Magnetic wedges

October 23, 2019

Confidential. Not to be copied, distributed, or reproduced without prior approval.
Why loss of magnetic wedges ?

Presentation Title Confidential. Not to be copied, distributed, or reproduced without prior approval. October 23, 2019 2
 Wedge
Glass braid What phenomenon cause the loss of magnetic wedges ?
conductors
Copper

GEPC magnetic wedges

are made of a mixture
of magnetic powder
Stator magnetic lamination
Stator magnetic lamination

and epoxy glue

Glass separator
conductors
Copper

Alternate
electromagnetic force
As the wedge is magnetic, the magnetic fields inside
the motor create an alternate stress on the wedge. If
Glass braid
Wedge the wedge is not correctly fixed inside its slots, it can
slide against the stator magnetic laminations. By
moving the edge of the magnetic wedge will wear by
sliding against the stator magnetic lamination

Schematic view of a
stator slot
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 What phenomenon cause the loss of magnetic wedges ?

Wedge is attracted out of

the stator slot due to
electromagnetic force

As the magnetic wedge is a softer material compared to the stator

steel lamination, by moving the wedge will wear of the edge. If the
Wear areas wedge width is shorter than the stator slot opening, the wedge will
be attracted out of its slot by the electromagnetic force.
Schematic view of wear areas

Process of wedge extraction:

GE magnetic wedges are made of iron
powder pressed and cast with epoxy resin.
This means that in case of extraction, the
magnetic wedge is crushed inside the air
gap of the motor and becomes iron dust.

THEREFORE, THERE IS NO DIRECT RISK FOR THE MOTOR IN CASE OF MAGNETIC WEDGES LOSS

Presentation Title Confidential. Not to be copied, distributed, or reproduced without prior approval. October 23, 2019 4
Process improvement from 2010

Presentation Title Confidential. Not to be copied, distributed, or reproduced without prior approval. October 23, 2019 5
 Magnetic slot wedges - history

2008 2010 2016 2018

Improvements of magnetic slot wedges process

Before 2008:
Magnetic slot wedges were 2010 – actions implemented to improve the 2018 – actions implemented to wedges quality
usually installed in our motors, Creation of an process • New supplier qualified in Oct/Nov 2018
and sometimes broken on site. Engineering + • Gluing of wedges • Update of magnetic wedge manufacturing
No significant impact on Manufacturing Task Force • Change of VPI resin (from polyester to epoxy) instruction
performances. • Implementation of POROMAT in slot wedge • Manufacturing tool maintenance
• 100% control by sound test before VPI
2008:
One major issue on a motor: Before 2018, many quality issues with magnetic wedges supplier
more than 50% of the magnetic (39 NCR from 2010 to 2018 / ~370 PO items during this period)
slot wedges broken because of a  Around 10% of non-conformity (bubbles, porosity, break
bad tightening. during assembly, dimensions…)
New epoxy resin qualified in 2016
• Qualification required due to EHS
restrictions with the previous one
• New epoxy resin has higher
mechanical characteristics

Presentation Title Confidential. Not to be copied, distributed, or reproduced without prior approval. October 23, 2019 6
 Magnetic slot wedges process
Comparison process before and after 2010
Before 2010: Since 2010:
Wedge Wedge
• The workers had to stuff the Glass braid • The workers stuff the stator slots Glass braid
stator slot with glass fiber with glass fiber (and if necessary
adding thin wedges of laminated
POROMAT
braid (and if necessary adding

Stator coil
Stator coil

upper leg
upper leg

thin wedges of laminated material) and add POROMAT

material) to define optimum following instructions
condition to enter the slot • POROMAT material increases its
wedge strongly under volume up to 150% during VPI, fills
pressure. all space under wedges and create Glass separator
Glass separator
• The pressure was depending a homogenous pressure under the
wedge.

bottom leg
bottom leg

on the experience of the

Stator coil
Stator coil

worker • Slot wedges are glued

• Slot wedges were not glued • Epoxy resin is used as standard
• Polyester resin was used as (mechanical strength 2x higher
standard compared to polyester resin)
Glass braid Glass braid
Schematic view Schematic view
of stator slot of stator slot
with POROMAT

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 Magnetic slot wedges process
Additional steps AFTER 2010

Improve wedge fixation: Control of good fixation:

Glue is applied is the stator slot All stators are checked by 100%
before magnetic wedge assembly regarding the good fixation of the
wedges by impact sound response
test following internal standard
IQ31028

POROMAT material is placed in

between the stator coil (upper
leg) and the glass braid.

The magnetic wedge close the

stator slot

POROMAT

Presentation Title Confidential. Not to be copied, distributed, or reproduced without prior approval. October 23, 2019 8