Stator Donut Wedge Assembly for Torque-Controlled Generator Mounting
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Solution Overview
Problem
The existing stator core assembly process for high voltage generators is inefficient and hazardous due to varying push-out forces on wedges, leading to inconsistent securing of stator packs to building bolts, which requires larger hammers and poses safety risks to technicians.
Innovation Solution
A wedge assembly with opposing wedges and a tensioning bolt system that uses a pre-calibrated torque tool to create a consistent locking force between the stator core and building bolts, featuring a ramped profile and curved surfaces for secure interlocking, allowing for safer and faster installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the driven wedge is manually fitted and hammered to secure the stator pack, then the stator pack can be attached to the building bolt, but the push-out forces vary widely causing inconsistent securing and safety hazards
Solution Approach 1:
The patent introduces a tensioning bolt with a calibrated torque specification that changes the operational parameter from variable manual hammering force to a controlled torque value. This standardized torque parameter ensures consistent wedge compression and reliable securing without the variability of manual hammering.
Solution Approach 2:
The patent replaces the manual hammering mechanical system with a torque-controlled fastening system. Instead of using variable impact forces from hammers, the system uses a precision torque tool to apply a specific rotational force to the tensioning bolt, which then translates to consistent wedge compression through the calibrated mechanical advantage of the wedge geometry.
2Strength
If larger hammers are used to drive the wedges flush, then the wedges can be secured, but safety hazards increase for technicians
Solution Approach 1:
The patent applies preliminary action by pre-calculating and pre-calibrating the torque value needed to achieve the desired wedge compression and securing force. This eliminates the need for technicians to use progressively larger hammers, as the correct force is determined in advance through engineering calculation and implemented through a calibrated torque tool.
Solution Approach 2:
The patent introduces feedback through a calibrated torque tool that provides real-time measurement and control of the applied force. The tool allows technicians to monitor the torque being applied and stop at the precise calibrated value, preventing over-tightening and ensuring consistent results without the need for excessive force that creates safety hazards.
3Ease of manufacture
If the driven wedge is cut and hammered until flush, then the wedge assembly can be completed, but installation time increases due to variability
Solution Approach 1:
The patent changes the installation parameter from variable impact hammering to a fixed torque value. This standardized parameter allows for predictable and consistent wedge compression, eliminating the need for repeated hammering adjustments and cutting operations, thereby significantly reducing installation time while maintaining proper assembly completion.
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 a consistent and secure attachment of stator packs to building bolts, reducing installation time and eliminating safety hazards by providing a controlled and precise locking force, thus enhancing the efficiency and safety of the stator core assembly process.
Implementation Method 1
The tensioning bolt is arranged to receive a torque effective to drive the set of opposing wedges in opposite directions
Implementation Method 2
a first side of the upper wedge is positioned to abut a wall of the groove
Implementation Method 3
The first opposing surface of the upper wedge and the second opposing surface of the lower wedge include a ramped profile that interlock when mated
Data Source
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.