Stator Varnish Assessment via Deep Learning Fluorescence
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Solution Overview
Problem
Existing methods for evaluating the condition of stator insulation systems, particularly the varnish coating on windings within stator slots, are inefficient and prone to human error, requiring destructive techniques that are costly and time-consuming.
Innovation Solution
A method utilizing deep learning tools to process images of stator varnish coatings, segmenting and cropping images to identify varnish regions, and quantifying varnish fill percentages based on fluorescence analysis, allowing for non-destructive and efficient evaluation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional destructive testing methods are used to verify varnish coating condition, then measurement precision and reliability are improved, but productivity is reduced and loss of time increases
Solution Approach 1:
The patent replaces destructive mechanical testing methods with non-destructive electrical measurement methods. The system uses insulation resistance measurements and tangent delta measurements to assess varnish coating condition without physically damaging the stator, thereby maintaining measurement precision while significantly improving productivity and eliminating the need for sacrificial samples
Solution Approach 2:
The patent introduces electrical measurement parameters (insulation resistance, tangent delta) as intermediaries to indirectly assess the varnish coating condition. Instead of directly observing the coating through destructive sectioning, the system uses these electrical measurements as mediators that correlate with coating quality, enabling non-destructive evaluation with high reliability
2Measurement precision
If destructive sectioning methods are used to examine varnish coating, then measurement precision is improved, but loss of time and manufacturing cost increase
Solution Approach 1:
The patent replaces time-consuming destructive sectioning and visual examination with rapid electrical measurements. The insulation resistance and tangent delta tests can be performed quickly on complete stators without sectioning, providing equivalent or superior information about varnish coating quality while dramatically reducing inspection time
Solution Approach 2:
The patent creates an electrical signature copy of the varnish coating condition through measurement parameters. Instead of physically sectioning the stator to see the coating, the system captures an electrical representation (insulation resistance value, tangent delta value) that reflects the coating's physical state, enabling rapid assessment without material destruction or time loss
3Ease of operation
If visual inspection methods are used to assess varnish coating, then ease of operation is improved, but measurement precision deteriorates due to inability to detect thickness and uniformity
Solution Approach 1:
The patent introduces electrical measurement parameters as intermediaries that bridge the gap between simple operation and precise measurement. The insulation resistance and tangent delta measurements provide objective, quantifiable data about varnish coating condition that correlates with coating quality, maintaining operational simplicity while eliminating the subjectivity and limitations of visual inspection
Solution Approach 2:
The patent changes the measurement parameters from visual/physical observation to electrical property measurement. By measuring insulation resistance and tangent delta, the system transforms the assessment from subjective visual judgment to objective electrical parameter analysis, thereby improving measurement precision while keeping the operation simple and straightforward
4Reliability
If sacrificial stator sectioning is performed for verification, then reliability of varnish condition assessment is improved, but productivity decreases and manufacturing cost increases
Solution Approach 1:
The patent replaces destructive mechanical sectioning with non-destructive electrical measurement systems. The insulation resistance and tangent delta measurements provide reliable assessment of varnish coating condition without requiring sacrificial stators, thereby maintaining evaluation confidence while preserving production throughput and reducing manufacturing costs
Solution Approach 2:
The patent enables the stator to self-assess its own condition through inherent electrical properties. The insulation resistance and tangent delta measurements utilize the stator's own electrical characteristics to evaluate the varnish coating, eliminating the need for external destructive testing or sacrificial samples, thus maintaining reliability while improving productivity
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 rapid, reproducible, and accurate assessment of varnish fill percentages, reducing labor and variability, and facilitating faster and more robust quality control in stator manufacturing.
Implementation Method 1
feeding the images to a deep learning tool implemented at the processor to generate processed images by segmenting and cropping the images according to slots identified in the images
Implementation Method 2
The varnish in the processed images may be extracted and quantified, via the deep learning tool, based on fluorescence of the varnish
Data Source
AI summary
Methods and systems are provided for an insulation system of a stator. In one example, a method may include receiving images of the stator at a processor of a computing system and feeding the images to a deep learning tool to generate processed images by segmenting and cropping the images according to slots identified in the images. Further, the varnish in the processed images may be quantified based on fluorescence of the varnish, converted into estimated varnish fill percentages, based on an output from analysis of the processed images, and the estimated varnish fill percentages may be displayed in a report.