Ripple Spring Symmetrical Layering for Crack Resistance
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Solution Overview
Problem
Existing ripple springs in electrical machines often malfunction due to asymmetrical layering, leading to reduced retaining force, vibration of stator bar windings, and potential electrical shorts, causing damage and failure.
Innovation Solution
A symmetrical stack of conductive and non-conductive layers in the ripple spring, with conductive layers generating signals for monitoring and fault identification, and a method for analyzing these signals to determine the condition of the ripple spring, enhancing crack resistance and bending strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If asymmetrical layering is used in ripple springs, then manufacturing is simpler, but bending strength and crack resistance decrease
Solution Approach 1:
The patent applies asymmetry in reverse - it deliberately creates a symmetrical layering structure where conductive and non-conductive layers are arranged in a balanced, repeating pattern. This symmetrical design distributes mechanical stresses uniformly across the ripple spring, significantly improving bending strength and crack resistance compared to asymmetrical designs, while maintaining manufacturing feasibility through standardized layering sequences.
Solution Approach 2:
The patent uses composite materials by combining multiple layers of conductive and non-conductive materials with different mechanical and electrical properties. The non-conductive layers provide structural support and insulation, while the conductive layers provide electrical conductivity and additional mechanical strength. This composite structure achieves superior bending strength and crack resistance that neither material could provide alone.
2Device complexity
If conventional ripple springs are used without conductive layers, then device complexity is lower, but monitoring and fault detection capabilities are absent
Solution Approach 1:
The conductive layers serve multiple functions simultaneously: they provide electrical conductivity for signal generation, act as structural reinforcement layers improving mechanical strength, and enable monitoring capabilities through signal analysis. This multi-functionality allows the ripple spring to maintain structural integrity while providing built-in health monitoring without requiring separate sensing components.
Solution Approach 2:
The ripple spring generates its own monitoring signals through the conductive layers that are inherently part of its structure. The conductive layers respond to mechanical stress, cracking, and deformation by changing electrical properties, which can be detected and analyzed. This self-service capability allows the component to monitor its own health status without external sensing systems.
3Reliability
If ripple springs malfunction or become loose, then retaining force is reduced, but detecting and measuring the fault becomes difficult
Solution Approach 1:
The conductive layers provide continuous feedback about the ripple spring's mechanical state through electrical signals. As the ripple spring experiences stress, deformation, or cracking, the conductive layers' electrical properties change in response. By monitoring these electrical signals, the system receives real-time feedback about the spring's condition, enabling early detection of retaining force degradation before it leads to failure.
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 symmetrical design significantly increases the bending strength of the ripple spring, reducing the likelihood of cracking and malfunction, thereby preventing unwanted machine shutdowns and costly repairs, while allowing for real-time monitoring and fault detection.
Implementation Method 1
A conductive layer is provided disposed within the ripple spring and configured to generate signals
Data Source
AI summary
A ripple spring is provided having one or more conductive layers, and one or more non-conductive layers. The conductive layers and the non-conductive layers are laminated together to form a symmetrical stack of layers. A method is also provided for monitoring the ripple spring. The method includes the steps of providing a ripple spring that holds a winding in place, where the ripple spring is positioned at least partially within a stator slot defined within an electromechanical device. Providing a conductive layer disposed within the ripple spring, and generating signals from the conductive layer, the signals corresponding to at least one aspect of the ripple spring. An analyzing step analyzes the signals to determine the at least one aspect of the ripple spring, wherein the at least one aspect facilitates an identification of faults in the ripple spring.