DE4207172A1 - Transposed conductor test method for stator coil of generator - automatically separating sub-conductors forming laminated stack, while maintaining reference point for measurement - Google Patents

Abstract

The set of generator winding conductors are arranged in two layers. At the remote end the conductors are soldered together in pairs. At the testing end, two test groups (55,56) are defined, where sensor connections (62,72) are applied in turn to conductors (10,56,57,66,67). Motorised transport mechanisms (58,59,60,61) etc. separate the conductors and apply the test circuit probes to test for isolation. USE/ADVANTAGE - For hydroelectric or turbo generators. Shortened testing time, can be easily integrated into mfr.

Description

The invention relates to a method for testing Roebel bars for stator windings of generators or the like, which rods from a package of layered in two layers ribbon-shaped, isolated from each other sub-conductors and pressed or drawn into an appropriate shape, wherein each partial conductor shunts to the entire lei ter package is checked, after separating all sub-conductors contacted each sub-conductor at the ends of the conductor package and the electrical properties are measured. Besides The invention also relates to the associated system to carry out the method with a jig device for the conductor packages and a contacting and measuring unit direction for the partial conductors.

Especially for stator windings of hydropower and turboge so-called Roebelstabe, who occasionally are also referred to as bars. Roebel rods are made up of a variety of insulated flat copper wires that completely ver together at the rod ends are soldered. In the areas of the staff responsible for the determinative appropriate use outside of the machine's laminated core, that is in the winding head area, the partial conductors become parallel guided. In the area of the rod that is used for the intended Ge need lies within the laminated core, on the other hand they are  Partial conductor twisted, d. H. each sub-leader carries out the Rod longitudinal axis 360 ° rotation, possibly also 540 °. The latter measures are necessary to reduce the current to keep losses in the windings small.

In the context of manufacturing electrical machines it is desirable to test the Roebel rods integrated in the production process and especially a shunt test of the sub-conductors perform. So far, this has been largely manual driven method used in which the partial conductor two rod ends in comb-like facilities that the part separate the head of the lattice bar for the test and con tact, must be introduced.

Because the handling of the individual sub-conductors of the described Roebelstifte is comparatively cumbersome, for the electrical testing of Roebel bars has so far been unacceptable takes a long time. The object of the invention is therefore, to specify suitable measures with which a Procedure for the electrical testing of Roebel bars Time is reduced. Furthermore, a suitable one Plant created with the in a practical way the electrical testing of Roebel bars in a flexible Manufacturing can be integrated.

The object is achieved in that the Se parry the subconductor is done automatically and that at Separate one reference point for the measurement a partial conductor is obtained.

In an advantageous implementation of the method according to the invention The two layers of the conductor package are located at their ends  mechanically separated as a separate bundle and each in one layer shot a bundle of conductors over a support body ben, whereby when a partial conductor slides off the support body this sub-conductor is mechanically detected and identified.

In an alternative embodiment of the invention The procedure is the one layer of the conductor package right relative to the other layer and are the when turning through those formed by the individual partial conductors stages as an approach to mechanical separation then carry out the electrical measurement of the partial conductors to be able to lead.

In another alternative embodiment of the invention according to the procedure, however, between the two layers of the Conductor package at least one cylindrical conical Rotating mandrel with a spiral profile on its conical surface retracted, the partial conductors in the spiral profile rela Actively move apart against the mandrel and thereby mechanically be separated.

In the associated system for performing the fiction according to the method in one of the Al Alternatively, there is a handling device that at least one separator and one guide has direction for the partial conductor of the Roebel rod.

With the inventive method and the associated An location results in a considerable time saving in the test of Roebelstäben, because the separation of the partial conductors lig automated: A Roebel rod to be tested is  placed on a test vehicle and using a quick release device clamped on both sides. Then in particular in the first alternative of the specified method the spread two sub-conductor layers, in one of two separators facilities introduced at the front and on the struts of the Quick release device attached. Then the Partial conductor layer on top to the left and the lower part ladder position pivoted to the right and the resilient counter holder positioned. The existing separation combs with open Take chambers for single conductors are in an initial position sition brought. Then the separation process can be done without further manual intervention proceed as follows:

• - The side-pivoted to a package Partial conductors of the upper layer are continually following pushed to the right to a drip edge, so that it follows slide off each other ("dripping down") and from the past tied separating comb. The separation comb is in rhythm with the falling individual conductors by one Division moved, which means that after one pass in each there is a partial conductor in the chamber.
• - The lower layer of the Sub-leader in the same way from right to right separated on the left, so after the run in each cam a single conductor of the corresponding separating comb lies.

