General Electric Company

Alan Michael Iversen

Jeffrey Michael Breznak

Kenneth John Hatley

James F Hopeck

Lawrence Lee Sowers

David Robert Schumacher

Yu Wang

Richard Michael Hatley

James Rollins Maughan

William Gene Newman

Thomas Richard Blakelock

Thomas Rufus Butman, Jr

Reed Roeder Corderman

Scott Andrew Weaver

Young Jin Kim

Sean Michael McDonnell

Paul Joseph Martiniano

Vincenzo Sofia

James Fredrick Hopeck

James Michael Fogarty

Robert John Nygard

Raymond Grant Rowe

Sameh Ramadan Salem

James Jun Xu

Michael John Bousquet

Leonard Paul Squillacioti

Jeffrey D Sheaffer

William Paul Dobbins

George Rowan Silliman

Robert Timothy Lembke

Stephen Frank Francese

Marc Herbert Rigby

Joseph Alan Worden

Mabel Shang Yung

Leonard George Pezzano

Lisa Marie Sternberg

Adrian Breitenstein

Ronald Richard Barlette

A method for preparing a field coil winding assembly including cleaning a plurality of copper coils followed by developing, after the cleaning, a copper oxide layer on each of the copper coils by oxidizing each of the copper coils in a solution. After the developing, each of the copper coils is rinsed followed by drying. After the drying, a turn insulation system is applied to each of the copper coils. The turn insulation system includes a turn insulation and an adhesive. The turn insulation includes at least one of a glass fiber re-enforced polyamideimide, a glass fiber re-enforced polyester, or a glass fiber re-enforced high temperature novolac epoxy. After the applying, each of the copper coils with the turn insulation system is cured. The plurality of copper coils with the turn insulation system are stacked in each of a plurality of rotor slots in a rotor.

Field coil winding assembly

A method for handling a stator bar at a braze station including: lifting the stator bar from a platform, wherein the stator bar is in a substantially horizontal orientation on the platform; turning the stator bar from the horizontal orientation to an orientation at least 45 degrees from horizontal; aligning an upper end of the bar with a brazing station and positioning a lower end of the bar in a pit; turning the bar to reverse positions of the ends of the bar, and returning the stator bar to a horizontal orientation.

Method for handling a stator bar using a pit

A method for handling a stator bar at a stator bar facility having a stator bar workstation, an in-ground pit proximate to and at an elevation below the workstation and a stator bar transport proximate to the in-ground pit including: loading the stator bar onto the stator bar transport; turning the stator bar at least 45 degrees in a vertical plane; positioning at least a third of a length of the stator bar down into the in-ground pit, aligning a first end of the bar with the workstation, and turning the bar to reverse positions of the ends of the bar, such that a second end of the bar is aligned with the workstation.

A method of forming a brazed joint between an armature bar and a hydraulic header clip including the steps of: locating ends of a plurality of hollow strands and a plurality of solid strands within a cavity in an end fitting such that free ends of said hollow strands extend axially beyond free ends of said solid strands; and pre-placing an essentially phosphorous-free silver braze alloy around and between said ends of said hollow strands and said solid strands such that said braze alloy extends axially beyond the free ends of said solid strands.

Method for applying braze end isolation layer for generator armature winding bar

A method of forming a brazed joint between an armature bar and a hydraulic header clip including: assembling free ends of hollow strands and of solid strands of the armature winding bar and positioning the assembly within the hydraulic header clip; interleaving a silver based braze alloy between the strands, wherein a portion of the braze alloy extends axially beyond the free ends of a plurality of the solid strands and the free ends of a plurality of the hollow strands extend axially beyond the braze material; positioning the assembly of the free ends, hydraulic header clip and the braze alloy in a braze chamber, such that the clip is seated in an induction heating coil of the chamber; heating the assembly to a first temperature below a solidus temperature of the braze alloy and within a 200 degrees Fahrenheit of the solidus temperature activating the induction heat coil to heat the clip; heating the assembly to a second temperature above the liquidus temperature of the braze alloy; pooling liquid braze alloy on ends of the armature bar, and cooling the assembly and clip thereby forming a braze isolation layer on the end of the armature bar.

Method for applying an isolation layer to a brazed end of a generator armature winding bar

A stator bar facility including: a stator bar workstation; an in-ground pit below the workstation; a stator bar elevator extending from the workstation pit, and a coupling mechanism attached to the elevator, wherein the coupling mechanism further comprises a rotational mount to receive at least one stator bar, wherein the rotational mount enables the received stator bar to be turned from a substantially horizontal position to a substantially vertical position.

Method and system for handling a stator bar using a pit

A method for manufacturing a liquid-cooled stator bar suitable for use in a generator. The method includes providing a stator bar comprising a plurality of conducting strands collectively formed into a desired shape, wherein at least one of the conducting strands is configured to channel a liquid for cooling the stator bar. At least one layer of ground wall insulation is applied to the outer portions of the stator bar, and then at least one layer of a conductive tape is applied to an outer area of the ground wall insulation. The ground wall insulation and the conductive tape are cured.

