Coil manufacturing
Products
RODS FOR AC ELECTRIC MOTORS AND GENERATORS
We cooperate with large enterprises, as well as small workshops. In order for the rods of the stator windings to serve as long as possible, special regulations must be strictly observed. Our specialists will leave for the installation supervision.
We supply stator winding rods
- Check the sections before placing them in the grooves.
- The ends of the bars are inspected prior to wrapping.
- Checking the insulation resistance before and after installation.
- The stator winding is tested after each phase.
- The stator winding must be checked after replacing damaged rods.
- Wedging of grooves after partial or complete replacement of bars.
• Total length of a formed bar:
5 000 mm
• Straight-line section length:
3 900 mm
• Bar cross section in the slotted area:
35,0х100,0 mm
• Indirect air or hydrogen cooling of a stator winding
5 000 mm
• Straight-line section length:
3 900 mm
• Bar cross section in the slotted area:
35,0х100,0 mm
• Indirect air or hydrogen cooling of a stator winding
RODS FOR AC ELECTRIC MOTORS AND GENERATORS
ROD WINDING PARAMETERS
INSULATION F, H, C CLASSES HEAT RESISTANCE AND ABOVE
VOLTAGE UP TO 18 000 V
THE MOST COMMON GENERATORS:
- Maximum overall length - 5000 mm.
- The maximum length of the straight part is 2500 mm.
- Cross-section 40x100 mm.
- It is possible to perform transposition in the cross-section.
INSULATION F, H, C CLASSES HEAT RESISTANCE AND ABOVE
- From soaked belts (hot pressing technology).
- From dry tapes based on mica paper or polyimide films
- (vacuum-injection impregnation technology).
- Hybrid VPI/Resin Rich technologies.
VOLTAGE UP TO 18 000 V
THE MOST COMMON GENERATORS:
- T-series (TC) turbogenerators from 2.5 to 63 MW
Stages of production
Technical capabilities
- In accordance with the CD (design documentation) of the customer
Up to 18000W
F(155°C), H(180°C)
Resin Rich is a hot pressing technology.
VPI is a vacuum-injection impregnation technology.
VPI is a vacuum-injection impregnation technology.
- Electrical tests are carried out by specialized devices: AID-700Mb Schleich MTC2-40kV, Parma Tensor-2 and others.
- Measurement of insulation resistance of rods.
- Tests of case insulation with AC voltage of industrial frequency in accordance with RD 34.45-51.300-97 . The maximum test voltage is 50kV.
- Tests of case insulation with DC voltage. The maximum test voltage is 70kV.
- Testing of inter-turn insulation by pulse voltage in accordance with IEEE 522, RD 34.45-51.300-97 . The maximum test voltage is 40kV.
- Measurement of the tangent of the dielectric loss angle in accordance with IEEE 286 and EN50209.
- The list of electrical tests, test voltages can be adjusted in accordance with the requirements of the customer's CD.
Range of bars manufactured at RBC grupo
Turns may be arranged in two ways: along either wide or narrow edge.
The structure is specified by EM (electric machine) design to comply with the required parameters.
The structure is specified by EM (electric machine) design to comply with the required parameters.
Transposition of conductors in the straight-line section of a bar
Conductor strands of the bars are placed not in parallel but at an angle to the slot bottom. They are interlaced with each other so as to ensure that each conductor passing through a slot occupies all possible positions along the slot height alternately while all conductors remain in the same magnetic conditions. Such rearrangement of conductors is called transposition.
Several kinds of transposition exist: 180°, 360°, and 540°. At present, Robel transposition is widely adopted. In this configuration, each conductor is bent in certain areas in accordance with the transposition structure.
Materials used for the manufacture of winding rods
a. PSDK, PSDT, PSD-1, PSD – rectangular copper wire with insulation based on glass threads impregnated with specialized lacquers. Breakdown voltage up to 500V. Heat resistance class F(155°C), H(180°C).
a. Elmikaterm 524019 – mica tape consisting of PET film, mica paper, glass substrate. The mica content is not less than 40%. Heat resistance class F(155°C).
b. Elmikaterm 52409 is a mica tape consisting of mica paper, a glass substrate. The mica content is not less than 50%. Heat resistance class F(155°C).
c. Elmikaterm 529029 is a mica tape consisting of a polyimide film of mica paper, a glass substrate. The mica content is not less than 35%. Heat resistance class H(180°C).
b. Elmikaterm 52409 is a mica tape consisting of mica paper, a glass substrate. The mica content is not less than 50%. Heat resistance class F(155°C).
c. Elmikaterm 529029 is a mica tape consisting of a polyimide film of mica paper, a glass substrate. The mica content is not less than 35%. Heat resistance class H(180°C).
a. Elmikapor 523119 is a mica tape consisting of a PET film of mica paper, a glass substrate. The mica content is not less than 60%. Heat resistance class F(155°C).
b. Elmikapor 523199 is a mica tape consisting of mica paper, a glass substrate. The mica content is not less than 50%. Heat resistance class F(155°C).
c. Elmikapor 53319 is a mica tape consisting of mica paper, a glass substrate. The mica content is not less than 80%. Heat resistance class F(155°C).
b. Elmikapor 523199 is a mica tape consisting of mica paper, a glass substrate. The mica content is not less than 50%. Heat resistance class F(155°C).
c. Elmikapor 53319 is a mica tape consisting of mica paper, a glass substrate. The mica content is not less than 80%. Heat resistance class F(155°C).
a. LES glass tape – designed to protect the housing insulation from mechanical influences.
b. Epoflex 219.61-10 – designed to protect the housing insulation from the negative effects of the environment. It is applied to the frontal parts of the coils.
c. Epoflex 324.03 – designed to protect the housing insulation from the negative effects of the environment. It is applied to the frontal parts of the coils.
d. LPP-400 – designed to protect the housing insulation from the effects of external partial discharges in the grooved parts.
e. EGSB 2969/2709 – designed to protect the hull insulation from the effects of external partial discharges in the frontal parts.
It is possible to use materials according to the customer's CD.
b. Epoflex 219.61-10 – designed to protect the housing insulation from the negative effects of the environment. It is applied to the frontal parts of the coils.
c. Epoflex 324.03 – designed to protect the housing insulation from the negative effects of the environment. It is applied to the frontal parts of the coils.
d. LPP-400 – designed to protect the housing insulation from the effects of external partial discharges in the grooved parts.
e. EGSB 2969/2709 – designed to protect the hull insulation from the effects of external partial discharges in the frontal parts.
It is possible to use materials according to the customer's CD.
Laying
1
The bottom row bars are the first to be laid. Special attention is paid to attachment of the end turns, because severe electromagnetic loads are applied to them in the course of operation.
2
After the bottom bars are laid, the laying of the top layer is started.
3
When all bars are laid, leads are soldered. This is quite a labor-intensive and diligent operation due to a great number of conductors in each bar. After that, the soldered sites are insulated and covered with special caps that are also fixed securely.
4
If direct water cooling is applied, then tubes through which water enters the hollow conductors are connected.
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