Check at the front end of the separating operations the Roebel rod can already be further separating devices attached for the rear end of the Roebel rod and the separation process can be initiated there.

In the method according to the invention, if appropriate the one previously required for the partial conductor test  Short circuit of all partial conductors at the rear end of the bar saved provided the contact control is carried out by means of double contact is carried out on the front side of the rod.

Through a practical implementation of the specified ver driving in contemporary technology can now automa The separation process is equally the basis for form a computer-aided test: The test computer first in a first operating mode "setup" the measurement conditions - such as the number of partial conductors, test voltage, test time and the like - entered. In a second mode "Automatic" is then measured and at the end of the test that Test result displayed, saved in the computer and from Printer printed out. The printout with control strips can be attached to the tested Roebel rod as documentation. In the event of an error, a visual and / or acoustic signal is issued that the test process has been stopped. On the computer screen can by a special error display of the short-circuited a sub-leader are documented.

Further details and advantages of the Ver driving especially in the execution of the first Alternati ve and the associated system result from the description Practice of embodiments. Doing so will focus on the drawing Referenced in particular in different figures the Roebel rods on the one hand and the associated separating and Clarify measuring device. In detail show in rough schematic representation

Fig. 1 shows the section of a Roebel bar with layered in two layers of conductor elements through the end

Fig. 2 is a longitudinal view in partial conductors,

Fig. 3 shows the schematic of the electrical testing of each conductor,

FIGS. 4 and Fig. 5 is an automated handling and Sepa riervorrichtung for the part of the Roebel bar conductor in a plan view and front view,

Fig. 5 shows the entire system concept as a block diagram.

To clarify the prior art, FIGS. 1 to 3 are first largely described together. At closing, reference is made to the illustration of the method according to the invention in particular with reference to FIGS . 4 and 5 on the one hand and FIG. 6 on the other hand.

In Fig. 1, 10 denotes a so-called Roebel or lattice rod, which consists of a plurality of insulated copper flat wires as separate subconductors. Specifically, two layers of partial conductors 11 to 20 and 21 to 30 with the stand of the individual partial conductors to illustrate the upper surface insulation, which is not shown in detail, are shown. Both superimposed layers are electrically separated from one another by an additional insulating layer 2 . In addition, the individual part conductors 11 to 20 and 21 to 30 are each isolated and surrounded as a whole package at least at the ends by a common main insulation 3 .

Such Roebel bars 10 can consist, for example, of two layers, each with 50 partial conductors.

A separate partial conductor is shown in FIG. 2 with the aid of a single electrical conductor 11 . The middle loading area of the partial conductor 11 is twisted by 360 or even 540 ° and thereby solidified overall, whereas at the ends the regions 11 'and 11 ''are not twisted and are therefore unconsolidated. Individual partial conductors 11 , 12 ,. . . parallel to each other. At the respective end of the Roebel rod 10 , to which no insulation is attached or to which it is subsequently removed, all the partial conductors 11 to 20 or 21 to 30 are soldered to one another for the intended use.

In Fig. 3 two conductors, for example the partial conductors 11 and 12 are indicated schematically, here the resistance of the conductive cement between two goiter points is schematically symbolized by an equivalent resistor 5 . One of the partial conductors 11 is connected to earth potential N, with a light bulb 6 being switched on; the other sub-conductor 12 can be switched from earth potential to test voltage by means of a slide 7 , so that an electrical measurement of the sub-conductor 11 is possible by applying the test voltage.

A comb-shaped contacting device can be used to implement the test principle described with reference to FIG. 3 for a large number of partial conductors. Such a contacting device consists, for example, of a frame made of insulating material, into which contacts for each partial conductor 21 , 22 ,. . . are incorporated. From the contacts who leads the leads for a measuring device.

In the previous test, the connections coming from the outside are carried out by the individual partial conductors of the Roebel rod 10 in the contacting grid, for example on spring-loaded contacts, and all are initially connected to ground potential. A slide corresponding to slide 7 in FIG. 3, which is guided along the contact grid by a motor, briefly presses the individual contacts successively against the test voltage, as a result of which the respective partial conductor is measured against all other partial conductors.

