Patent Abstract:
A tool for applying a bending or impact load to one or more conductors in a dynamoelectric machine is provided. The tool includes an elongate, substantially tubular handle having an opening at a first end, a second end opposed to the first end, and the handle has a handle axis. A head is connected to the second end of the handle, and includes a striking surface for applying impact loads, and an interchangeable tool socket located opposite to the striking surface. The head has a head axis oriented orthogonal to the handle axis. The interchangeable tool socket can accept one of a plurality of tool inserts and the tool inserts may be rotated generally around the head axis and locked in at least one position within the interchangeable tool socket so that the angle of each tool insert can be adjusted to user preferences.

Full Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to new or existing electrical power producing generators and particularly relates to a tool for use in aligning and bending the leads for the stator, rotor and other elements in the generator. 
     Electrical generators typically comprise a plurality of stator bars disposed in slots in a stator core. As well known, each stator bar is generally comprised of a plurality of individual electrically conductive strands. Each stator bar has opposite end sections which are twisted and extend in a generally circumferential conical direction. Each end section is connected, for example by brazing, to another stator bar to complete an electrical circuit in at least one phase about the stator. Sections of the stator bars intermediate the end sections are generally rigid and extend linearly. The ends of the stator bars, oftentimes called end windings, may index conically clockwise or counterclockwise as the ends extend from the stator core and twist from the linear intermediate section. The end windings define unique shapes at opposite ends of each stator bar for each different type of generator. The main leads may also need to conform to specific shapes to properly connect the bore copper to the field coil end windings. The process to obtain these unique or specific shapes (e.g., bends of specific angles, conductors bent at specific locations, etc.) is time consuming and laborious. Many different tools and jigs are required to obtain specific shapes for the various conductors in generators. 
     BRIEF DESCRIPTION OF THE INVENTION 
     Briefly and in accordance with one aspect of the present invention, a tool for applying a load to one or more conductors in a dynamoelectric machine is provided. The tool includes an elongate, substantially tubular handle having an opening at a first end, a second end opposed to the first end, and the handle has a handle axis. A head is connected to the second end of the handle, and includes a striking surface for applying impact loads, and an interchangeable tool socket located opposite to the striking surface. The head has a head axis oriented orthogonal to the handle axis. The interchangeable tool socket can accept one of a plurality of tool inserts and each tool insert may be rotated generally around the head axis and locked in at least one position within the interchangeable tool socket so that the angle of each tool insert can be adjusted to user preferences. 
     In accordance with another aspect of the present invention, a tool for applying a bending or impact load to one or more conductors in a dynamoelectric machine is provided. The tool includes an elongate, substantially tubular handle having an opening at a first end, a second end opposed to the first end, and the handle has a handle axis. A head is connected to the second end of the handle, and includes a striking surface for applying impact loads, and an interchangeable tool socket located opposite to the striking surface. The head has a head axis oriented orthogonal to the handle axis. The interchangeable tool socket can accept one of a plurality of tool inserts and each tool insert may be rotated generally around the head axis and locked in at least one position within the interchangeable tool socket so that the angle of each tool insert can be adjusted to user preferences. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic illustration of stator bars extending through a stator core of an electrical generator; 
         FIG. 2  is a partial, cross-sectional illustration of the collector end of a generator rotor; 
         FIG. 3  is an isometric illustration of a tool for bending, shaping and aligning conductors in a dynamoelectric machine, according to an aspect of the present invention. 
         FIG. 4  is an isometric illustration of a tool for bending, shaping and aligning conductors in a dynamoelectric machine, according to an aspect of the present invention. 
         FIG. 5  is a cross-sectional illustration of a tool for bending, shaping and aligning conductors in a dynamoelectric machine, according to an aspect of the present invention. 
         FIG. 6  is a cross-sectional illustration of a tool insert for bending, shaping and aligning conductors that can be used with the tool of  FIG. 3 , according to an aspect of the present invention. 
         FIG. 7  is an isometric illustration of a tool for bending, shaping and aligning conductors incorporating the tool insert of  FIG. 6 , according to an aspect of the present invention. 
