# Patent

## Title
Locking wedge for maintaining a winding in a slot and dynamoelectric machine incorporating same

## Abstract

A locking wedge for a slot of a dynamoelectric machine is provided. The locking wedge has a main body extending in an axial direction, and includes a top and a bottom surface. The bottom surface has a greater surface area than the top surface. A first end surface faces towards an axial-inward direction and a second end surface faces towards an axial-outward direction. A locking slot extends in the axial direction into a portion of the main body, and begins in the second end surface and extends axially inward. A locking member is disposed to fit into the locking slot, and is inserted into the locking slot to lock the locking wedge in the slot.

## Background
BACKGROUND OF THE INVENTION
This invention relates generally to dynamoelectric machines and more particularly, to a locking wedge for maintaining a winding in a slot of a dynamoelectric machine.
Armature windings, also known as stator bar or rotor windings, are routinely inspected in at least some known electrical power generators, to verify their operation. In some known generators, a stator yoke in the generator surrounds an armature core and partially encloses the armature windings. The armature windings are formed from a plurality of copper conductors that are wound in the armature to form loops. The armature windings may be arranged within a stator slot in such a manner that desired voltage and current characteristics may be maintained by the generator during operation.
At least one known generator includes a wedge system to induce a radial retaining force (RRF) to the stator from wedges to facilitate reducing movement of the stator bar windings within the stator slot. The wedge system typically includes various filler strips disposed above and/or below the windings and a series of wedges located at the top of the slot. However, if the wedge system itself becomes loose, the amount of RRF is reduced such that the stator bar windings may move during operation. Accordingly, locking wedges have been used at the axial ends of the stator core to retain a series of interposed body wedges within a groove in the stator slot. However, known locking wedges are difficult to remove without sustaining damage during the removal process.
BRIEF DESCRIPTION OF THE INVENTION
In one aspect of the invention, a locking wedge is provided for a slot in a dynamoelectric machine. The locking wedge has a main body extending in an axial direction, and includes a top and a bottom surface. The bottom surface has a greater surface area than the top surface. A first end surface faces towards an axial-inward direction and a second end surface faces towards an axial-outward direction. A locking slot extends in the axial direction into a portion of the main body, and begins in the second end surface and extends axially inward. A locking member is disposed to fit into the locking slot, and is inserted into the locking slot to lock the locking wedge in the slot.
In another aspect of the invention, a locking wedge for a slot in a dynamoelectric machine is provided. The dynamoelectric machine includes a core having a slot extending in an axial direction. The slot has a central portion located in an axially-inward direction and an end portion in an axially-outward direction. The locking wedge includes a wedge body extending in an axial direction, and the wedge body has a top surface and a bottom surface, where the bottom surface has a greater surface area than the top surface. A locking slot is disposed in at least a portion of the wedge body, and extends in an axial direction. A locking member is configured to engage the locking slot.
In a further aspect of the present invention, a dynamoelectric machine is provided having a core with at least one slot extending in an axial direction. The slot has a central portion located in an axially-inward direction and an end portion in an axially-outward direction. The dynamoelectric machine includes at least one locking wedge having a wedge body extending in an axial direction. The wedge body has a top surface and a bottom surface, where the bottom surface has a greater surface area than the top surface. A locking slot is disposed in at least a portion of the wedge body, and extends in an axial direction. A locking member is configured to engage the locking slot.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective end illustration of an exemplary electric generator;
FIG. 2 is a partial isometric illustration of a portion of the stator core in the electric generator stator shown in FIG. 1;
FIG. 3 is an enlarged partial isometric illustration of a portion of the stator core shown in FIG. 2;
FIG. 4 is an isometric illustration of a locking end wedge, according to an aspect of the present invention;
FIG. 5 is a top plan illustration of the locking end wedge of FIG. 4;
FIG. 6 is an isometric illustration of a locking member that can be used with the locking end wedge of FIG. 4, according to an aspect of the present invention; and
FIG. 7 is a partial top plan illustration of a slot filled with the locking end wedge of FIG. 4 and a plurality of body wedges.