In order to be able to carry out the test described above in principle with a large number of partial conductors sufficiently quickly and safely, the handling for introducing the partial conductors into the contacting rod must be improved. In particular, this should be changed from manual processing by the inspector to a largely automated way of working as part of flexible manufacturing. This is shown in FIG. 4:

In Fig. 4 and Fig. 5 50 shows a Schnellspannvorrich device for a Roebel rod 10 , by means of which the rod package to be tested is fixed on a test vehicle or the like, not shown. There can be two Schnellspannvor devices 50 , 50 'on both sides for a Roebel rod 10 (once each front and rear), only the front quick release device 50 is shown. In Fig. 5, two separators 55 and 65 , which is inserted between the two layers with the partial conductors 11 to 20 and 21 to 30 of the Roebel rod 10 and fastened to the struts of the quick-clamping device 50 .

On the separating device 55 , the overhead partial layer of the Roebel rod package 10 is pivoted to the left and on the separating device 65, the partial conductor layer below is pivoted to the right. Both layers are positioned by means of movable counterholders 60 with mandrel 61 or counterholders 70 with mandrel 71 , the respective partial conductor lying in front in the bundle or remaining bundle being held firmly by the mandrels.

The separating devices 55 and 65 are assigned separating combs 56 and 66 , which are laterally displaceable and, in particular, must be in a defined starting position before the separation of the partial conductors 11 to 20 or 21 to 30 of a Roebel rod package 10 . At least one geared motor 58 and 68 is present for shifting the partial guide on the separating device 55 and 65 on the one hand and for the opposite movement of the separating combs 56 and 66 on the other hand. There can be two motors for the coordinated movement of the counterholders 60 and 70 and the separating comb 56 and 66, respectively.

To separate a complete partial conductor layer, for example, the partial conductors 11 to 20 of the upper layer lying together to form the package are held by the counter-holder 60 with mandrel 61 and a corresponding movement of the spindle 59 continuously against the internal stress in front of the edge 61 of the separating device 55 , where they are are released one after the other and, as it were, "dripping off" by sliding over the edge 61 . They fall directly into a chamber of separation comb 56 . The separating comb 56 is moved according to the movement of the spindle 59 in time with the falling A cell ladder by one division, so that after a pass in each chamber of the separating comb 56 there is exactly a single conductor. For checking purposes, a sensor 62 can be present. A corresponding sensor 72 is associated with the lower separating device 65 .

When the latter process is carried out automatically, the speed is predetermined, for example, such that two sub-conductors are separated per second with a separating device. After the separation, contacting grids are placed on the upper side of the rod in a known manner. At closing, the test of the respective partial conductors 11 to 20 or 21 to 30 of the Roebel rod 10 can follow him, which is now advantageously possible under computer control. For this purpose, the block diagram is given again in FIG. 6.

In Fig. 6, 100 denotes a personal computer (PC) for sequence control of the entire measuring system: the operating program is designed for automatic insulation testing of a number of n partial conductors. As an option, individual sub-conductors can be measured separately, whereby only the signal acquisition and processing as well as the documentation of all data takes place via the computer. Convenient operation can be ensured using the appropriate user programs.

The personal computer 100 is assigned a printer 101 for log output. Via the computer 100 , a control unit 110 for controlling an electrical power part 120 and the actual contacting device 140 is activated. There is also an electronic selection unit 150 for individual partial conductors. The Kontaktiervor direction 140 corresponds functionally essentially to the previously known devices. Common parts of electrical engineering / electronics are also used for the power section 120 with triac's, relays and other components.

In an alternative of the "From drip" device described with reference to FIG. 5, one layer of the conductor pack is bent relative to the other by means of a suitable device, and the one when turning through the steps formed by the partial conductors as a mechanical reference point for handling and Measurement of the individual conductors used. The two partial conductor bundles can either be deflected parallel to one another or also in any direction relative to one another. In the first case, the approaches for the mechanical separation are realized by the steps formed by the end faces of the individual partial conductor ends and in the second case by the steps formed by the longitudinal edges of the partial conductors. A pin that can be inserted into the bundle is used to identify the partial conductors. The pin can optionally be moved along the contour of the conductor bundle by means of a handling device such as a robot.

In another alternative of the "draining" device described with reference to FIG. 4, a cylindrical pointed cone mandrel with a spiral profile on its circumference is inserted with a rotational movement between the two layers of the conductor package. As a result, the partial conductors in the spiral profile move apart relative to the mandrel and are thus separated. It can be advantageous to retract a mandrel with a spiral profile between the two layers of the conductor package in opposite directions along a common axis from both sides of the conductor package.

