Segmented Winding Head Support for Large Rotor Diameters
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Solution Overview
Problem
Existing methods for producing winding head supports for large electric machines are limited by the size of forging and rolling equipment, and transportation constraints, restricting the maximum inner diameter to approximately 6 m.
Innovation Solution
The method involves creating ring segments that are then connected to form a ring, allowing for the production of winding head supports without the need for equipment capable of producing complete rings of large diameters. Ring segments can be produced using various methods and materials, such as steel, and connected through welding or other bonding techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If complete rings are produced using forging or rolling equipment, then the winding head support achieves high strength and structural integrity, but the maximum inner diameter is limited to approximately 6 m due to equipment size constraints
Solution Approach 1:
The ring is divided into multiple ring segments that can be produced separately using smaller forging or rolling equipment, then connected to form the complete ring. This segmentation allows production of rings with inner diameters exceeding 6 m while using equipment with smaller capacity, thereby resolving the contradiction between structural integrity and size limitations.
2Adaptability or versatility
If complete rings of large diameter are produced, then the winding head support meets the design requirements for large electric machines, but transportation from fabrication facility to power plant becomes infeasible
Solution Approach 1:
By dividing the ring into multiple smaller segments, each segment can be transported independently from the fabrication facility to the power plant location. This eliminates transportation constraints while maintaining the capability to produce large-diameter rings for large electric machines, as the segments are assembled on-site to form the complete ring structure.
3Ease of manufacture
If ring segments are used instead of complete rings, then production equipment requirements are reduced and transportation is simplified, but additional connection processes are required
Solution Approach 1:
The ring is segmented into multiple parts that can be manufactured using standard equipment with greater flexibility and ease. While this requires additional connection processes, the segmentation enables production of custom sizes and simplifies manufacturing logistics, overall improving ease of manufacture despite increased assembly steps.
Solution Approach 2:
Connection elements or joining processes serve as intermediaries to assemble the ring segments into a complete ring. These intermediaries facilitate the assembly process by providing standardized interfaces and connection methods, thereby managing the complexity introduced by segmentation while maintaining production flexibility.
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 enables the production of winding head supports with inner diameters exceeding 6 m, simplifying fabrication and transportation by allowing ring segments to be produced and assembled on-site, thus overcoming size and logistical limitations.
Implementation Method 1
connected through welding or other bonding techniques
Implementation Method 2
formed, typically using cold forming or by bending, in order to transform the initially roughly flat metal sheets into corresponding circular segments
Data Source
AI summary
A method for producing an annular winding head support for a rotor of a rotating electric machine. In order to be able to produce a winding head support for particularly large machines in a simple manner, ring segments are created, after which the ring segments are connected to create a ring that constitutes the winding head support. In addition, the electric machine has a stator and a rotor, with the rotor including at least one winding head at an end side. A winding head support is provided in order to accommodate centrifugal forces occurring during operation.