Winding Head Support Additive Manufacturing for Large Diameters

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Solution Overview

Problem

Existing winding head supports for electric machines are limited in size by forging and rolling equipment and transportation constraints, restricting their maximum inner diameter to approximately 6 meters, which can hinder machine design and require on-site production.

Innovation Solution

The method employs additive manufacturing, specifically wire arc buildup welding, to produce winding head supports independently of these limitations, allowing for larger sizes and on-site production, using materials like austenitic steel to achieve high strength and non-magnetizable properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If winding head supports are produced by forging and rolling, then high strength is achieved, but maximum size is limited to approximately 6 meters inner diameter

Engineering Contradiction:

ImprovestrengthVSAvoidinner diameter

Core Design Contradiction:

StrengthVSLength of stationary object

Solution Approach 1:

The patent replaces traditional mechanical forging and rolling processes with additive manufacturing (wire arc buildup welding). This substitution allows production of winding head supports with inner diameters exceeding 6 meters while maintaining high strength properties through controlled welding parameters and material deposition techniques.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the manufacturing parameters from conventional forging/rolling to additive manufacturing parameters (wire feed rate, welding current, travel speed). This parameter change enables production of larger diameter components by building them layer by layer, overcoming the size limitations of traditional mechanical processes.

Inventive Principle:

Principle #35Parameter changes

2Strength

If winding head supports are produced by forging and rolling, then high strength is achieved, but production must occur in facilities with specialized equipment

Engineering Contradiction:

ImprovestrengthVSAvoidproduction flexibility

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent replaces specialized forging and rolling equipment with additive manufacturing technology (wire arc welding apparatus). This substitution enables production in more locations, including on-site at power plants, while maintaining high strength through controlled welding processes and appropriate material selection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The additive manufacturing process allows the winding head support to be built up layer by layer directly at the installation location. The welding apparatus can be transported to various sites and operates autonomously to deposit material and form the structural rings, eliminating dependence on fixed specialized production facilities.

Inventive Principle:

Principle #25Self-service

3Adaptability or versatility

If larger winding head supports are produced, then machine design flexibility is improved, but conventional production methods cannot accommodate sizes exceeding 6 meters

Engineering Contradiction:

Improvemachine design flexibilityVSAvoidmanufacturability

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent replaces conventional manufacturing systems with additive manufacturing, enabling production of winding head supports in any size required by machine design. The wire arc buildup welding process can accommodate large diameters by adjusting welding parameters and build time, providing unlimited design flexibility.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention transitions from planar forging/rolling to three-dimensional additive construction. By building the winding head support rings layer by layer in the radial direction, the process can accommodate any inner diameter size, transforming the manufacturing approach from two-dimensional deformation to three-dimensional material deposition.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 the production of winding head supports with diameters exceeding 6 meters, providing high strength and flexibility in design, allowing for larger electric machines to be built outside conventional production facilities, while ensuring stability against centrifugal forces.

Implementation Method 1

the winding head support is formed by an additive manufacturing process, in particular by wire are buildup welding

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 2

wire arc buildup welding

Methodology Applied

Scientific EffectArc heating: Electric Arc

Implementation Method 3

the winding head support is formed by an additive manufacturing process

Methodology Applied

Scientific EffectAdditive manufacturing: 3D Printing

Data Source

PatentUS20230070084A1Method for producing a winding head support, and winding head support

Publication Date: 2023.03.09 ANDRITZ HYDRO GMBH

AI summary

A method for producing a winding head support for a rotor of a rotating electric machine. To enable the production of even particularly large winding head supports in a simultaneously simple manner, it is provided that the winding head support is formed using an additive manufacturing process, in particular by wire arc buildup welding. Embodiments also relate to a winding head support.