         FIG. 8  is a cross-sectional illustration of a wire bend extension that can be used with the tool of  FIG. 3 , according to an aspect of the present invention. 
         FIG. 9  is an isometric illustration of a tool for bending, shaping and aligning conductors incorporating the wire bend extension of  FIG. 8 , according to an aspect of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     While the present invention is applicable to stator or rotor rewinds in existing generators it may also find utility in stator/rotor winding installation in new generators as well. 
       FIG. 1  is a perspective end view of an exemplary 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 . More specifically, each stator bar winding  104  includes at least one circumferential bend  110  defined between a turbine end  112  and a generator end (not shown) of each winding  104 . Bends  110  are one portion of each stator bar winding  104  that need to be bent into specific shapes. In the exemplary embodiment, stator bar windings  104  are formed from a plurality of flat bar conductors or stator bars that are coupled together prior to form to a pre-determined winding path through winding  104 . In one embodiment, the stator bars are fabricated from copper. The conductor ends are electrically connected together to form each winding of generator  100 . 
       FIG. 2  is a partial, cross-sectional illustration of the collector end  200  of a generator rotor. The collector end includes the collectors  210 , collector terminal  220 , bore copper  230 , main terminal  240 , main leads  250 , field coil end windings  260  and retaining ring  270 . An axial fan  280  may also be used to facilitate cooling. The main leads  250  are an example of one conductor that must be bent to specific shapes and bent in specific locations. In the past, many tools and jigs were required to obtain the specific shapes and bends required in specific generators. The main leads, and other conductors used in the generator  100 , may be comprised of one or more strands of conductors (e.g., copper). 
       FIG. 3  is an isometric illustration of a tool  300  that can be used for bending, shaping and aligning leads in a dynamoelectric machine, such as a generator, according to one aspect of the present invention. The tool can take the general shape of a hammer and includes a handle  310 , grip  320  and head  330 . The handle can take any shape desired, and may be substantially tubular in shape with a cylindrical cross section. In one aspect, the handle could be formed by a suitable length of pipe formed of steel or aluminum. The grip  320  may be elastomeric or formed of a rubber-like material, and may be formed in an ergonomical shape to facilitate gripping by an operator. However, any length, material and shape for handle  310  and/or grip  320  may be employed, as desired by the specific application. 
     The head  330  includes a striking element  340  which may include a replaceable striking element  345 . The striking element  345  can be replaced if it becomes worn or damaged, and can be formed of a polymeric material which is designed to reduce localized impact to the relatively soft conductors (e.g., copper) in the generator. The opposite side of head  330  includes an interchangeable tool socket  350  that is designed to accept tool insert  360 . The tool inserts can include many differently shaped tools which can be used for many different bending and shaping tasks. 
     The tool insert  360 , as shown in  FIG. 3 , includes two substantially parallel plates  362  and  364 . At least one of these plates (e.g.,  364 ) is adjustable to vary the distance between plate  362 . In one aspect of the present invention, plate  362  can be fixed and plate  364  includes a trapezoidal projection which fits into a dovetail shaped groove in tool insert  360 . A set screw or pin can be used to lock the plate  364  in the desired position. 
       FIG. 4  illustrates an isometric view of tool  300  where the tool insert  360  has been rotated to a new position. The handle can be oriented along a handle axis  402  which extends along the center of the handle. The head can be generally oriented along a head axis  404 , which is generally orthogonal to the handle axis  402  and centered on the point of rotation within socket  350 . The tool insert  360  can rotate within the socket  350  in a circumferential direction about head axis  404 . A plurality of stops (to be described later) enable the operator to lock the insert  360  in a plurality of angular positions. 
     The plates  362 ,  364  can be used to closely fit against a conductor so that an operator can make a bend at a specific point along the conductor. The operator places the conductor between the two plates  362 ,  264 , and then applies force to handle  310  to bend the conductor the desired amount. An advantage to the adjustable jaws or plates  362 ,  364  and the pivotable or rotatable insert  360 , is that the operator can adjust the plates to fit snugly around a conductor and can set the most suitable angular position to obtain leverage when bending and/or shaping conductors. The pivoting or rotating tool insert  360  is very advantageous when compared to other known non-adjustable tools. 
