Assembling stator windings
Overview
This standard identifies the competences you need to assemble stator windings, in accordance with approved procedures. This will involve selecting the correct components and materials, fitting and insulating the components and fitting and terminating the coil windings. You will be required to select the appropriate tools and equipment to use, based on the operations to be performed and type of components to be fitted and to check that they are in a safe and serviceable condition. In carrying out the operations, you will be required to follow laid-down procedures and specific assembly techniques. The assembly activities will also include making all necessary checks and adjustments to ensure that components are correctly positioned and free from damage.
Your responsibilities will require you to comply with organisational policy and procedures for the assembly activities undertaken and to report any problems with the assembly activities, components or equipment that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.
Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to applying stator winding assembly techniques and procedures. You will understand the stator being assembled and its application and will know about the assembly techniques, tools and methods, in adequate depth to provide a sound basis for carrying out the activities to the required specification.
You will understand the safety precautions required when carrying out the assembly operations. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety legislation, regulations, directives and other relevant guidelines
- follow the relevant instructions, assembly drawings and any other specifications
- ensure that the specified components are available and that they are in a usable condition
- assemble the components in their correct positions, using appropriate methods and techniques
- secure the components using the specified connectors and securing devices
- check the completed assembly to ensure that all operations have been completed and it meets the required specification
- deal promptly and effectively with problems within your control and report those that cannot be solved
- ensure that work records are completed, stored securely and available to others, as per organisational requirements
- leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
- the health and safety requirements of the work area and the activities, and the responsibility these requirements place on you
- the hazards associated with the activities, and how to minimise them and reduce risks
- the personal protective equipment and clothing (PPE) to be worn during the activities
- how to obtain and interpret drawings, planning sheets and records and other documents needed for the assembly activities
- the factors to consider when choosing pre-formed coils
- the assembly methods and techniques to be used when assembling rotating equipment stator windings
- the common types of winding configuration used for stator assembly
- the basic operating principles of the stator being assembled
- the methods used to fit slot insulators
- the purpose of insulation cuffs
- factors that determine the wedge length, width, squareness and profile
- the methods used to mark out and cut materials for the manufacture and trimming of wedges
- the methods used to fit wedges into slots
- the factors to be considered when selecting and fitting coils to multi-phase stators
- the factors that influence the selection of coil ends
- the method used to check for the electrical integrity of joints
- the methods used to apply insulating varnish and the types used
- the common methods used to ensure good varnish penetration when using a dipping bath
- the visual checks and preparation requirements for the components to be used
- the methods and tools/equipment used to transport, handle and lift the components into position
- how to check that the tools/equipment are within current certification dates, free from damage and defects , in a safe and usable condition, and configured correctly for purpose
- the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve
- how to access, use and maintain information to comply with organisational requirements and legislation
Scope/range
Scope Performance
Assemble of the stator windings. by carrying out all of the following activities:
- use the correct assembly drawings, specifications and job instructions
- adhere to health and safety regulations, systems and procedures to realise a safe system of work
- ensure that components are free from damage, foreign objects, dirt or other contamination
- check that all tools and equipment are within calibration date, where appropriate
- use safe and approved techniques to assembly and connect stator components
- leave the work are in a safe and tidy condition
Prepare and assemble stator windings, using all of the following:
- winding wiring
- slot wedges
- brazing materials
- pre-formed coils
- dummy coils
- solders
- insulating materials
- equaliser rings
- fluxes
- separating strips
- resin/glass bonding tapes
Use six of the following tools and equipment for the assembly operations:
- tinning and soldering equipment
- drying and baking ovens
- brazing equipment
- multimeter
- coil winding machines
- insulating resin baths
- impedance testers
Complete all of the following assembly procedures:
- prepare components (such as coil ends, wedge length, width, squareness and profile)
- fit windings (such as preformed, wound directly into slot, loop, diamond, concentric)
- insulate windings (such as slot, end winding support)
- secure windings (such as packing, tapes, cords, wedges)
- solder and/or braze winding connections
- check mechanical integrity
- check electrical integrity (such as continuity, insulation, voltage withstand)
Assemble rotating equipment to one of the following quality and accuracy standards:
- organisational drawings and procedures
- customer drawings and requirements
- current industry standards, codes of practice and procedures
- other international standards