Slip Ring Removal Fixture Using Mechanical Leverage
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Solution Overview
Problem
Current methods for removing slip rings from rotating electrical machinery, such as wind turbine generators, are inefficient and often result in damage to the slip ring assemblies, leading to high material costs and safety risks due to the lack of a controlled, non-destructive removal process.
Innovation Solution
A lightweight slip ring removal fixture that uses a jacking mechanism with mechanical leverage to safely disengage the slip ring from its heat-shrink fit mounting, minimizing damage and operator effort, and is designed for easy installation and operation, including the use of a pneumatic, hydraulic, or electric jack to apply disengaging force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional hammering methods are used to remove slip rings, then the removal process is simple and quick, but the slip ring assembly is damaged and safety risks increase
Solution Approach 1:
The patent introduces a removal fixture as an intermediary device between the hammer and the slip ring assembly. This fixture includes a holder that attaches to the slip ring assembly and a protrusion that engages with the rotor shaft, providing a controlled interface for force application. The intermediary fixture distributes and directs the removal force, preventing direct impact damage to the slip ring while maintaining removal effectiveness.
Solution Approach 2:
The patent replaces the direct mechanical impact system (hammer striking slip ring) with a controlled mechanical leverage system. The removal fixture creates a lever arm where the holder attaches to the slip ring assembly and the protrusion engages the rotor shaft, allowing force to be applied through rotational movement rather than direct impact. This substitutes the harmful direct impact mechanism with a controlled leverage-based extraction mechanism.
2Reliability
If controlled non-destructive removal methods are used, then slip ring damage is minimized, but the device complexity and operator effort increase
Solution Approach 1:
The removal fixture is segmented into distinct functional components: a holder portion that attaches to the slip ring assembly, a protrusion that engages with the rotor shaft, and a structural body that provides leverage. This segmentation allows each component to perform its specific function efficiently while keeping the overall device relatively simple. The modular nature of the segmented design makes the complex task of non-destructive removal manageable through divided functional elements.
Solution Approach 2:
The removal fixture is designed to be self-sufficient, requiring no external power source, tools, or assistance. The fixture itself provides all necessary functions: attachment to the slip ring assembly, engagement with the rotor shaft, and provision of mechanical leverage. The operator simply attaches the fixture and applies manual force, allowing the device to perform the complex non-destructive removal function without adding operational complexity.
3Loss of substance
If traditional removal methods are used, then material costs increase due to damage, but the removal process requires less specialized equipment
Solution Approach 1:
The removal fixture is designed to be attached before the actual removal force is applied. The holder portion is secured to the slip ring assembly in advance, and the protrusion is positioned to engage with the rotor shaft before extraction begins. This preliminary positioning ensures that the force application path is pre-established and controlled, preventing damage during the removal process. The preliminary action of proper fixture attachment is what enables the non-destructive removal and reduces material waste.
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 fixture significantly reduces slip ring damage during removal, allows for cost-effective refurbishment, and enhances safety and efficiency, enabling a single operator to manage the process with reduced material and manpower costs.
Implementation Method 1
uses a jacking mechanism with mechanical leverage to safely disengage the slip ring from its heat-shrink fit mounting
Data Source
Figure 1A~1B
Figure 2
Figure 3A~3D
AI summary
An apparatus (100) and method for removing a slip ring assembly (10) from rotating electrical machinery (5). The apparatus (100) attaches directly to the slip ring assembly (100) through bolted connection points (120) for ease of installation and removal. A jacking mechanism (105) provides mechanical leverage to pry the slip ring assembly (10) from its heat-shrunk fit mounting location in a manner that is reliable and safe for the service worker and the slip ring assembly (10). The apparatus (100) is lightweight and portable, facilitating use with electrical generators in the field and especially with wind turbine generators located on a wind turbine tower.