Two piece electrical and fluidic connector and installation method therefore

• US RE40,585 E1
• Filed: 01/21/2004
• Issued: 11/25/2008
• 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): Prasad; Chandrika
• Application Number:
  US10/762,187
• Time in Patent Office: 1,770 Days
• Field of Search: 439/190, 439/191, 439/196, 174/9.R, 174/9.F, 298/892.2
• 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. A 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 that facilitates fluidic connection to a fluid conductor and said second member being configured to facilitate electrical connection to an electrical conductor, said method comprising the steps of:

(a) 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

(b) matably connecting said first member to said second 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 themselves define an electrical connection between said electro-fluidic conductor and said electrical conductor when said electrical conductor is attached to said second member.

2. The method of claim 1, A 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 that facilitates fluidic connection to a fluid conductor and said second member being configured to facilitate electrical connection to an electrical conductor, said method comprising the steps of:

(a) 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

(b) matably connecting said first member to said second 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 themselves define an electrical connection between said electro-fluidic conductor and said electrical conductor when said electrical conductor is attached to said second member, wherein said method further comprises the step of removing a defective electrical and fluidic connector from said electro-fluidic conductor prior to said securing step (a).

3. The method of claim 2, wherein said defective electrical and fluidic connector comprises a single piece electrical and fluidic connector such that said method includes removing said single piece electrical and fluidic connector from said electro-fluidic conductor prior to said securing step (a).

4. The method of claim 2, wherein said removing said defective electrical and fluidic connector comprises the step of heating said defective electrical and fluidic connector to soften an existing brazing alloy securing said defective electrical and fluidic connector to said electro-fluidic conductor such that said removing step is facilitated.

5. The method of claim 1, wherein said method further comprises the step of verifying said fluid tight seal of said securing step (a) prior to said matably connecting step (b).

6. The method of claim 5, wherein said verifying step 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.

7. The method of claim 1, wherein said securing step (a) comprises the step of brazing said first member to said electro-fluidic conductor using a first brazing alloy.

8. The method of claim 7, wherein prior to said brazing step, said securing step (a) includes placing said first brazing alloy around said end portion of said electro-fluidic conductor.

9. The method of claim 7, A 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 that facilitates fluidic connection to a fluid conductor and said second member being configured to facilitate electrical connection to an electrical conductor, said method comprising the steps of:

(a) 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

(b) matably connecting said first member to said second 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 themselves define an electrical connection between said electro-fluidic conductor and said electrical conductor when said electrical conductor is attached to said second member, wherein said securing step (a) comprises the step of brazing said first member to said electro-fluidic conductor using a first brazing alloy, wherein said matably connecting step (b) comprises brazing said first member to said second member using a second brazing alloy having a lower melting temperature than a melting temperature of said first brazing alloy.

10. The method of claim 9, wherein said connecting step (b) comprises 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 such that the first brazing alloy does not melt during said connecting step (b).

11. The method of claim 1, A 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 that facilitates fluidic connection to a fluid conductor and said second member being configured to facilitate electrical connection to an electrical conductor, said method comprising the steps of:

(a) 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

(b) matably connecting said first member to said second 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 themselves define an electrical connection between said electro-fluidic conductor and said electrical conductor when said electrical conductor is attached to said second member, wherein said first member has at least one groove on an outer surface thereof, and wherein said method further comprises inserting a third brazing alloy into said at least one groove such that said matably connecting step (b) comprises brazing said first member to said second member using said third brazing alloy.

12. The method of claim 11, wherein said matably connecting step (b) comprises inserting said first member flush into said second member prior to said brazing of said first member to said second member.

13. The method of claim 12, wherein said method includes placing a ribbon alloy or an outer surface of said first member after said inserting of said third brazing alloy into said at least one groove and prior to said inserting said first member into said second member, said ribbon alloy securing said first member to said second member as a result of said brazing of said first member to said second member.

14. The method of claim 1, A 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 that facilitates fluidic connection to a fluid conductor and said second member being configured to facilitate electrical connection to an electrical conductor, said method comprising the steps of:

(a) 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

(b) matably connecting said first member to said second 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 themselves define an electrical connection between said electro-fluidic conductor and said electrical conductor when said electrical conductor is attached to said second member, wherein said matably connecting step (b) comprises inserting said first member into said second member and brazing said first member to said second member.

15. The method of claim 14, wherein said method includes placing a ribbon alloy on an outer surface of said first member prior to said inserting said first member into said second member.

16. The method of claim 14, wherein said method further comprises applying pressure that forces said first member into said second member during said brazing of said first member to said second member.

17. The method of claim 1, wherein said method further comprises the step of connecting said electrical conductor and said fluidic conductor to said electrical and fluidic connector for facilitating electrical and fluidic connection thereto.

18. The method of claim 17, wherein said step of connecting said electrical conductor and said fluidic conductor to said electrical and fluidic connector comprises brazing said electrical conductor and said fluidic conductor to said electrical and fluidic connector.

19. The method of claim 18, A 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 that facilitates fluidic connection to a fluid conductor and said second member being configured to facilitate electrical connection to an electrical conductor, said method comprising the steps of:

(a) 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

(b) matably connecting said first member to said second 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 themselves define an electrical connection between said electro-fluidic conductor and said electrical conductor when said electrical conductor is attached to said second member, wherein said method further comprises the step of connecting said electrical conductor and said fluidic conductor to said electrical and fluidic connector for facilitating electrical and fluidic connection thereto, wherein said step of connecting said electrical conductor and said fluidic conductor to said electrical and fluidic connector comprises brazing and electrical conductor and said fluidic conductor to said electrical and fluidic connector, wherein said fluidic conductor and said electrical conductor comprise a single conductive pipe such that said step of connecting said electrical conductor and said fluidic conductor to said electrical and fluidic connector comprises brazing said single conductive pipe to said electrical and fluidic connector.

20. The method of claim 17, wherein said method further comprises the step of insulating the electrical and fluidic connector.

21. The method of claim 1, A 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 that facilitates fluidic connection to a fluid conductor and said second member being configured to facilitate electrical connection to an electrical conductor, said method comprising the steps of:

(a) 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

(b) matably connecting said first member to said second 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 themselves define an electrical connection between said electro-fluidic conductor and said electrical conductor when said electrical conductor is attached to said second member, wherein said electro-fluidic conductor comprises a stator bar in a water cooled electric machine, and wherein said securing step (a) and said matably connecting step (b) are performed while said stator bar is installed in said water cooled electric machine.

22. The method of claim 2, wherein the first member is a sleeve and the second member is a clip.

23. The method of claim 22, wherein the sleeve encircles an end portion of said electro-fluidic conductor without substantially overhanging said end.

24. The method of claim 23, wherein the clip is matably fitted and brazed over the sleeve so that substantially the entire length of the sleeve is disposed in the clip with substantially its entire outer surface forming a fluid tight seal with an interior surface of the clip for passing fluid between said electro-fluidic conductor and said fluid port of said clip.

25. The method of claim 9, wherein pressure is applied during the brazing step so as to force the sleeve into the clip.

26. The method of claim 2, where said removing of the defective electrical and fluidic connector from said electro-fluidic conductor includes heating said defective connector to soften an existing brazing alloy while chilling the electro-fluidic conductor near the defective connector to remove excess heat from the defective conductor.