembly
Data Source
AI summary
A method and apparatus for visually detecting and measuring retention assembly tightness are disclosed. In an embodiment, an optical device is used to obtain at least an image of a retention assembly, the optical device being insertable into a slot between two stator core laminations and directable toward a side view of the retention assembly. The image is displayed on a display, and a measurer is used to determine a tightness of a retention assembly.