Generator Stator Bar Profile Strip for Strand Orientation
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Solution Overview
Problem
The existing manufacturing process for generator stator bars faces defects due to stator bar strands tilting or rotating during consolidation, leading to increased electrical losses and performance issues, as uncured materials soften under pressure and heat, while pre-cured materials lack sufficient bonding strength.
Innovation Solution
A profile strip comprising an uncured strip with a pre-cured strip enclosed within, where the uncured material melts and flows through cavities in the pre-cured strip under pressure and heat to bond with the stator bar strands, maintaining strand orientations and providing bonding strength in a single press and heat operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If uncured material is used in profile strips, then bonding strength between profile strip and stator bar strands is improved, but stator bar strands tilt or rotate during consolidation
Solution Approach 1:
The profile strip is segmented into two distinct functional zones: an uncured material region for bonding and a pre-cured material region for structural support. This segmentation allows each region to perform its specific function without interfering with the other, resolving the contradiction between bonding strength and strand orientation precision
Solution Approach 2:
Different regions of the profile strip are assigned different material states (cured vs. uncured) based on local functional requirements. The pre-cured region provides local structural support where strand orientation control is critical, while the uncured region provides local bonding capability where adhesive strength is needed
2Manufacturing precision
If pre-cured material is used in profile strips, then stator bar strands maintain orientation during consolidation, but bonding strength between profile strip and stator bar strands is insufficient
Solution Approach 1:
The profile strip is divided into functional segments with different cure states. The pre-cured segment maintains rigidity for orientation control, while the uncured segment provides bonding capability, thus resolving the contradiction between maintaining orientation and achieving bonding strength
Solution Approach 2:
The profile strip uses a composite structure combining cured and uncured material phases. This composite approach allows the strip to simultaneously exhibit rigid behavior for orientation control and adhesive behavior for bonding, resolving the contradiction between these two opposing requirements
3Strength
If two separate press and heat operations are used, then bonding strength and strand orientation are both satisfied, but manufacturing cost and cycle time increase significantly
Solution Approach 1:
The profile strip design merges the functions of two separate operations into a single press and heat cycle. The multi-phase material structure allows simultaneous achievement of bonding and orientation control in one operation, eliminating the need for sequential processing and thus reducing cycle time and manufacturing cost
4Manufacturing precision
If two separate press and heat operations are used, then bonding strength and strand orientation are both satisfied, but manufacturing cost increases significantly
Solution Approach 1:
The invention combines multiple processing steps into a single press and heat operation by designing a profile strip with multi-phase material structure. This merging eliminates the need for separate operations, reducing manufacturing complexity and cost while maintaining high manufacturing precision for strand orientation
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 ensures parallel strand orientations, improves performance and longevity, and reduces manufacturing costs and cycle time by allowing a single press and heat operation, while maintaining the desired geometry and bonding strength.
Implementation Method 1
The uncured material of the uncured strip melts and flows through the cavities of the pre-cured strips under pressure and heat during a consolidation of the stator bar strand assembly
Implementation Method 2
The uncured material of the uncured strip melts and flows through the cavities of the pre-cured strips under pressure and heat
Implementation Method 3
The pre-cured material of the pre-cured strip maintains rigidity under the pressure and heat during the consolidation of the stator bar strand assembly to keep orientations of the stator bar strands parallel to the profile strip
Data Source
AI summary
Generator stator bar having profile strip and process for manufacturing a generator stator bar are presented. The generator stator bar includes stator bar strands assembled together. The profile strip is placed on top side and bottom side surfaces of the stator bar strand assembly. The profile strip includes uncured strip consisting of uncured material. The profile strip includes pre-cured strip consisting of pre-cured material. The pre-cured strip includes cavities perforated through its thickness. The profile strip enables the generator stator bar to be manufactured by a single press and heat operation to achieve a rectangular geometry having round outer edges and to maintain orientations of stator bar strands parallel to the profile strip.