Solidified Stator Bar Braze Method for Series Loop Connection
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Solution Overview
Problem
Strand-to-strand brazing offers flexibility but is time-consuming and costly, while single shot braze techniques are cost-effective but lack flexibility in stator bar assembly.
Innovation Solution
The method involves brazing a solidified stator bar with stranded stator bars using side plates to connect them in a series loop configuration, allowing for misalignment compensation and reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If strand-to-strand brazing is used, then flexibility in stator bar assembly is improved, but assembly time and cost increase
Solution Approach 1:
The invention applies preliminary action by pre-solidifying the stranded bar ends before assembly. The stranded bar ends are solidified in a mold to create a solidified bar that can be easily handled and assembled, eliminating the need for time-consuming layer-by-layer brazing during final assembly while maintaining the flexibility benefits of stranded bars.
Solution Approach 2:
The invention changes the physical state parameter of the stranded bar from soft and flexible to solidified and rigid at the ends. This parameter change allows the bar to maintain flexibility in the middle section while having solidified ends that are easy to assemble and connect, resolving the contradiction between flexibility and assembly time.
2Adaptability or versatility
If strand-to-strand brazing is used, then flexibility in stator bar assembly is improved, but manufacturing cost increases
Solution Approach 1:
The solidification of stranded bar ends is performed as a preliminary action during bar manufacturing rather than during final assembly. This preliminary solidification creates bars that are easier to handle, position, and connect, reducing the complexity and cost of the assembly process while preserving the flexibility advantages of stranded construction.
Solution Approach 2:
The invention uses a mold for solidifying the bar ends that can be easily discarded or reused. The mold itself is a simple, low-cost tool that enables the transformation of stranded bar ends without requiring expensive specialized equipment, thereby reducing manufacturing costs while maintaining flexibility.
3Ease of manufacture
If single shot braze technique is used, then production cost is reduced, but flexibility in stator bar assembly is lost
Solution Approach 1:
The invention applies local quality by solidifying only the ends of the stranded bars while leaving the middle sections as flexible stranded construction. This localized solidification provides the cost benefits of rigid bar handling and connection while preserving the flexibility and adaptability of stranded bars in the connection zones where it is most needed.
Solution Approach 2:
The invention segments the stranded bar into different zones: solidified ends for easy handling and connection, and flexible stranded middle sections for adaptability. This segmentation allows each portion of the bar to have the properties needed for its specific function, resolving the contradiction between cost reduction and flexibility retention.
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 reduces the cost of stator bar brazing while maintaining flexibility by using stranded bars to align and secure the connection between solidified and stranded bars, enhancing efficiency and reducing assembly time.
Implementation Method 1
strand-to-strand brazing is a procedure for brazing series loops
Implementation Method 2
the pre-placed braze alloy flows. The assembly reaches the proper temperature when the strands are dull cherry red in color and the pre-placed braze alloy flows
Implementation Method 3
The assembly is then allowed to cool and solidify
Implementation Method 4
Heat is applied such that the joint is heated rapidly, but evenly to a brazing temperature of 1292° F. to 1364° F. (700° C. to 740° C.)
Implementation Method 5
the strands are dull cherry red in color
Data Source
AI summary
A stator bar series loop connection is provided that is comprised of a solidified stator bar and a stranded stator bar disposed in a stator slot so that one of the bars is disposed as a top bar and the other of the bars is disposed as a bottom bar in the slot. A first side plate is brazed adjacent a first end thereof to a first side of an end of the solidified bar and adjacent a second end thereof to a first side of the stranded bar. Further, a second side plate is brazed adjacent a first end thereof to a second side of the end of the solidified bar and adjacent a second end thereof to a second side of the stranded bar. Accordingly, the stranded bar is series connected to the solidified bar.