       FIG. 5  illustrates a cross-sectional view of the tool  300 . The striking element  345  can include a recessed socket  342  that can accept the replaceable striking element  345 . On the opposite side of the head, the interchangeable tool socket  350  is formed by a generally cylindrical recess within a portion of head  330 . The socket  350  incorporates an opening for a fastener  552  that can be locked into place. As non-limiting examples, the fastener  552  could be a screw with threads that engage complementary threads in the opening in socket  350 , or the fastener  552  could be a spring biased plunger designed to retract towards the center of socket  350 . 
     The fastener  552  can engage stops  566  placed around the circumference of a generally cylindrical projection  568  on tool insert  360 . The stops may be flat regions, concave regions or any other suitable regions that engage with the end of fastener  552  to lock the tool insert  360  at any of a number of angular positions. 
     In operation, an operator can use the opening in the bottom (near the end of grip  320 ) of the handle  310  to fit over a conductor. The operator can then apply force to the handle  310  and/or head  330  to bend or shape the conductor the desired amount. The striking element  345  may also be used to apply impact forces to conductors or other elements to obtain the desired results. The tool insert  360  can be placed about a portion of a conductor and the operator can then apply force to the handle  310  to bend or shape the conductor the desired amount. 
     In some applications it is difficult to obtain the desired angle of handle  310  to apply the desired amount of force. By releasing the fastener  552 , the tool insert  360  can be rotated to a plurality of axial positions. When the desired angular position is achieved, the operator locks the fastener  552  against one of the stops  566 . The conductor can now be bent or shaped the desired amount by applying force to handle  310 . 
       FIG. 6  illustrates a cross-sectional view of another tool insert in the shape of a pick  600 . The pick  600  includes a generally cylindrical projection  668  that includes a plurality of stops  666 . The cylindrical projection  668  fits into socket  350  of tool  300 . The pick end  661  can be used to pry apart individual strands of multi-strand conductors. 
       FIG. 7  illustrates an isometric view of tool  700  having pick  600  installed. The tool  700  includes handle  710 , grip  720  and head  730 . The head  730  includes a striking element  740  which may include a replaceable striking element  745 . The striking element  745  can be replaced if it becomes worn or damaged, and can be formed of a polymeric material which is designed to reduce localized impact to the relatively soft conductors (e.g., copper) in the generator. The opposite side of head  730  includes an interchangeable tool socket that is designed to accept tool insert  600 . 
       FIG. 8  illustrates a cross-sectional view of a wire bend extension  800 . The wire bend extension includes an opening  810  sized to accept the insertion of a portion of handle  310 . A locking mechanism  815  locks the wire bend extension to the handle, and may include fasteners, a pin or a spring biased spherical bearing. An adjustable screw  820  is connected to a clamping element  830  that can be extended into opening  840 . The clamping element can be a generally rectangular piece of steel or aluminum, or any other suitable shaped element capable of clamping onto a conductor. In use, an operator can insert a wire or conductor within opening  840 . The screw  820  can be adjusted to force clamping element  830  against the conductor to lock the tool  300  to a specific location on the conductor. An operator can the apply force to bend or shape the conductor at the location where clamping element  830  meets the conductor. 
       FIG. 9  illustrates a cross-sectional view of tool  900  incorporating pick  600  and wire bend extension  800 . The tool  900  includes handle  910 , grip  920  and head  930 . The head  930  includes a striking element  940  which may include a replaceable striking element  945 . The striking element  945  can be replaced if it becomes worn or damaged, and can be formed of a polymeric material which is designed to reduce localized impact to the relatively soft conductors (e.g., copper) in the generator. The opposite side of head  930  includes an interchangeable tool socket that is designed to accept tool insert  600 . 
     While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

Technology Classification (CPC): 1