Stator Core Mounting via Pre-laminated Bundle and Key Bar Alignment
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Solution Overview
Problem
The existing methods for mounting a stator core on a generator, particularly for large-sized generators, are complicated and inefficient, leading to spatial interferences and manual inconveniences when using spring bar type key bars, which hinder the precise alignment and mounting of donut-shaped stator core bundles.
Innovation Solution
A method involving key bar alignment adjustment using fixing jigs and wedges to ensure precise alignment of key bars with dove tails, and a conveyor system to mount a pre-laminated donut-shaped stator core bundle on the generator, reducing interference and facilitating efficient installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If spring bar type key bars are mounted on the frame body, then the key bars can be easily installed and adjusted, but spatial interferences occur with fixing jigs during stator core bundle mounting
Solution Approach 1:
The stator core is divided into multiple fan-shaped stator core sheets that are laminated together to form a donut-shaped stator core bundle. This segmentation allows the stator core to be manufactured separately from the frame body and installed as a complete unit, avoiding spatial interference issues during assembly.
Solution Approach 2:
The stator core bundle is pre-laminated and prepared in advance before being installed on the frame body. This preliminary preparation of the stator core bundle eliminates the need for complex fixing jigs during installation, as the pre-assembled bundle can be directly mounted onto the key bars.
2Manufacturing precision
If fixing jigs are used to align key bars, then precise alignment can be achieved, but the fixing jigs interfere with the mounting of donut-shaped stator core bundles
Solution Approach 1:
The key bars are pre-aligned on the frame body using fixing jigs before the stator core bundle is installed. This preliminary alignment ensures that the key bars are precisely positioned to receive the stator core bundle, eliminating the need for complex adjustments during the actual mounting operation.
Solution Approach 2:
The alignment process is separated into two distinct phases: first, aligning the key bars using fixing jigs; second, installing the stator core bundle onto the aligned key bars. This segmentation allows each operation to be optimized independently, with the fixing jigs used only for key bar alignment and then removed or repositioned for bundle installation.
3Manufacturing precision
If stator core sheets are manually mounted one by one, then precise positioning is possible, but the working time and labor requirements increase significantly
Solution Approach 1:
The stator core is segmented into multiple fan-shaped sheets that are laminated together to form a complete donut-shaped bundle. This segmentation allows the stator core to be prepared in manageable sections that can be quickly assembled into a complete unit and installed as one piece, significantly reducing installation time compared to mounting individual sheets.
Solution Approach 2:
The stator core sheets are laminated together to form complete donut-shaped bundles in advance, before installation on the generator. This preliminary assembly of the stator core bundles allows for efficient pre-fabrication and quality control, and enables rapid installation onto the frame body without time-consuming on-site assembly.
4Strength
If welding is used to mount key bars directly on the frame body, then the key bars are firmly fixed, but the stator core must be mounted as fan-shaped sheets rather than donut-shaped bundles
Solution Approach 1:
The stator core is divided into fan-shaped sheets that are laminated to form donut-shaped bundles. This segmentation allows the stator core to be manufactured and prepared separately, enabling installation as complete bundles rather than individual sheets, thereby simplifying the mounting process while maintaining secure fixation through the key bar system.
Solution Approach 2:
Spring bar type key bars serve as an intermediary element between the frame body and the stator core bundle. These key bars provide a flexible mounting interface that can accommodate the donut-shaped stator core bundles, bridging the connection between the rigid frame body and the laminated stator core structure.
Data Source
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AI summary
Provided is a method for mounting a stator core on a generator, the generator having key bars and spring bars disposed between the key bars and a frame body, the method including pre-laminating stator core sheets to form a stator core bundle in a given unit; conveying the stator core bundle laminated in the given unit; and mounting the stator core bundle on the inner peripheral surface of the frame body.