DETAILED DESCRIPTION OF THE INVENTION
A dynamoelectric machine is defined as any apparatus that converts electrical energy between the electrical and the mechanical state by means of an electromagnetic effect. As non-limiting examples, a dynamoelectric machine may include motors and/or generators. Windings are employed in the armature and field of a dynamoelectric machine, and may be held in place by a retaining system incorporating various components (e.g., wedges, ripple springs, etc.).
FIG. 1 is a perspective end view of an exemplary electric generator 100. A rotor 102 is transparently represented by dashed lines. A plurality of stator bar windings 104 are positioned in slots 106 defined around an inner circumference of a stator core 108. In the exemplary embodiment, stator bar windings 104 are formed from a plurality of flat bar conductors or stator bars that are coupled together to form a pre-determined winding path through winding 104. In one embodiment, the stator bars are fabricated from copper.
FIG. 2 illustrates a partial, perspective illustration of a stator core 108. The stator core 108 has a plurality of slots 106, generally extending in an axial direction, which contain the windings 210. As one example, two windings 210 may be contained within each slot 106. The windings 210 are housed in the lower portion of the slots 106. Various filler strips 220, slides 230, body wedges 240 and end wedges 250 may be installed above the windings 210.
FIG. 3 is an enlarged, partial perspective illustration of a stator core, and shows the interrelation between the slots 106, slides 230, body wedges 240 and locking wedges 250. The dovetail shaped wedge 240 engages a dovetail groove 315 and a slide 230 is normally driven under the wedge 240. The stator core 108 may be comprised of many laminations of magnetic steel or iron material. The laminations form groups, and these groups are separated by spacers. The spacers define cooling vent slots 350, which are generally orthogonal to the slots 106. The cooling vents 350 between the groups of laminations allow for ventilation and cooling of the stator core. Typically, the vent gaps 242 in the wedges 240 are aligned with the cooling vents 350.
The locking wedge 250 has a plurality of channels or cuts 255. These cuts 255 allow the angled end portions 257 to compress inward during installation as the locking wedge 250 is axially inserted through dovetail groove 315. Once the angled end portions 257 extend past the first cooling vent they snap into place and lock the wedge in position. The cuts 255 face in an axially-inward direction, towards the center of the slot or core. A disadvantage to this design is that the cuts 255 remain un-secured and the possibility exists that the locking wedge 250 could work loose or become damaged.
FIG. 4 illustrates an isometric view of an improved locking wedge 400, according to aspects of the present invention. The locking wedge 400 has a main body 405 that extends in an axial direction 410. The wedge has a top surface 420 and a bottom surface 425. The bottom surface 425 may have a larger surface area than top surface 420. In this variation, the sides 430 of the locking wedge may have angled surfaces. A first end surface 470 faces in an axially-inward direction and a second end surface 475 faces in an axially-outward direction. The locking wedge may also include angled vent gaps 440 which can be aligned with the cooling vents 350 in the core if desired.
A projection 450 may be included in one or both sides of the wedge and can be used to lock or snap into the first cooling vent slot. A locking slot 460 is axially disposed in at least a portion of the wedge body 420. The locking slot may also include a pair of axial oriented grooves 465 formed in the sides thereof. In one embodiment, the locking slot 460 may extend into about one quarter to about one half or more of the length of the wedge 400. The locking slot is preferably disposed in the axially-outward direction when the locking wedge is installed in the slot 106. The locking slot 460 gives the portions of the wedge on either side of the locking slot flexibility so that they may flex inward during insertion of the wedge 400 into dovetail groove 315.
FIG. 5 illustrates a top view of wedge 400. The locking slot 460 extends in the axial direction and includes a groove 465 on both sides thereof. The locking slot can extend past projections 450 and enable the side portions 570 to flex inward during installation of the locking wedge 400.
FIG. 6 illustrates an isometric view of a locking member 600 that is configured to fit into locking slot 460. The locking member 600 includes a main body 610 and side rails 620, both of which extend in an axial direction. The side rails 620 are configured to fit into the grooves 465 of the locking slot 460. Once the locking wedge 400 is inserted into the dovetail groove 315, the locking member 600 can be inserted into locking slot 460. The locking member 600 locks the locking wedge into slot 106 and dovetail groove 315 by preventing the side portions 570 from flexing inward.
FIG. 7 illustrates a top view of a portion of slot 106 filled with an end wedge 400 and body wedges 240. Only a portion of the slot is shown and it is to be understood that two end wedges 400 are used per slot (i.e., one end wedge 400 is placed at each end of slot 106). The locking slot 460 (which has locking member 600 inserted therein) is oriented to face the end of slot 106. In other words, the locking slot 460 faces the axially-outward direction towards the end of slot 106. The body wedges 240 would be located in an axially-inward direction with respect to end wedge 600. A plurality of body wedges 240 can be placed between the two end wedges 400, and the number of body wedges is determined by the requirements of the specific application.
The grooves 465 and rails 620 are shown with a rectangular profile, but could be designed to have any suitable shape or profile. As non-limiting examples, the groove 465 could have an arcuate, dovetail or trapezoidal shape. Accordingly, the rails 620 should be designed to have a complementary shape to fit into grooves 465 (e.g., an arcuate, dovetail or trapezoidal shape, respectively). Further, the overall cross-sectional profile of the locking slot and 460 and locking member 600 are generally rectangular, but could be configured to have any desired cross-sectional profile, including but not limited to polygonal, circular, hexagonal, trapezoidal, etc.
The locking wedge 400 and locking member 600 may be constructed of any suitable material, such as but not limited to, fiberglass, fiberglass laminates, fiberglass composites, magnetic materials, cotton phenolic, woven aramid fabrics, etc. In addition, the locking wedge 400 may have any suitable length as desired in the specific application, and as non-limiting examples, may include lengths from about one inch to about sixteen inches or more.
While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.

