Two piece electrical and fluidic connector and installation method therefore

• US 5,791,924 A
• Filed: 03/31/1997
• Issued: 08/11/1998
• Est. Priority Date: 03/16/1995
• Status: Expired due to Term

• Current Assignee: Mechanical Dynamics & Analysis, Ltd.
• Original Assignee: Mechanical Dynamics and Analysis, Inc.
• Inventors: Taillon, James Kenneth, Reidelberger, Frank Richard III
• Primary Examiner(s): Paumen, Gary F.
• Assistant Examiner(s): STANDIG, BARRY
• Application Number:
  US08/828,978
• Time in Patent Office: 498 Days
• Field of Search: 439/191, 439/192, 439/193, 439/194, 439/195, 29/596
• US Class Current: 439/191
• CPC Class Codes: F16L 13/08 Soldered joints specially adapted for connecting metal hoses to rigid members F16L33/26
• CPC Class Codes: H01R 13/005 Electrical coupling combined with fluidic coupling
• CPC Class Codes: H01R 9/11 End pieces for multiconductor cables supported by the cable and for facilitating connections to other conductive members , e.g. for liquid cooled welding cables
• CPC Class Codes: H02K 15/0093 Manufacturing or repairing cooling fluid boxes, i.e. terminals of fluid cooled windings ensuring both electrical and fluid connection
• CPC Class Codes: H02K 3/12 arranged in slots
• CPC Class Codes: H02K 3/24 with channels or ducts for cooling medium between the conductors
• CPC Class Codes: H02K 3/505 for large machine windings, e.g. bar windings H02K3/51 takes precedence
• CPC Class Codes: Y10T 29/49323 Assembling fluid flow directing devices, e.g., stators, diaphragms, nozzles

Abstract

In water cooled electric generators, an electrical and fluidic connector connects a stator bar to an electrical bus and to a water source. The connector comprises two pieces, a clip and a sleeve. During installation, the sleeve is brazed to the stator bar in a fluid tight manner, and the clip is then brazed to the sleeve. Fluidic connection from the generator'"'"'s water source to the stator bar is provided by a hose attached to a fluid port on the clip. Connection to the electrical bus of the generator is provided by copper leaves and/or copper piping brazed onto the clip. The clip and the sleeve are both formed from copper to form an electrical connection between the copper leaves and/or copper piping and the stator bar. The connector may be further used to replace a defective electrical and fluidic connector that terminates a stator bar in a water cooled electric generator.

Claims

1. An electrical and fluidic connector for connecting an electro-fluidic conductor to a fluidic conductor and an electrical conductor, said electrical and fluidic connector comprising:

a first member that is formed of an electrically conductive material and is configured to encircle and thereby electrically attach to an end portion of said electro-fluidic conductor;

a second member that is formed of an electrically conductive material and is configured for engagement to said first member, said second member including a fluid port for coupling to said fluidic conductor and said second member being electrically couplable to said electrical conductor; and

wherein said first member and said second member define a hollow inner chamber when said first member and said second member are in engagement, said hollow inner chamber comprising a fluid tight chamber such that fluid is passed between said electro-fluidic conductor and said fluid port of said second member, said fluid passing through said hollow inner chamber, and wherein said first member and said second member provide electrical coupling between said electro-fluidic conductor and said electrical conductor when said second member is electrically coupled to said electrical conductor.

2. The electrical and fluidic connector of claim 1, wherein said electrical and fluidic connector and said electro-fluidic conductor are within a liquid cooled electric machine, and wherein said electro-fluidic conductor comprises a stator bar, said first member being configured to encircle and thereby electrically attach to an end portion of said stator bar.

3. The electrical and fluidic connector of claim 2, wherein said stator bar includes a plurality of electrically conducting strands, at least one electrically conducting strand of said plurality of electrically conducting strands being adapted to conduct fluid, and wherein said first member is configured to encircle and electrically attach to an end portion of said plurality of electrically conducting strands.

4. The electrical and fluidic connector of claim 2, wherein said first member and said second member are each fabricated of machined copper such that said first member and said second member have a lower porosity than a porosity of cast copper.

