Horizontal Stator Core Assembly Using Extended Keybar Rails

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Solution Overview

Problem

The existing methods for assembling generator stator cores are cumbersome, requiring large spaces and heavy cranes due to the need for vertical stacking of laminations and donuts, which is impractical and time-consuming, especially in limited spaces where vertical stacking is not feasible.

Innovation Solution

The method involves extending keybars within the stator frame to act as rails for horizontally inserting and positioning laminations and donuts, allowing for secure engagement and alignment, with options for support from various angles and the use of slide pads to reduce friction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If vertical stacking method is used, then gravity can guide donuts into place, but large floor space and heavy cranes are required

Engineering Contradiction:

Improveease of stackingVSAvoidfloor space

Core Design Contradiction:

Ease of operationVSArea of stationary object

Solution Approach 1:

The patent inverts the traditional vertical stacking approach by implementing horizontal stacking. Instead of stacking donuts vertically from top to bottom using gravity, the method extends keybars horizontally and slides donuts horizontally along these extended keybars into the stator frame, eliminating the need for vertical clearance and heavy lifting equipment.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent transitions the stacking operation from a vertical dimension to a horizontal dimension. By extending keybars horizontally and sliding donuts along this horizontal axis, the method utilizes the horizontal dimension for assembly operations, thereby reducing requirements for vertical space and overhead crane capacity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Productivity

If vertical stacking is used, then assembly can proceed, but manufacturing time and complexity increase

Engineering Contradiction:

Improveassembly speedVSAvoidmanufacturing complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by extending the keybars horizontally before the donuts are installed. This pre-positioning of the guiding structure (extended keybars) allows donuts to be slid into place along a predetermined path, simplifying the assembly process and reducing manufacturing complexity compared to vertical stacking methods.

Inventive Principle:

Principle #10Preliminary action

3Area of stationary object

If horizontal stacking is attempted with traditional methods, then space is saved, but stacking becomes extremely difficult

Engineering Contradiction:

Improvefloor spaceVSAvoidease of stacking

Core Design Contradiction:

Area of stationary objectVSEase of operation

Solution Approach 1:

The patent introduces an intermediary element (the extended keybar) that mediates between the donut and the stator frame during horizontal stacking. The extended keybar serves as a rail or guide that facilitates the horizontal insertion of donuts, making the operation feasible and easy despite the horizontal orientation, which would otherwise be extremely difficult with traditional methods.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS7353586B2Method of horizontally stacking a stator core within a stator frame

Publication Date: 2008.04.08 SIEMENS ENERGY INC

AI summary

The present invention provides a method for the horizontal stacking of laminations 10 and donuts to form a stator core. A stator generator frame 2 has multiple keybars 6 that run the axial length of the frame. The laminations 10 have grooves 12 there-in that engage the keybars to provide a secure fit of the laminations to the generator frame. By extending two or more of the keybars 6, these extensions 7 may be used as rails on which the laminations may be horizontally inserted into the stator frame.