Method for manufacturing liquid-cooled stator bars

A liquid-cooled armature bar end fitting-to-strand brazed connection. The end fitting is comprised of a main body and a cover, and defines a cavity, a bottom wall of which is defined in part by the cover. An armature winding bar strand package including solid strands and hollow strands arranged in a tiered array extends into the end fitting so that at least the free ends of the hollow strands extend beyond the bottom wall, into the cavity. The side wall of the cavity is spaced from the hollow strands. A braze alloy joins the strands to each other and to the end fitting. The braze alloy forms an isolation layer over the free ends of the solid strands and over the said bottom wall of the cavity to a depth above a horizontal junction between the main body and the cover.

Liquid-cooled armature bar clip-to-strand connection and method

A method for metallurgically bonding a stator bar to a coupling to reduce the incidence of leak paths resulting from corrosion. The stator bar comprises strands through which a liquid coolant can flow. Adjacent ends of the strands are received in an interior cavity of the coupling through an opening in the coupling. A joining material is provided on a first portion of the stator bar within the coupling opening and adjacent the ends of the strands. The first portion is heated to melt the joining material. At essentially the same time, a second portion of the stator bar outside the coupling is also heated. Once the joining material is suitably molten, the first portion is allowed to cool while the second portion remains heated, thereby causing the joining material nearest the ends of the strands to solidify first.

Method of metallurgically bonding a stator bar

A method to heat a stator bar and clip assembly in a brazing chamber including: placing the stator bar and clip assembly in the brazing chamber, wherein the assembly is seated in a heating coil; positioning a conductive mass between a press and the stator bar and clip; applying the press to the assembly while the assembly is seated in the coil; heating the stator bar and clip by applying energy to the coil; brazing the stator bar to the clip with the heat from the coil, and removing the press and cooling the brazed clip.

Movable heating method and system having fixed heating source for brazing stator bars

A method of forming a brazed joint between an armature bar and a hydraulic header clip including: assembling an end of the armature bar, hydraulic header clip and a substantially phosphorus-free braze material; positioning the assembly of the armature bar, hydraulic header clip and the braze material in a braze chamber, such that the clip is seated in an induction heating coil; heating the assembly to a first temperature within 200 degrees Fahrenheit of and below a solidus temperature of the braze material by applying electrical current to the induction heat coil; heating the assembly to a second temperature above the liquidus temperature of the braze material; pooling liquid braze material on ends of the armature bar, and cooling the assembly and thereby forming a braze layer on the end of the armature bar.

System for applying an isolation layer to a brazed end of a generator armature winding bar

A brazed joint between an armature winding bar strand package and a hydraulic header clip end fitting including: a plurality of solid strands and a plurality of hollow strands arranged in a tiered array and forming the strand package, the plurality of hollow strands having free ends that extend axially beyond corresponding free ends of solid strands; a cavity in the end fitting into which extents the free ends of the hollow strands and solid strands, and an essentially phosphorous-free silver braze alloy joining the free ends of the plurality of hollow strands and said corresponding free ends of solid strands to each other and to interior surfaces of the end fitting, wherein said braze alloy forms an isolation layer over the free ends of the solid strands.

Braze end isolation layer for generator armature winding bar and method for applying the isolation layer

A brazed joint between an armature bar strand package and an end fitting includes a plurality of strands arranged in a tiered array and forming the strand package; a cavity in the end fitting, free ends of the plurality of strands extending through opening in the end fitting and received in the cavity; and an essentially phosphorous-free copper-silver braze alloy joining the free ends of the plurality of strands to each other and to interior surfaces of the end fitting.

Crevice corrosion-resistant liquid-cooled armature bar clip-to-strand connection and related method

A water-cooled stator bar clip for electrical generators and a method for applying a corrosion-resistant protective coating, preferably Sc, Ti, Cr, Zr, Nb, Mo, Hf, Ta, W, Ni, and Al, and their alloys or oxides to existing stator bar end fittings in order to significantly reduce the possibility of leaks through the brazed connections of the copper stator bar end connections. The coatings can be applied locally using various known physical vapor deposition ('PVD'), chemical vapor deposition ('CVD') or other direct coating techniques known in the art. For example, the coatings can be applied using ion plasma deposition, sputtering or wire arc techniques (all PVD processes) or by using electroplating, high velocity oxygen free (&#x201c;HVOF&#x201d;) deposition, DC arc or electroless plating. Preferably, the coatings are applied either to new stator bar clips or to existing clips in the field.

Corrosion protective coating for extending the lifetime of water cooled stator bar clips

A method of forming a brazed joint between an armature bar and a hydraulic header clip including: assembling an end of the armature bar, hydraulic header clip and a substantially phosphorous-free braze material; positioning the assembly of the armature bar, hydraulic header clip and the braze material in a braze chamber, such that the clip is seated in an induction heating coil; heating the assembly to a first temperature within 200 degrees F. of and below a solidus temperature of the braze material by applying electrical current to the induction heat coil; heating the assembly to a second temperature above the liquidus temperature of the braze material; pooling liquid braze material on ends of the armature bar, and cooling the assembly and thereby forming a braze layer on the end of the armature bar.

Growing community of inventors

Clifton Park, NY, United States of America

Alan Michael Iversen