5. In a liquid cooled electric machine having a plurality of stator bars, wherein a first stator bar is coupled to a second stator bar, said first stator bar and said second stator bar each having a plurality of electrical and fluidic conductive strands extending therethrough, and wherein an electrical and fluidic connector is employed in coupling said first stator bar and said second stator bar, said electrical and fluidic connector comprising:

an electrically conductive first member configured to encircle and thereby electrically attach to an end of said plurality of electrical and fluidic conductive strands of said first stator bar;

an electrically conductive second member configured for engagement to said first member, said second member being electrically couplable to said plurality of electrical and fluidic conductive strands of said second stator bar, said second member further including a fluid port; and

wherein said first member and said second member define a hollow inner chamber when said first member and said second member are in engagement, said hollow inner chamber comprising a fluid tight chamber such that fluid is passed between said plurality of electrical and fluidic conductive strands of said first stator bar and said fluid port of said second member, said fluid passing through said hollow inner chamber, and when said first member and said second member are in engagement electrical connection of said plurality of electrical and fluidic conductive strands of said first stator bar to said plurality of electrical and fluidic conductive strands of said second stator bar can be achieved.

6. The electrical and fluidic connector of claim 5, wherein said first member and said second member each comprise machined copper.

7. The electrical and fluidic connector of claim 5, further comprising a strand brazing alloy for securing said first member to said electrical and fluidic conductive strands.

8. The electrical and fluidic connector of claim 7, further comprising a member brazing alloy for securing said second member to said first member in a fluid tight manner.

9. The electrical and fluidic connector of claim 8, wherein said strand brazing alloy has a first melting temperature and said member brazing alloy has a second melting temperature, said first melting temperature being higher than said second melting temperature to facilitate brazing of said second member to said first member without melting said strand brazing alloy.

10. The electrical and fluidic connector of claim 5, wherein said first member comprises a sleeve that is configured to encircle and attach to the end of said plurality of electrical and fluidic conductive strands of said first stator bar.

11. A repair method for providing an electrical and fluidic connector on an electro-fluidic conductor, said electrical and fluidic connector having a first member and a second member that are separate and both electrically conductive, said second member having a fluid port for coupling to a fluid conductor and said second member being electrically conductive for electrical coupling to an electrical conductor, said repair method comprising the steps of:

(a) removing an existing electrical and fluidic connector from said electro-fluidic conductor;

(b) securing said first member to said electro-fluidic conductor such that said first member encircles an end portion of said electro-fluidic conductor and forms a fluid tight seal thereto, and electrically connects therewith; and

(c) securing said second member to said first member such that said first member and said second member define a hollow inner chamber that comprises a fluid tight chamber for passing fluid between said electro-fluidic conductor and said fluid port of said second member, and wherein said first member and said second member electrically couple said electro-fluidic conductor to said electrical conductor when said electrical conductor is electrically coupled to said second member.

12. The repair method of claim 11, wherein said removing (a) comprises heating said existing electrical and fluidic connector to soften an existing brazing alloy securing said existing electrical and fluidic connector to said electro-fluidic conductor such that said removing step is facilitated.

13. The repair method of claim 11, further comprising cleaning the end portion of the said electro-fluidic conductor subsequent to said removing step (a) and prior to said securing step (b).

14. The repair method of claim 11, further comprising verifying said fluid tight seal of said securing step (b) prior to said securing step (c).

15. The repair method of claim 14, wherein said verifying includes affixing a test cap to said first member and pressurizing said electro-fluidic conductor such that any leaks between said first member and said electro-fluidic conductor are detected.

16. The repair method of claim 11, wherein said securing step (b) comprises brazing said first member to said electro-fluidic conductor using a first brazing alloy, and wherein said securing step (c) comprises brazing said second member to said first member using a second brazing alloy, said second brazing alloy having a lower melting temperature than a melting temperature of said first brazing alloy.

17. The repair method of claim 16, wherein said securing step (c) includes heating said first member and said second member to a temperature at least as high as the melting temperature of the second brazing alloy but lower than the melting temperature of the first brazing alloy, wherein the first brazing alloy does not melt during said securing step (c).

18. The repair method of claim 11, further comprising coupling the electrical conductor and the fluidic conductor to said electrical and fluidic connector subsequent to said securing (c).

19. The repair method of claim 11, wherein said removing step (a) comprises removing any insulation over said existing electrical and fluidic connector prior to removing of said existing electrical and fluidic connector.

20. The repair method of claim 11, wherein said electro-fluidic conductor comprises a stator bar in a liquid cooled electric machine, and wherein said securing steps (b) &

(c) are performed while said stator bar is installed in said liquid cooled electric machine.

21. The repair method of claim 20, further comprising insulating the electrical and fluidic connector subsequent to said securing step (c).

22. The repair method of claim 21, further comprising prior to said insulating, performing a pressure test on said stator bar and said electrical and fluidic connector.