Stator Bar Installation Fixture Angular Positioning
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Solution Overview
Problem
The manual handling and positioning of heavy stator bars in rotating electrical equipment is labor-intensive, hazardous, and prone to errors, requiring multiple workers and makeshift equipment, which complicates the installation and removal process and can result in damage to the stator bars or core.
Innovation Solution
A stator bar installation fixture with rotating mechanisms at each end of the equipment, featuring a stator bar insertion mechanism that supports and aligns the stator bar for precise angular positioning and insertion into specific slots around the full 360-degree inner surface of the stator core, utilizing actuating mechanisms for safe and efficient placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual handling methods are used to transport and position stator bars, then flexibility and adaptability are maintained, but labor intensity increases, safety hazards arise, and installation time increases
Solution Approach 1:
A stator bar insertion mechanism acts as an intermediary device between workers and the stator bar. This mechanism includes a holding structure that secures the stator bar, a positioning system with adjustable arms, and an insertion system that guides the bar into the slot. The intermediary mechanism eliminates direct manual handling of the heavy stator bar, thereby improving safety and reducing labor intensity while maintaining controlled operation
Solution Approach 2:
The installation system is segmented into distinct functional modules: a holding structure for securing the stator bar, a positioning system with adjustable arms for angular and radial positioning, and an insertion system for guiding the bar into the slot. This segmentation allows each component to perform its specific function efficiently while reducing the overall complexity through modular design
2Manufacturing precision
If makeshift equipment is used for positioning stator bars, then device complexity is reduced, but manufacturing precision and positioning accuracy deteriorate
Solution Approach 1:
The positioning system employs dynamic adjustable arms that can be positioned and locked at various angles and radii to accommodate different stator bar sizes and slot positions. The arms feature adjustable length and angle capabilities with locking mechanisms, allowing the system to adapt to different positioning requirements while maintaining high precision through controlled adjustment rather than fixed rigid structures
Solution Approach 2:
The positioning system is designed as a universal mechanism that can handle various stator bar dimensions and slot configurations. The adjustable arms and positioning mechanisms can be configured for different angles and radii, making the same device capable of precise positioning for multiple different stator bar sizes and slot positions without requiring separate specialized equipment for each case
3Adaptability or versatility
If existing support equipment is used to service different quadrants of the stator core, then adaptability is limited, but device complexity is reduced
Solution Approach 1:
The positioning system merges multiple positioning capabilities into a single integrated structure. The adjustable arms can be configured to service slots in different quadrants of the stator core by adjusting their angular and radial positions. This combination of positioning capabilities in one device provides full 360-degree coverage of the stator core without requiring separate equipment for different quadrants
Solution Approach 2:
The support equipment incorporates dynamic adjustable arms that can be repositioned to service different quadrants of the stator core. The arms feature adjustable length, angle, and radial position capabilities with locking mechanisms, allowing the same device to adapt to different slot locations around the entire stator core circumference without requiring disassembly or reconfiguration
4Productivity
If manual lifting and positioning is performed around the full inner radius of the stator core, then adaptability is maintained, but loss of time and productivity decrease
Solution Approach 1:
The insertion system performs preliminary positioning and alignment actions before the actual insertion of the stator bar. The holding structure secures the bar in advance, the adjustable arms pre-position the bar at the correct angle and radius, and the insertion mechanism pre-aligns the bar with the slot entrance. This preliminary preparation eliminates the need for time-consuming manual adjustments during the insertion process, thereby improving productivity
Solution Approach 2:
The insertion mechanism serves as an intermediary that automates the insertion process. It includes a holding structure that secures the stator bar, a positioning system that pre-positions it at the correct location, and an insertion system that guides and pushes the bar into the slot. This intermediary mechanism eliminates the need for manual lifting and positioning around the full inner radius, significantly reducing installation time while maintaining the ability to service all slots
Data Source
AI summary
A stator bar installation fixture and method for installing stator bars into specific stator core slots within a stator core of rotating electrical equipment. The stator bar installation fixture includes rotating mechanisms, rotatingly fixed at each end of the rotating electrical equipment, for supporting and controlling an angular positioning of a stator bar insertion mechanism relative to the stator core. The stator bar insertion mechanism supports a stator bar within the stator core, angularly locates a stator bar in alignment with the specific stator core slot, and inserts the stator bar into the specific stator core slot.