## Claims

1. A locking wedge for a slot of a dynamoelectric machine, said locking wedge comprising:
a main body extending in an axial direction, said main body having a top and a bottom surface, said bottom surface having a greater surface area than said top surface;
a first end surface facing towards an axial-inward direction and a second end surface facing towards an axial-outward direction;
a locking slot extending in the axial direction into a portion of said main body, said locking slot beginning in said second end surface and extending axially inward, the locking slot extending from the bottom surface to the top surface;
a locking member disposed to fit into said locking slot;
wherein said locking member can be inserted into said locking slot to lock said locking wedge in said slot.

2. The locking wedge according to claim 1, further comprising:
a pair of projections disposed on said side surfaces;
wherein said projections engage a cooling vent slot.

3. The locking wedge according to claim 1, said locking slot further comprising a pair of grooves disposed on opposing surfaces of said locking slot and extending in an axial direction.

4. The locking wedge according to claim 3, said locking member further comprising a pair of rails disposed on opposing surfaces thereof, said rails for engaging said grooves.

5. The locking wedge according to claim 1, wherein said locking wedge is constructed of a fiberglass laminate.

6. The locking wedge according to claim 1, wherein said locking wedge has a width of about one inch or greater.

7. A locking wedge for a slot in a dynamoelectric machine, said dynamoelectric machine comprising a core having a slot extending in an axial direction, said slot having a central portion located in an axially-inward direction and an end portion in an axially-outward direction, said locking wedge comprising:
a wedge body extending in an axial direction, said wedge body having a top surface and a bottom surface, said bottom surface having a greater surface area than said top surface;
a locking slot disposed in at least a portion of said wedge body, said locking slot extending in an axial direction, the locking slot extending from the bottom surface to the top surface; and
a locking member configured to engage said locking slot.

8. The locking wedge according to claim 7, wherein the locking wedge is placed in said end portion of said slot and positioned so that said locking slot is towards the axially-outward direction.

9. The locking wedge according to claim 7, said locking slot further comprising a pair of grooves disposed on opposing surfaces of said locking slot and extending in the axial direction.

10. The locking wedge according to claim 9, said locking member further comprising a pair of rails disposed on opposing surfaces thereof, said rails for engaging said grooves.

11. The locking wedge according to claim 7, wherein said locking wedge is constructed of a fiberglass laminate.

12. The locking wedge according to claim 7, wherein said locking wedge has a width of about one inch or greater.

13. A dynamoelectric machine comprising a core having at least one slot extending in an axial direction, said slot having a central portion located in an axially-inward direction and an end portion in an axially-outward direction, said dynamoelectric machine comprising:
at least one locking wedge having a wedge body extending in an axial direction, said wedge body having a top surface and a bottom surface, said bottom surface having a greater surface area than said top surface;
a locking slot disposed in at least a portion of said wedge body, said locking slot extending in an axial direction, the locking slot extending from the bottom surface to the top surface; and
a locking member configured to engage said locking slot.

14. The dynamoelectric machine according to claim 13, wherein the at least one locking wedge is placed in said end portion of said slot and positioned so that said locking slot is towards the axially-outward direction.

15. The dynamoelectric machine according to claim 13, said locking slot further comprising a pair of grooves disposed on opposing surfaces of said locking slot and extending in the axial direction.

16. The dynamoelectric machine according to claim 15, said locking member further comprising a pair of rails disposed on opposing surfaces thereof, said rails for engaging said grooves.

17. The dynamoelectric machine according to claim 13, wherein said at least one locking wedge is constructed of a fiberglass laminate.

18. The dynamoelectric machine according to claim 13, wherein said at least one locking wedge has a width of about one inch or greater.

19. The dynamoelectric machine according to claim 13, wherein said core is chosen from at least one of a stator core and a rotor core.

20. The dynamoelectric machine according to claim 13, wherein said dynamoelectric machine is chosen from at least one of a generator and a motor.