Abstract: Certain embodiments of the invention may include systems and methods for providing stator bar shape tooling. According to an example embodiment of the invention, a method is provided for shaping an element. The method can include providing at least one constraining surface, wherein the at least one constraining surface is fabricated at least in part by selective laser sintering, and deforming an element with the at least one constraining surface to define at least an external shape of a formed element.

Abstract: Certain embodiments of the invention may include systems and methods for providing stator bar shape tooling. According to an example embodiment of the invention, a method is provided for shaping an element. The method can include providing at least one constraining surface, wherein the at least one constraining surface is fabricated at least in part by selective laser sintering, and deforming an element with the at least one constraining surface to define at least an external shape of a formed element.

Abstract: Certain embodiments of the invention may include systems and methods for providing stator bar shape tooling. According to an example embodiment of the invention, a method is provided for shaping an element. The method can include providing at least one constraining surface, wherein the at least one constraining surface is fabricated at least in part by selective laser sintering, and deforming an element with the at least one constraining surface to define at least an external shape of a formed element.

Abstract: Certain embodiments of the invention may include systems and methods for providing stator bar shape tooling. According to an example embodiment of the invention, a method is provided for shaping an element. The method can include providing at least one constraining surface, wherein the at least one constraining surface is fabricated at least in part by selective laser sintering, and deforming an element with the at least one constraining surface to define at least an external shape of a formed element.

Abstract: A bearing manipulator for supporting and manipulating a bearing is provided. In one embodiment, the bearing manipulator includes a frame having at least one adjustable roller to support the bearing, and at least one adjustable arm to secure the bearing to the frame. The bearing manipulator further includes a motor configured to incrementally rotate the bearing.

Abstract: Certain embodiments of the invention may include systems for providing stator bar shape tooling. According to an example embodiment of the invention, a system for shaping an element is provided. The system includes tooling that having at least one constraining surface that is fabricated at least in part by selective laser sintering, where the at least one constraining surface includes at least one curved element section to facilitate bending of at least a portion of an element around the at least one curved element section.

Abstract: A bearing manipulator for supporting and manipulating a bearing is provided. In one embodiment, the bearing manipulator includes a frame having at least one adjustable roller to support the bearing, and at least one adjustable arm to secure the bearing to the frame. The bearing manipulator further includes a motor configured to incrementally rotate the bearing.

Abstract: Certain embodiments of the invention may include systems and methods for providing stator bar press tooling. According to an example embodiment of the invention, a method is provided for pressing and curing insulation material on a shaped element. The method can include providing tooling. The tooling can include an inner press and an outer press, wherein at least an inner press surface associated with the inner press and an outer press surface associated with the outer press are fabricated at least in part by sintering. The method can include applying at least one of pressure or heat to insulation material in contact with a shaped element with the tooling, wherein the inner press surface and the outer press surface of the tooling conform to least an external portion of the shaped element.

Abstract: Certain embodiments of the invention may include systems and methods for providing stator bar shape tooling. According to an example embodiment of the invention, a method is provided for shaping an element. The method can include providing at least one constraining surface, wherein the at least one constraining surface is fabricated at least in part by selective laser sintering, and deforming an element with the at least one constraining surface to define at least an external shape of a formed element.

Abstract: The process for stator bar rewinds includes disassembly of the stator bars at the generator site, measurement of the stator bars, forwarding digital representations of the measurements to a manufacturing center and forming 3-Dimensional models of the stator bars requiring replacement and the stator. The stator bar 3D model is placed in the stator 3D model to insure accuracy of fit. Tooling and stator bar drawings are generated and sample stator bars are manufactured. 3D modeling of the manufactured sample stator bars are compared to the nominal 3D models to insure accuracy. The replacement stator bars are manufactured and forwarded in batches for assembly into the extant generator.