Wedge Fixing Force Measurement Using Controlled Hammering and Vibration Analysis
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Solution Overview
Problem
Current methods for evaluating the fixing force of a wedge in a generator stator are imprecise due to variability in human judgment and are not suitable for small, elongated objects, as they rely on organoleptic examination and are affected by hammering position and force, leading to insufficient precision in quantifying the wedge's fixing force.
Innovation Solution
An apparatus that applies a controlled hitting force to the wedge, collects the resulting sound, and processes it to obtain feature quantities such as center-of-gravity frequency and energy, using a database to estimate the fixing force based on previously obtained correlations, thereby enhancing precision and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If organoleptic examination is used to judge the fixing state of the coil, then the inspection can be performed without specialized equipment, but the measurement precision is poor due to dispersion in judgment results
Solution Approach 1:
The patent replaces the mechanical/organoleptic examination method with an acoustic measurement system. A hammer strikes the wedge to generate vibrations, and a vibration sensor detects the vibration response. This substitution eliminates the subjectivity and dispersion inherent in human-based organoleptic examination while providing quantitative, objective measurement data.
Solution Approach 2:
The patent introduces vibration response as an intermediary parameter to indirectly measure the fixing force. Instead of directly measuring the fixing force or relying on subjective judgment, the system uses the vibration characteristics of the wedge as a mediator that correlates with the fixing state, enabling objective quantification.
2Measurement precision
If the center of energy band of spectra is used for spectral analysis, then some quantification is achieved, but the measurement precision is insufficient due to changes in hammering sound frequency
Solution Approach 1:
The patent changes the measurement parameter from the center of energy band frequency to the maximum amplitude frequency of the vibration response. This parameter change addresses the issue of frequency variation by focusing on the peak amplitude characteristic, which provides more stable and reliable correlation with the fixing force regardless of hammering position or force variations.
Solution Approach 2:
The patent establishes a feedback mechanism where the vibration response is continuously measured and compared against reference data to determine the fixing state. This feedback approach allows for real-time assessment and adjustment, improving both the precision and reliability of the measurement by accounting for variations in hammering conditions.
3Ease of operation
If impulse hammer method is applied to small plate-like objects, then the measurement can be performed, but the measurement precision is insufficient due to weak correlative relationship
Solution Approach 1:
The patent enhances the impulse hammer method by substituting the traditional acoustic measurement approach with a vibration-based measurement system. A vibration sensor directly measures the vibration response of the wedge, providing a stronger and more reliable correlation with the fixing force compared to acoustic methods, thereby improving measurement precision for small plate-like objects.
Solution Approach 2:
The patent changes the measured parameter from acoustic characteristics to vibration amplitude and frequency characteristics. This parameter change strengthens the correlative relationship between the measurement and the fixing force, as vibration response provides a more direct and sensitive indicator of the mechanical fixing state in small components.
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 allows for precise quantification of the wedge's fixing force, improving the reliability of assembly and enabling efficient maintenance by tracking temporal changes, reducing maintenance costs and energy consumption.
Implementation Method 1
a vibration sensor 35 that converts the vibrations into electric signals
Implementation Method 2
A solenoid actuator 31 generates an electromagnetic force F in response to a drive current
Data Source
AI summary
A fixing force measuring apparatus including a section for applying a predetermined controlled hammering force to a wedge surface to generate a hammering sound, a section for controlling the hammering sound generated, a section for obtaining plural kinds of feature quantities such as a feature quantity due to a hammering sound energy, and a feature quantity due to a frequency of the hammering sound from the hammering sound collected by an arithmetic operation, and a section for obtaining a fixing force corresponding to the plural kinds of feature quantities by using a correlative relationship between the wedge fixing force previously obtained, and the plural kinds of feature quantities.