Title of Invention | IMPROVEMENT IN PROCESS OF ALIGNMENT OF STATOR CORE FOR CORRECT ASSEMBLY OF CONNECTING BUS BAR TO REDUCE MISMATCH OF TERMINAL CONNECTORS IN TOTAL IMPREGNATED TURBO GENERATOR |
---|---|
Abstract | A process for alignment of stator core and correct assembly of connecting bus bar comprising the steps of : setting and alignment of fixture beam (2) by a rectangular alignment steel beam, positioning top core bar (4) and bottom core bar by rotating the stator core on rollers, alignment top core bar (4) with bottom core bar with a plumb line suspended on exciter and from the center of top core bar (4), measuring and recording parallelity of six vertical spring holders by square sprit level at the center of machined face of spring holder, characterized in aligning said fixture beam (2) by a rectangular steel beam positioned on a slot on said fixture beam with the core axis, in drilling two holes on each spring basket (1) after control marking and measuring chord values and in ensuring that the top surface of fixture beam is aligned parallel to x-z plane of the stator core (3) through spirit level and adjusting height of fixture beam to required level. |
Full Text | FIELD OF INVENTION: The present invention relates to improvement in process of alignment in the filed of stators for electrical rotating machines in general, and particularly to alignment of stator core winding of turbogenerators. BACKGROUND AND PRIOR ART: Total VPI Turbo Generators are being manufactured in one place and Stator Core and Stator Frame are manufactured in separate manufacturing facility. Stator Core is manufactured outside in vertical condition. Two numbers core bars (diagonally opposite) have three numbers locating pins on each. Three numbers Spring Baskets (each in two halves) are assembled over core guided by two diagonally opposite locating holes in each basket. Each of each half basket is stretched and welded. Core is made horizontal and centerlines are marked. Winding brackets are welded and it is sent for assembly of stator windings. After this Connecting Bus Bars are assembled. A fixture is used for assembly of Connecting Bus Bar. It is mounted on extreme ring of Spring Basket on exciter end (EE) of core. Distances of palm of connecting bus bar is maintained with respect to core and assembled. Wound Core is totally impregnated, cured. Ready wound core is placed on C-Beam after alignment of verticality of spring basket holders. Stator Frame is inserted over wound stator with the help of crane, aligned with core and bushes are welded to spring basket holders and springs for load transfer. Then it is shifted on test bed and Terminal Box, Terminal Bushings are assembled. Finally, connecting links are assembled between terminals of Connecting bus bars and terminal bushings. The following problems are faced during the above process: (A) Mismatch of ends of Terminal Connectors - Since assembly of spring basket is a fitting job, its plane does not remain perpendicular to axis of Stator Core. This results in to mis-matching of palm of connecting bus bar (6 numbers) with connecting links coming from Terminal Bushings (6 numbers). The order of mis-match is about 30 to 40 mm. It requires many more Man-Hours to correct the mis-match in position and assemble. (B) Interference between Bush and Spring Holder Plate - Sometimes bush was found to interfere with a collar on Spring holder. Due to this a step had to be machined on bushes to accommodate assembly. OBJECTS OF INVENTION: The process was analysed at different stages in detail starting from machining of Spring Baskets & core assembly up to insertion of wound core into stator frame. Reasons for problems were narrowed down to following assemblies: 1. Machining of spring basket 2. Measurement of parallelity of spring basket holder 3. Assembly of fixture for mounting connecting bus bars 4. Insertion of wound core into stator frame To overcome the drawbacks of the prior art, innovative remedial actions were undertaken to improve it. DESCRIPTION OF THE INVENTION: (a) Machining of Spring Baskets- Three number Spring Baskets are used after core assembly to apply radial pressure on stator core to make it monolithic. Each spring basket has two diametrically opposite holes having diameter in the range 20-25 mm preferably 21 mm. (1) Process Requirements - Location of these holes are very important because these are used for locating spring baskets on core. Two numbers core bars (diametrically opposite) has pins where the holes locate the basket (makes spring holder vertical and horizontal with respect to core axes). Variation in this dimension will make spring holders more inclined leading to interference of Bush with collar on the spring basket. Improvement Process Implemented - Control marking was introduced for the holes and all chord values were recorded before drilling. Locations of holes were ensured by control marking. (b) Alignment of center of top & bottom slot with vertical plane and Measurement of