Electro-hydraulic Stator Wedge Installation Tool
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Solution Overview
Problem
Conventional methods for installing stator wedges in dynamoelectric machines are time-consuming and labor-intensive, causing worker fatigue and potential damage to the stator core, and existing powered tools are limited in their ability to drive wedges over filler layers.
Innovation Solution
A powered tool with an axial shaft and foot mechanism, actuated by an electro-hydraulic pump, applies a uniform axial force to drive wedges over filler layers, reducing installation time and eliminating manual labor-related issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual methods (block and mallet) are used to install wedges, then installation can be performed with simple tools, but installation time is excessive (20 seconds per wedge) and worker fatigue causes potential damage to the stator core
Solution Approach 1:
The patent replaces the manual mechanical system (block and mallet requiring worker fatigue) with a powered mechanical system featuring an electro-hydraulic pump, shaft, and foot mechanism that automatically drives the wedge, eliminating worker fatigue and reducing installation time from 20 seconds to approximately 7 seconds per wedge
Solution Approach 2:
The patent employs an electro-hydraulic pump to generate hydraulic force that actuates the shaft and foot mechanism, providing controlled mechanical power to drive the wedge into the slot, thereby replacing manual striking forces with hydraulic actuation
2Productivity
If existing powered tools are used to drive wedges, then installation time is reduced, but the tools are limited in their ability to drive wedges over filler layers
Solution Approach 1:
The patent adds a radial dimension to the tool design with the foot extending radially from the shaft, allowing the foot to engage and drive the wedge over filler layers that occupy the radial space, thereby overcoming the limitation of existing powered tools that could not handle filler layers
Solution Approach 2:
The foot acts as an intermediary component between the shaft and the wedge, transferring the axial force from the shaft to the wedge while navigating over the filler layers, enabling the tool to drive wedges in the presence of filler layers that would block direct shaft-to-wedge contact
3Reliability
If uniform axial force is applied to drive wedges, then damage to the stator core is prevented, but manual methods cannot ensure uniform force application
Solution Approach 1:
The patent incorporates a control system that monitors the force applied by the foot to the wedge and adjusts the hydraulic pump operation accordingly, ensuring uniform axial force is maintained throughout the wedge installation process to prevent damage to the stator core
Solution Approach 2:
The patent controls the hydraulic pressure and flow parameters to the electro-hydraulic pump, dynamically adjusting these parameters to maintain consistent axial force application on the wedge, thereby ensuring uniform force distribution and preventing stator core damage
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 tool significantly reduces installation time per wedge from 20 seconds to approximately 7 seconds, reducing total installation time for all wedges from 10 hours to 3.5 hours and ensures a uniform axial force to prevent damage to the stator core.
Implementation Method 1
a pump operatively coupled to the shaft to actuate the shaft in an axial direction
Data Source
Figure 1~2A
Figure 2B~3
Figure 4A~4B
AI summary
A tool (110) is presented for installing a wedge (104) in a slot (101) of a stator core (100). The tool (110) includes a housing (112) and a shaft (128) extending axially from the housing. An end of the shaft (128) is positioned in the slot (101) on a first side of the wedge (104) to engage a wedge surface (118). The tool (110) further includes a pump (120) operatively coupled to the shaft (128) to actuate the shaft in an axial direction (122) external to the housing (112) to install the wedge in the slot. The tool (110) further includes a tongue (124) inserted in a vent gap (126) of the slot (101) on the first side of the wedge to brace the tool against the slot during the installation of the wedge. A system (200) and method (300) are also presented for installing the wedge.