Stator Insulation Tester Using Conductive Brush

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Solution Overview

Problem

Existing continuity testers are inadequate in detecting small insulation defects in stator windings of electric machines, as they often require high voltages and are labor-intensive, lacking in automated testing capabilities and sensitivity.

Innovation Solution

A continuity tester with a conductive brush and an analog-to-digital converter that uses a power supply to detect insulation defects by forming an electrical circuit with the stator windings, featuring a manual or automated brush configuration to identify defects with a lower voltage and provide faster response times.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If significantly high voltages are used in continuity testers to detect small defects, then measurement precision is improved, but safety risk increases

Engineering Contradiction:

Improvedefect detection sensitivityVSAvoidsafety risk to technicians

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent changes the voltage parameter from significantly high voltage to lower voltage operation. The system achieves improved defect detection sensitivity not through high voltage but through a specialized conductive brush design with multiple closely-spaced conductive elements that increase the probability of contact with small defects, thereby resolving the contradiction between measurement precision and safety risk

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces a specialized conductive brush as an intermediary between the power supply and the stator windings. This brush with multiple conductive elements acts as a mediator that distributes the electrical contact across multiple points, increasing detection sensitivity without requiring high voltage, thus reducing safety risks while maintaining measurement precision

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If visual inspection with magnifying glass is used to identify insulation defects, then measurement precision is improved, but productivity decreases

Engineering Contradiction:

Improvedefect detection accuracyVSAvoidinspection speed

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The patent replaces the manual visual inspection method with an automated electrical testing system. Instead of technicians using magnifying glasses to visually examine insulation, the system uses a conductive brush that automatically detects insulation defects through electrical continuity testing, thereby maintaining measurement precision while significantly improving productivity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The testing system performs self-inspection through automated electrical testing. The conductive brush automatically contacts the stator windings and the system autonomously detects insulation defects without requiring manual visual examination, eliminating labor-intensive operations while maintaining defect detection accuracy

Inventive Principle:

Principle #25Self-service

3Ease of operation

If manual brush inspection is used to test stator windings, then ease of operation is improved, but productivity decreases

Engineering Contradiction:

Improvetesting simplicityVSAvoidtesting speed

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent transitions from static manual brush inspection to a dynamic automated testing system. The brush assembly can be automatically positioned and moved across the stator windings by a control system, enabling faster testing while maintaining ease of operation through automated control, thus resolving the contradiction between operational simplicity and testing speed

Inventive Principle:

Principle #15Dynamics

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 solution effectively detects smaller insulation defects with reduced risk to technicians, offering automated and faster testing capabilities while ensuring safety and precision in identifying defects in stator windings.

Implementation Method 1

The conductive brush is selectively positioned against the exposed windings of the stator, and if an electrical circuit is formed as a result of loss of insulation, the potential at the input of the A/D converter drops, which can be detected.

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Data Source

PatentUS9476944B2Insulation inspection instrument

Publication Date: 2016.10.25 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A continuity tester that has particular application for inspecting the insulation on the stator windings in an electric machine. The continuity tester includes a power supply, a brush having conductive bristles, and an analog-to-digital (A/D) converter. One terminal of the power supply is electrically coupled to the brush and another terminal of the power supply is electrically coupled to the A/D converter and the stator being tested. The conductive brush is selectively positioned against the exposed windings of the stator, and if an electrical circuit is formed as a result of loss of insulation, the potential at the input of the A/D converter drops, which can be detected. In one embodiment, the conductive brush is a manual brush that is moved across the stator windings, and in alternate embodiments the conductive brush is specially configured to be positioned against the conductive windings in an automated process.