parallelity of spring holders on spring baskets - Stator core is made horizontal after assembly of spring baskets. Centre of top and bottom stator slots are aligned with vertical plane and measurements of parallelity of six vertical spring holders are taken with respect to vertical plane. So these values are to be used as reference for all further operations. Parallelity of machined spring holders holders on spring baskets are ensured to be within limits. Process requirements - Centre of top and vertical slots to be set in vertical plane. (2) Measurement of parallelity of six vertical spring basket holders with respect to vertical plane so that when these values are reproduced, it will set the center of top and bottom slots in vertical plane. (ii) Improved Process Implemented - A plumb was dropped on Exciter end side from center of top core bar and core was rotated on rollers to bring center of bottom core bar in line of the plumb. The center of top and bottom slots were also observed to be in line of plumb and minor correction was carried out by rotating the core on rollers. Measurement of parallelity of six vertical spring holders was carried out with the help of square sprit level (size 200x200) at the center of machined face of spring holder and recorded. This value of setting was used for all further operations. (c) Alignment of connecting bus bar mounting fixture on stator core Locations of terminals of connecting bus bar are defined in the drawing with respect to vertical and horizontal centerline of stator core. Therefore, x,y, and z co-ordinates (Fig. 1) of terminal of connecting bus bar should be controlled with respect to vertical and horizontal planes and axial center of stator core. I. Process requirements - 1. Longitudinal axis of core should be horizontal. 2. Fixture Beam should be assembled perpendicular to the axis of core (Fig-2). 3. Top face of beam should be aligned with x-z plan in both z-direction and x-direction 4. Height of the fixture should be maintained at specified height with respect to a reference plane. 5. Actual length of core should be taken in to account while adjusting distance between palm of connecting bus bars along axial direction . (ii) Earlier process described as under, has the following drawbacks - Fixture (Fig-4) is assembled on the extreme ring of spring basket on Exciter End with the assumption that plane of the ring is perpendicular to z-axis of the core. But this is not true due to following reasons - a) When spring basket is assembled on the stator core, the position of ring deviates from that of desired position by about 8 to 10 mm along its whole periphery in spite of all efforts. b) Fixture mounting holes are dependent upon how accurately basket has been assembled which in turn depends upon actual drilled location of 21mm radial holes. c) It is not ensured that top plane of beam is parallel to xz-plane as shown in the diagram. It means that ring of the basket can not be taken as a reference for assembly of fixture beam. Since, stampings of core is punched to a very close tolerance, centerline of top core bar can be taken as reference and beam should be aligned with this. (iii) Improved Process implemented - Following improved process were adopted for setting and aligning of fixture beam for improved assembly of connecting bus bar - 1. Fixture beam for assembly of connecting bus bar was improved. In following way- (a) A close tolerance slot was machined at center of fixture beam in perpendicular direction to its length. (Fig.5) (b) A special rectangular alignment beam was designed and manufactured for alignment of fixture beam with center of top core bar. 2. Stator core is placed on tow pairs of rollers. Height of the rollers were checked with a sprit level and found to be alright. 3. Stator core was rotated before mounting of fixture such that parallelity values were achieved as measured earlier in step b-(ii) after taking care that top of core is placed now at bottom for assembly of connecting bus bar. 4. Centreline was marked on top core bar and bottom spring holder on exciter end side. 5. Rectangular steel bar was fixed in the slot of fixture beam. 6. Fixture beam was assembled on extreme ring of spring basket on exciter end side. 7. A plumb was dropped from edge of rectangular beam at two locations (first near to beam and next at far end of rectangular bar) and it was aligned with cecterline of top core bar by placing packers at mounting locations of fixture between fixture and spring basket ring. This has aligned the beam perfectly perpendicular to core axis 8. A sprit level was placed on top surface of fixture beam in both x and z direction (Fig.2) and its surface was aligned parallel to x-z plane by assembling a few packers below fixture. Height of the beam was also set as per requirement. 