Stator Core Wedge Assembly for Controlled Bolt Locking
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Solution Overview
Problem
The existing process for securing stator core packs to building bolts in generators is unsafe and inefficient, with varying push-out forces leading to potential safety hazards and prolonged installation times due to the need for manual adjustment and large hammers.
Innovation Solution
A wedge assembly comprising opposing wedges with a ramped profile and a tensioning bolt is used to create a locking force between the stator core and building bolts, allowing for secure and efficient attachment using a pre-calibrated torque tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the driven wedge is manually adjusted and hammered to be flush with the static wedge and filler piece, then the stator pack can be secured to the building bolts, but the installation process becomes time-consuming and creates safety hazards due to varying push out forces requiring large sledge hammers
Solution Approach 1:
The wedge assembly incorporates a tensioning bolt that allows precise control of the wedging force through torque application, replacing the uncontrolled manual hammering process. This parameter control eliminates the need for large sledge hammers and reduces installation time while maintaining safety
Solution Approach 2:
The manual hammering and adjusting process is replaced with a mechanical tensioning bolt system that applies controlled force through threading mechanics. This substitution eliminates the safety hazards of manual hammering while reducing installation time through predictable, controlled force application
2Reliability
If the driven wedge is cut and hammered to be flush with the static wedge and filler piece, then the stator pack can be secured, but the process requires large sledge hammers creating safety hazards due to overly tight wedges
Solution Approach 1:
The complex manual process of cutting and hammering wedges is replaced with a simple tensioning bolt mechanism. The threaded bolt provides controlled, reversible force application that eliminates the need for cutting and hammering operations, reducing both safety risks and installation complexity
Solution Approach 2:
The wedge assembly is designed to be self-adjusting through the tensioning bolt mechanism. The bolt automatically applies the necessary force to secure the stator pack without requiring external hammering or cutting operations, simplifying the installation process while maintaining safety
3Reliability
If opposing wedge sets are used to secure stator packs to building bolts, then the stator core can be attached to the stator frame, but the varying push out forces make the installation process unpredictable and dangerous
Solution Approach 1:
The tensioning bolt enables precise control and standardization of the wedging force through calibrated torque values. This eliminates the variability in push out forces, ensuring consistent and predictable attachment reliability across all stator packs while improving manufacturing precision
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
The wedge assembly ensures safe and rapid installation by maintaining consistent locking forces, reducing safety risks and installation time, while maintaining structural integrity.
Implementation Method 1
a set of opposing wedges configured to slide into a notch of a stator core and provide a locking force between the building bolt and the stator core
Implementation Method 2
The tensioning bolt sets the opposing wedges to create a locking force between the stator core and the building bolt
Data Source
Figure 1~2
Figure 3~5
Figure 4
AI summary
A generator including a stator frame, a plurality of stator donuts including a plurality of circumferentially disposed notches, and a plurality of a wedge assemblies for mounting the stator donuts to a plurality of building bolts is presented. Each wedge assembly includes a set of opposing wedges. The set of opposing wedges are positioned within a notch in a stator donut to create a locking force between a building bolt and the stator core. The wedge assembly also includes a tensioning bolt to set the opposing wedges to a position creating the locking force between the stator core and the building bolt.