Stator End Winding Stability via Pin-Connected Phase Blocks
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Solution Overview
Problem
The existing winding head designs for electrical machines in power plants face stability issues due to settlement phenomena in insulation materials under heat and vibrations, leading to reduced axial holding forces and potential rocking movements of round connectors, which can cause friction and wear.
Innovation Solution
The proposed solution involves rigidly connecting phase connection blocks using pin-shaped elements that are partially fastened in recesses, allowing for initial alignment and subsequent cohesive bonding with an adhesive, providing increased rigidity and stability by allowing for mobility during assembly and maintaining it at high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If round connectors are attached to support brackets using spacers and press fit, then assembly is simplified, but settlement phenomena occur under heat and vibrations causing reduced axial holding forces
Solution Approach 1:
The patent applies preliminary action by pre-assembling round connectors with support brackets using spacers and press fit before final installation. This allows alignment and positioning to be completed in advance, simplifying the main assembly process while ensuring proper fit before operational loads are applied.
Solution Approach 2:
The patent uses composite construction by combining different materials for spacers (providing axial positioning) and support brackets (providing mechanical attachment). This composite approach allows each component to be optimized for its specific function while working together to secure the round connectors.
2Stability of the object's composition
If round connectors are securely fixed to prevent movement, then stability is improved, but assembly complexity increases due to alignment requirements
Solution Approach 1:
The patent reduces assembly complexity by performing alignment and preliminary fixation of round connectors to support brackets before final installation. This preliminary action ensures proper positioning is achieved while maintaining simple assembly procedures.
Solution Approach 2:
The patent uses spacers as intermediary elements between round connectors and support brackets. These spacers facilitate alignment and positioning during assembly, acting as mediators that simplify the connection process while ensuring stable final positioning.
3Object-affected harmful factors
If insulation material is used to attach round connectors, then electrical insulation is provided, but settlement phenomena cause insulation to give way under heat and vibrations
Solution Approach 1:
The patent employs composite construction by combining insulation material with mechanical fastening elements (spacers and support brackets). This composite approach provides both electrical insulation and mechanical stability, with the rigid components preventing settlement while the insulation maintains electrical isolation.
Solution Approach 2:
The patent applies preliminary action by pre-positioning insulation material on round connectors before assembly with support brackets. This ensures proper insulation placement is achieved in advance, preventing settlement issues during operation while maintaining electrical insulation integrity.
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
This design enhances the stability and rigidity of the winding head, preventing rocking movements and reducing wear, while ensuring secure fixation of round connectors, thus improving the overall performance and longevity of the electrical machine.
Implementation Method 1
pin-shaped elements, which are at least partially fastened in a materially bonded manner in recesses in the mutually facing side surfaces of the phase connection blocks
Data Source
Figure 1~2
Figure 3~4
AI summary
The coil head has two round connectors via which current is passed out from winding bars of a stator. The head is attached to the stator by supporting brackets. The round connectors have a radial section (10), and phase connection blocks (6) are arranged at ends of the radial section. The phase connection blocks of a phase are arranged together in a circumferential direction. The adjacent phase connection blocks are connected by a pin element (9), which is partially attached in openings (12) in the mutually facing side surfaces of the phase connection blocks and is made of metallic substance. An independent claim is also included for a method for mounting a coil head.