Rotating Electric Machine End Winding Support via T-Hammer Profile
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Solution Overview
Problem
Existing rotating electrical machines, such as hydro-generators, face challenges in protecting the end winding from centrifugal forces and thermal expansion, with complex assembly and cooling issues due to large solid steel rings, and previous solutions like tension rods require individual preparation for tilting movement, increasing design and assembly complexity.
Innovation Solution
The use of screw bolts arranged in a T-hammer profile, where multiple bolts with the same radial orientation are fastened to a common T-hammer profile, allowing for axial movement to compensate for thermal expansion and absorb centrifugal forces through a common retaining element, reducing shearing forces and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If bandages made of prestressed steel wire in combination with a solid one-piece steel ring are used to support the end winding, then the end winding is protected against centrifugal forces, but the assembly complexity increases and cooling efficiency decreases
Solution Approach 1:
The patent divides the previously solid one-piece steel ring into multiple separate rings (first ring, second ring, third ring) that can be assembled independently. This segmentation allows for simpler assembly procedures and better cooling flow paths while maintaining the necessary structural strength to support the end winding against centrifugal forces.
Solution Approach 2:
The patent replaces the rigid solid steel ring with a lattice structure formed by tension rods arranged in a grid pattern. This lattice structure provides the necessary mechanical strength while allowing cooling media to flow through the structure, improving cooling efficiency and reducing assembly complexity compared to a solid ring.
2Strength
If a solid one-piece steel ring is used to support the end winding, then centrifugal forces are countered, but cooling flow through the end winding is impaired
Solution Approach 1:
The patent replaces the solid steel ring with a lattice structure made of tension rods arranged in a grid pattern. This structure maintains the necessary mechanical strength to support the end winding while creating channels for cooling media to flow through, thereby improving cooling efficiency and reducing energy loss.
Solution Approach 2:
The lattice structure functions as a porous structure that allows cooling media to pass through while providing mechanical support. The spaces between the tension rods enable effective cooling flow paths, solving the contradiction between structural strength and cooling efficiency.
3Adaptability or versatility
If tension rods with spherical bearing surfaces are used to allow tilting movement, then thermal expansion is compensated, but design and assembly complexity increases
Solution Approach 1:
The patent introduces dynamic capability to the tension rod assembly by allowing the bolts to rotate within the T-hammer profile slots. This dynamic adjustment enables the structure to adapt to thermal expansion while maintaining a relatively simple design without requiring complex spherical bearing surfaces for each tension rod.
Solution Approach 2:
The patent combines multiple tension rods with the same radial orientation onto a common T-hammer profile, merging their functions into a single integrated assembly. This reduces the number of individual components requiring complex bearing surfaces and simplifies both design and assembly procedures while still compensating for thermal expansion.
4Reliability
If multiple bolts are fastened to individual profiles, then each bolt can be secured independently, but assembly complexity increases
Solution Approach 1:
The patent merges multiple bolts with the same radial orientation onto a single common T-hammer profile, consolidating what would otherwise be multiple separate assembly operations into one integrated unit. This maintains reliable securing of all bolts while significantly reducing assembly complexity by reducing the number of individual profiles and assembly steps.
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 solution effectively neutralizes thermal expansion and absorbs centrifugal forces without complex assembly, enhancing structural simplicity and cooling efficiency by allowing axial movement of the winding head attachment, thus reducing the need for individual preparation of components.
Implementation Method 1
the axial thermal expansion of the winding when it is heated can have the result that the winding presses on the winding head bolts
Implementation Method 2
The end winding can be supported against centrifugal forces by means of bandages made of prestressed steel wire
Data Source
Figure 1
Figure 2a~2b
AI summary
The rotary electric machine (10) has a bundle of laminations (12) with rotor windings extended towards axis (20) of a rotor. The rotor windings are provided at ends of rotor bundle. The centrifugal energy is intercepted by windings radially passed through bolts (18) at end windings. Rims (13) are concentrically arranged in end windings along axial direction of bundle of laminations. T-shaped groove (16), T-hammer profile (17), bolts and holders are arranged for receiving axial elongations of end windings. The rims are supported by axially sliding along T-groove.