Generator Rotor Wedge Design for Winding Stability
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Solution Overview
Problem
Generator rotor windings experience displacement due to centrifugal forces during high-speed rotation, leading to imbalance and reduced reliability, and existing solutions require complex fastening methods that increase mass and aerodynamic drag.
Innovation Solution
A lightweight, durable wedge with a monolithic design that includes radially inward contact surfaces and outward tabs, which are shaped to conform to the rotor poles, providing support to windings without the need for fastening, and featuring axial apertures to reduce mass and enhance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex fastening methods are used to secure windings, then reliability of winding fixation is improved, but device complexity and mass increase
Solution Approach 1:
The wedge structure utilizes the centrifugal force generated during rotor rotation to automatically press the windings against the pole surface. The outwardly extending tabs engage with the pole and the inwardly extending surface presses the winding, creating a self-locking mechanism that eliminates the need for additional fastening components while maintaining reliable winding fixation under high-speed rotation conditions.
Solution Approach 2:
The wedge is designed to dynamically respond to the centrifugal forces during rotor rotation. The tabs are positioned to engage with the pole surface when centrifugal force pushes the wedge outward, automatically activating the winding retention function only when needed during operation, rather than requiring static fastening elements.
2Reliability
If traditional wedge designs are used to prevent winding displacement, then winding retention is improved, but aerodynamic drag increases
Solution Approach 1:
The wedge structure features localized tabs that extend outward to engage with the pole surface only at specific points where winding retention is needed. The majority of the wedge surface remains streamlined and smooth, maintaining aerodynamic efficiency while providing localized mechanical retention at the tab engagement points with the pole and winding.
3Strength
If heavy-duty wedge structures are used to withstand centrifugal forces, then rotor structural integrity is improved, but rotor mass increases
Solution Approach 1:
The wedge structure is segmented into functional zones: outwardly extending tabs for pole engagement, an inwardly extending surface for winding contact, and a streamlined body for aerodynamic efficiency. This segmentation allows each portion to be optimized for its specific function while using minimal material, reducing overall wedge mass compared to a solid heavy-duty structure.
Solution Approach 2:
The wedge is constructed from composite materials that combine high strength-to-weight ratio properties, allowing the structure to withstand centrifugal forces during high-speed rotation while maintaining minimal mass. The composite construction enables the wedge to provide structural integrity without requiring excessive material thickness.
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 wedge effectively prevents winding displacement, enhances rotor stability, and reduces aerodynamic drag while maintaining structural integrity and efficiency by transferring centrifugal forces and minimizing mass, thus improving the overall performance of the generator.
Implementation Method 1
During operation, the generator rotor rotates at very high speeds, creating centrifugal forces on the poles and windings that may cause the wires of the windings on the poles to become displaced
Data Source
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AI summary
A wedge 48 for use in a generator rotor includes a wedge body having a generally triangular cross-section with a first side 52, second side 54 and third side 56 with the third side being at a 90 degree angle to the second side and equal in length to the second side. The wedge also includes a first contact surface 60A adjacent to the second side at an interface between the first side and the second side, a second contact surface 60B adjacent to the third side at an interface between the first side and the third side, a first tab 62A extending outward from the first contact surface at a location between the first contact surface and the first side, and a second tab 62B extending outward from the second contact surface at a location between the second contact surface and the second side with the second tab having an equal height to the first tab.