Generator Stator Strand Failure Detection via Radiography
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for detecting failures in generator stator coils, such as voltage detection tests, are inadequate for identifying low-number strand failures and can be time-consuming, and may not detect cracked or broken strands effectively, leading to potential undetected malfunctions and future failure points.
Innovation Solution
A method using radiography with a radiation source and image capture device to non-destructively assess strand failures in generator stator coils, selecting inspection areas based on stator characteristics and performing digital enhancements to improve image quality, allowing for a risk analysis of strand failures and determining the need for replacement or repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If voltage detection test is used to detect strand failures, then the detection method is simple, but it cannot detect low-number strand failures and cracked or broken strands effectively
Solution Approach 1:
The patent replaces the electrical measurement system (voltage detection test) with a radiographic imaging system. Instead of measuring voltage drops to infer strand conditions, the invention uses X-ray or gamma ray imaging to directly visualize strand integrity, cracks, and breaks, providing superior detection capability without relying on indirect electrical measurements
Solution Approach 2:
The patent introduces radiographic imaging as an intermediary method between the stator winding and detection. Rather than directly measuring electrical properties that may not reveal strand failures, the radiographic technique provides a visual intermediary representation of the strand condition, allowing direct observation of cracks and breaks
2Reliability
If voltage detection test is performed, then a failure can be detected, but the test preparation is time-consuming due to drilling holes in the winding
Solution Approach 1:
The patent replaces the mechanical drilling process required for voltage detection tests with a non-contact radiographic imaging system. The imaging system can inspect windings through external placement of radiation sources and detectors, eliminating the need to drill holes into the winding structure and significantly reducing preparation time
Solution Approach 2:
The radiographic imaging system allows for preliminary inspection of windings before installation or during maintenance without requiring disruptive preparation. The ability to image through the winding structure enables assessment to be performed in advance, reducing downtime and avoiding the need for time-consuming hole drilling and subsequent plugging
3Productivity
If voltage detection test is used, then the test is quick to perform, but it may not detect failures allowing current to pass through cracks or breaks
Solution Approach 1:
The patent replaces electrical resistance-based detection with radiographic imaging that directly visualizes physical strand integrity. Since the imaging method detects actual strand continuity and crack presence rather than relying on electrical current flow, it maintains high testing speed while dramatically improving detection accuracy for cracked or broken strands that still conduct electricity
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 approach enables early and accurate detection of strand failures, extending the life of the winding by providing a risk analysis that determines the appropriate maintenance actions, such as replacement, repair, or monitoring, thereby reducing downtime and operational costs.
Implementation Method 1
A method using radiography with a radiation source and image capture device to non-destructively assess strand failures in generator stator coils
Data Source
Figure 1~3
Figure 4
AI summary
A method of determining the risk of a stator failure is provided. The stator includes multiple stator coil windings. Each of the windings includes multiple conductive metal strands. The number of strand failures is determined from an image captured by a radiography. A risk analysis is assessed from the determined number of strand failures.