Horizontal Stator Core Installation via Rail Trolley Support
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Solution Overview
Problem
Existing methods for replacing a stator core in a power generator stator frame often require the frame to be upright, which can be difficult for generators that have been in operation, and rely on direct coupling of keybars to the frame for support, limiting flexibility in installation.
Innovation Solution
A method for installing a replacement stator core in a horizontal stator frame using spring assemblies and a support assembly with a trolley and rail system that allows for axial movement and positioning of laminations without direct coupling of keybars to the main housing, enabling secure insertion and support within the frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the stator frame is placed in an upright position to install a new stator core, then the stator core can be lowered into the frame using gravity, but this becomes very difficult for generators that have been in operation for some time
Solution Approach 1:
Instead of placing the stator frame upright and lowering the core using gravity, the patent inverts the approach by keeping the frame horizontal and using a support assembly with rails to guide and support the stator core modules during horizontal installation. This inversion makes the process adaptable to in-service generators that cannot be easily repositioned to an upright orientation
Solution Approach 2:
The patent introduces a support assembly with rails as an intermediary mechanism between the stator core modules and the frame. This intermediary provides guidance and support during installation, enabling horizontal placement of the core without requiring the frame to be upright, thus solving the adaptability issue for in-service generators
2Device complexity
If keybars are directly coupled to the main housing to support the stator core, then the structure is simplified, but this limits flexibility in installation and servicing
Solution Approach 1:
The patent segments the support structure into separate components: the keybars remain attached to the stator core modules, while a separate support assembly with rails is coupled to the main housing. This segmentation provides structural simplicity while enabling flexibility, as the support assembly can be configured for horizontal installation and removed during servicing
Solution Approach 2:
The support assembly is designed to be temporary and removable, allowing the system to transition from a fixed keybar configuration to a flexible support configuration during installation and servicing. This dynamic approach enables flexibility in installation while maintaining structural simplicity
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
Enables efficient replacement of stator cores in a horizontal position without the need for direct keybar coupling to the frame, facilitating easier maintenance and reducing installation complexity while ensuring secure stator core support.
Implementation Method 1
spring assemblies and a support assembly with a trolley and rail system
Data Source
Figure 1~3
Figure 2
Figure 4
AI summary
A method for servicing a stator frame of a power generator includes removing a first stator core from a main housing of the frame. A support assembly including a plurality of rails and a trolley is used to insert second laminations of a second stator core into the main housing. The rails extend axially within a bottom portion of the main housing and provide support for the trolley and for the second laminations as they are being inserted into the main housing. The trolley is provided for axial movement on the rails for inserting the second laminations into the main housing.