9. Now the beam is perfectly ready for further assembly of connecting bus bars (Fig. 6) (d) Alignment of wound core on C-beam - Impregnated wound core is placed on C-beam with line joining center of top and bottom slot aligned with vertical. Stator Frame is inserted over wound core with the help of crane, aligned and bushes are welded, (i) Process Requirements - Vertical centerline of core should be in vertical plane, (ii) Improved Process Implemented - Wound core is to be placed on C-beam in such a way so that values of parallelity of spring holders matches with earlier measurements carried out in step b-(ii). This makes the centerline of top and bottom slot aligned with vertical. Stator Frame is inserted over the wound core. Alignment is done for achieving desired radial gaps between stator wall and ring of spring basket at specified locations. Bushes are inserted and welded. Brief DESCRIPTION OF THE ACCOMPANYING DRAWINGS: Fig.1 shows x,y and z co-ordinates of terminals of connecting bus bar. Fig. 2 shows elevation and side view of stator core with spring baskets and the fixture in accordance with the invention. Fig. 3,4,5,and 6 are photographic views of spring basket, fixture for mounting connecting bus bars (both Front and sideview), slot made on fixture for alignment and connecting bus bars mounting under process respectively. WE CLAIM : 1. A process for alignment of stator core and correct assembly of connecting bus bar comprising the steps of : - setting and alignment of fixture beam (2) by a rectangular alignment steel beam, - positioning top core bar (4) and bottom core bar by rotating the stator core on rollers, - alignment top core bar (4) with bottom core bar with a plumb line suspended on exciter and from the center of top core bar (4), - measuring and recording parallelity of six vertical spring holders by square spring level at the center of machined face of spring holder, - characterized in aligning said fixture beam (2) by a rectangular steel beam positioned on a slot on said fixture beam with the core axis, in drilling two holes on each spring basket (1) after control marking and measuring chord values and in ensuring that the top surface of fixture beam is aligned parallel to x-z plane of the stator core (3) through spirit level and adjusting height of fixture beam to required level 2. A process as claimed in claim 1, wherein the diameter of the holes in the spring baskets is between 20-25mm. 3. A fixture comprising of fixture beam (2), a rectangular steel bar being positioned in a slot provided on the fixture beam (2), the fixture being placed on the extreme ring of the spring basket at the exciter end side, wherein the plane of the ring is perpendicular to the z-axis of the stator core (3) thereby aligning the fixture beam (2) perfectly perpendicular to the core axis. 4. A fixture as claimed in claim 3, wherein the said slot is perpendicular to the length of the fixture beam(2). A process for alignment of stator core and correct assembly of connecting bus bar comprising the steps of : setting and alignment of fixture beam (2) by a rectangular alignment steel beam, positioning top core bar (4) and bottom core bar by rotating the stator core on rollers, alignment top core bar (4) with bottom core bar with a plumb line suspended on exciter and from the center of top core bar (4), measuring and recording parallelity of six vertical spring holders by square sprit level at the center of machined face of spring holder, characterized in aligning said fixture beam (2) by a rectangular steel beam positioned on a slot on said fixture beam with the core axis, in drilling two holes on each spring basket (1) after control marking and measuring chord values and in ensuring that the top surface of fixture beam is aligned parallel to x-z plane of the stator core (3) through spirit level and adjusting height of fixture beam to required level. |
---|
00968-kol-2008-correspondence others.pdf
00968-kol-2008-description complete.pdf
968-KOL-2008-(13-02-2014)-ABSTRACT.pdf
968-KOL-2008-(13-02-2014)-CLAIMS.pdf
968-KOL-2008-(13-02-2014)-CORRESPONDENCE.pdf
968-KOL-2008-(13-02-2014)-DESCRIPTION (COMPLETE).pdf
968-KOL-2008-(13-02-2014)-DRAWINGS.pdf
968-KOL-2008-(13-02-2014)-FORM-1.pdf
968-KOL-2008-(13-02-2014)-FORM-2.pdf
968-KOL-2008-(13-02-2014)-FORM-3.pdf
968-KOL-2008-(13-02-2014)-PA.pdf
Patent Number | 264910 | |||||||||||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
Indian Patent Application Number | 968/KOL/2008 | |||||||||||||||
PG Journal Number | 05/2015 | |||||||||||||||
Publication Date | 30-Jan-2015 | |||||||||||||||
Grant Date | 28-Jan-2015 | |||||||||||||||
Date of Filing | 30-May-2008 | |||||||||||||||
Name of Patentee | BHARAT HEAVY ELECTRICALS LIMITED | |||||||||||||||
Applicant Address | REGIONAL OPERATION DIVISION (ROD), PLOT NO: 9/1, DJBLOCK 3RD FLOOR, KARUNAMOYEE, SALT LAKE CITY, KOLKATA-700091, HAVING ITS REGISTERED OFFICE AT BHEL HOUSE, SIRI FORT, NEW DELHI-110049 | |||||||||||||||
Inventors:
|
||||||||||||||||
PCT International Classification Number | H02K 15/06 | |||||||||||||||
PCT International Application Number | N/A | |||||||||||||||
PCT International Filing date | ||||||||||||||||
PCT Conventions:
|