Abstract: An insulation system and method are disclosed for insulating formed coils of electrical machines, such as motors and generators. The system includes strand/turn insulation that may include one or more layers of different materials, depending upon the dielectric requirements. A ground wall insulation is applied over the group of turns. The coil may be sized in a slot cell section. Additional insulation layers are provided, including a slot corona suppression insulation that extends just beyond stator slots, a voltage grading layer, and an armor layer. The resulting system is highly adaptable to different machine designs and ratings, and affords superior resistance to degradation.

Abstract: An insulation system and method are disclosed for insulating formed coils of hydroelectric machines, such as a hydroelectric generator. The system includes strand/turn insulation that may include one or more layers of different materials, depending upon the dielectric requirements. A ground wall insulation is applied over the group of turns. The coil may be sized in a slot cell section. Additional insulation layers are provided, including a slot corona suppression insulation that extends just beyond stator slots, a voltage grading layer, and an armor layer. Time temperature profiles and preheating may be used to cure coil sections via press and heat. The resulting system is suitable for installation in situ, and affords superior resistance to degradation.

Abstract: An insulation system and method are disclosed for insulating formed coils of hydroelectric machines, such as a hydroelectric generator. The system includes strand/turn insulation that may include one or more layers of different materials, depending upon the dielectric requirements. A ground wall insulation is applied over the group of turns. The coil may be sized in a slot cell section. Additional insulation layers are provided, including a slot corona suppression insulation that extends just beyond stator slots, a voltage grading layer, and an armor layer. Time temperature profiles and preheating may be used to cure coil sections via press and heat. The resulting system is suitable for installation in situ, and affords superior resistance to degradation.

Abstract: An insulation system and method are disclosed for insulating formed coils of electrical machines, such as motors and generators. The system and methods additionally apply to refurbishing of the formed coils. The system includes strand/turn insulation that may include one or more layers of different materials, depending upon the dielectric requirements. A ground wall insulation is applied over the group of turns. The coil may be sized in a slot cell section. Additional insulation layers are provided, including an armor layer. The various insulation layers may each be applied in one continuous wrap. The resulting system is highly adaptable to different machine designs and ratings, and affords superior resistance to degradation.

Abstract: According to one aspect, the present technique provides methods and apparatus for inserting coil windings into a stator. Advantageously, the windings may be wound in a vertical configuration to facilitate insertion of the windings into stator slots. Moreover, the exemplary embodiment provides a transfer tool that maintains the stepped and vertical configurations of the coil windings developed during winding upon separation of the wire from the winding form. Advantageously, the present technique may decrease motor fabrication times and improve motor performance.

Abstract: A technique is provided for insulating a winding or coil for an electrical machine such as a motor. The coil is wound and placed in a taping station. Multiple layers of insulating tape are applied along an end region with leads bent back from the end region. The taping station permits the leads to be then placed over the insulated end region, and the main body region of the coil is similarly taped in a continuous uninterrupted manner. The tape wrap pitch may be varied along certain regions, where increased dielectric strength is desired. Following the insulating tape application, an armor tape may be applied over both the end region and the main region of the coil in a continuous uninterrupted manner. The coil can then be finished and assembled in a machine such as an electric motor stator.

Abstract: A technique is provided for insulating a winding or coil for an electrical machine such as a motor. The coil is wound and placed in a taping station. Multiple layers of insulating tape are applied along an end region with leads bent back from the end region. The taping station permits the leads to be then placed over the insulated end region, and the main body region of the coil is similarly taped in a continuous uninterrupted manner. The tape wrap pitch may be varied along certain regions, where increased dielectric strength is desired. Following the insulating tape application, an armor tape may be applied over both the end region and the main region of the coil in a continuous uninterrupted manner. The coil can then be finished and assembled in a machine such as an electric motor stator.