Claims (21)

1. A method for electrical testing of Roebel bars for stator windings of generators or the like, which bars consist of a package of two-layered band-shaped, mutually insulated partial conductors and are pressed or drawn into a suitable shape, each of the partial conductors being shunted against the Entire Lei terpaket is checked, for which purpose, after separating all the partial conductors at the ends of the conductor package, each partial conductor is contacted and its electrical properties are measured, characterized in that the separation of the partial conductors takes place automatically, and that when separating, a reference point for measuring a partial conductor is equally given is obtained. 2. The method according to claim 1, characterized ge indicates that the individual layers of the lei mechanically at their ends as separate bundles be separated and one layer each of the conductor bundle a support body is pushed, ei when slipping nes individual conductor from the support body of this conductor mechanically separated and held in a separate position becomes. 3. The method according to claim 2, characterized ge indicates that the separated partial conductors in the position suitable for contacting is shifted. 4. The method according to claim 2, characterized ge indicates that each of the sub-leaders of  upper and lower layers at the same time via a support pushed, separated and into the body for the contact suitable location. 5. The method according to claim 1, characterized ge features contacting all part head over a common contacting device with pa parallel individually activatable contacts. 6. The method according to claim 1, characterized ge indicates that one layer of the Conductor package bent relative to the other layer and that the steps that occur when turning off the sub-branches tern are formed as a mechanical approach to the hand habung and the measurement of the partial conductor can be used. 7. The method of claim 6, wherein the conductor on her Make a straight cut end, thereby ge indicates that the two layers of the conductor largely deflected parallel to each other and that the stages for the mechanical approach from the End faces of the individual conductor ends are formed. 8. The method according to claim 6, characterized ge indicates that the two layers of the conductor deflected relative to each other in the spatial direction and that the stages for the mechanical approach of the longitudinal edges of the partial conductors are formed. 9. The method according to claim 1, characterized ge indicates that for handling the partial conductor a pin that can be inserted into the bundle is used.   10. The method according to claim 1, characterized ge indicates that between the two layers of the Conductor package a pointed cone, profiled mandrel rotie rend is retracted, whereby the partial conductor in the Spi ralprofil move apart against the mandrel and thus be separated. 11. The method according to claim 10, characterized ge indicates that from both sides of the head packages each a profiled mandrel rotating in opposite directions retracted between the two layers of the conductor package becomes. 12. System for performing the method according to claim 1 or one of claims 2 to 11 with a Einspannvorrich device for the conductor packs and a Kontaktier- and Meßein direction for the partial conductor, characterized in that a handling device ( 50 , 55 , 65 ) is available is the at least one separating means and a guide means (59, 60, 69, 70) for the conductor part (11 - 20, 21 - 30) comprises the Roebel bar (10). 13. Plant according to claim 12, characterized in that the separating device is a separating bridge ( 55 , 65 ) which can be introduced statically between the two layers of the conductor bundle. 14. Plant according to claim 12, characterized in that the movement device consists of a displacement device ( 56 ) for a bundle of conductors ( 11 - 20 ), which is a relatively movable Auffangein direction ( 65 ) for the partial conductors ( 11 - 20 , 21 - 30 ) is assigned. 15. Plant according to claim 14, characterized in that the activation of the device ( 59 , 60 , 69 , 70 ) for the partial conductors ( 11 - 20 , 21 - 30 ) on the one hand and the collecting device ( 56 , 66 ) on the other hand via motors ( 58 , 68 ) takes place, sensors ( 62 , 72 ) being available for coordinating both movements. 16. Plant according to claim 12, characterized in that a Move Barer in any spatial direction pin is present, for separating the partial conductors (11 - 20, 21 - 30) of the can be moved between individual flat wires of curved guide bundle. 17. Plant according to claim 17, characterized records that the pen along one of the steered bundle of conductors adapted backdrop is movable. 18. Plant according to claim 17, characterized records that the pin for retracting between the Single conductor can be actuated pneumatically. 19. Plant according to claim 12, characterized records that the separator at least is a drill-like cylinder body, which by means of overlaid Rotation and feed movement dynamically between the two Layers of the conductor bundle can be introduced. 20. Plant according to claim 19, characterized records that two drill-like, rotating Zy  lind body along an axis in opposite directions to each other be moved. 21. Plant according to claim 19 or claim 20, there characterized in that the cylinder body has a circumferential spiral groove on its surface points.