阅读说明：本技术 发电机接地条模块 (Generator grounding strip module ) 是由 M·D·贾蒙 J·N·恩格兰 T·I·奈尔逊 K·M·麦克雷特 T·J·加纳 于 2020-01-27 设计创作，主要内容包括：一种发电机接地模块,其可选择性地安装到支撑支架并且可选择性地与转子接合,所述发电机接地模块包括：板构件,该板构件沿着安装轴线可移动以将发电机接地模块选择性地附接到支撑支架,板构件在第一位置和第二位置之间可移动,在所述第二位置中,板构件相对于支撑支架是基本固定的。安装块沿着安装轴线相对于板构件可移动,接地条被联接到安装块并且在脱离位置和接合位置之间可移动,在所述接合位置中,接地条接触转子,并且偏压组件被连接到板构件和安装块并且可操作成沿着安装轴线朝向板构件偏压安装块,其中板构件在处于第二位置中时被固定地附接到支撑支架且偏压组件将接地条偏压到接合位置中。(A generator grounding module selectively mountable to a support bracket and selectively engageable with a rotor, the generator grounding module comprising: a plate member movable along a mounting axis to selectively attach the generator grounding module to the support bracket, the plate member movable between a first position and a second position in which the plate member is substantially fixed relative to the support bracket. The mounting block is movable relative to the plate member along a mounting axis, the ground access strip is coupled to the mounting block and movable between a disengaged position and an engaged position in which the ground access strip contacts the rotor, and a biasing assembly is connected to the plate member and the mounting block and operable to bias the mounting block toward the plate member along the mounting axis, wherein the plate member is fixedly attached to the support bracket and the biasing assembly biases the ground access strip into the engaged position when in the second position.)

1. A generator grounding module selectively mountable to a support bracket and selectively engageable with a rotor, the generator grounding module comprising:

a plate member movable along a mounting axis to selectively attach the generator grounding module to the support bracket, the plate member movable between a first position and a second position in which the plate member is substantially fixed relative to the support bracket;

a mounting block movable relative to the plate member along the mounting axis;

a ground access bar coupled to the mounting block and movable between a disengaged position and an engaged position in which the ground access bar contacts the rotor; and

a biasing assembly connected to the plate member and the mounting block and operable to bias the mounting block along the mounting axis toward the plate member, wherein the plate member is fixedly attached to the support bracket when in the second position and the biasing assembly biases the grounding bar into the engaged position.

2. The generator grounding module of claim 1, wherein the mounting axis is a radial axis of the rotor.

3. The generator grounding module of claim 1, further comprising a mounting arm fixedly attached to the mounting block and defining a first end and a second end spaced apart from the first end, the grounding bar being attached to the first end and the second end.

4. The generator grounding module of claim 3, wherein the mounting arm includes a first arm defining the first end and a separate second arm defining the second end.

5. The generator grounding module of claim 3, further comprising a second grounding bar attached to the first end and the second end and spaced a non-zero distance from the grounding bar in the installation direction.

6. The generator grounding module of claim 5, further comprising a sensor positioned to generate a signal in response to a failure of the grounding bar and the second grounding bar.

7. The generator grounding module of claim 1, wherein the biasing assembly includes a biasing member that applies a constant biasing force to the mounting block as the mounting block moves between the disengaged position and the engaged position.

8. The generator grounding module of claim 7, wherein the biasing member comprises a coiled metal strip having a coiled end attached to the plate member and a free end attached to the mounting block.

9. The generator grounding module of claim 1, further comprising a handle coupled to the plate member and operable to move the plate member along the mounting axis between the first position and the second position.

10. The generator grounding module of claim 9, wherein the handle includes a locking member selectively engageable with the support bracket to lock the plate member in the second position.

11. The generator grounding module of claim 1, further comprising a sensor positioned to detect displacement of the mounting block toward the plate member when the plate member is in the first position.

12. The generator grounding module of claim 11, wherein the sensor comprises a switch positioned to be activated in response to a failure of the grounding bar.

13. The generator grounding module of claim 1, wherein the grounding strap is formed of braided metal.

14. A generator grounding module selectively mountable to a support bracket and selectively engageable with a rotor, the generator grounding module comprising:

a mounting block movable relative to the support bracket along a mounting axis;

a first ground strip;

a second ground strip;

an attachment assembly operable to connect the first and second ground access strips to the mounting block, the mounting block movable between a disengaged position and an engaged position in which the first ground access strip contacts the rotor and the second ground access strip is spaced apart from the rotor; and

a biasing assembly connected to the support bracket and the mounting block and operable to bias the mounting block along the mounting axis toward the rotor, wherein the biasing assembly biases the first ground access stripe into the engaged position.

15. The generator grounding module of claim 14, wherein the mounting axis is a radial axis of the rotor.

16. The generator grounding module of claim 14, further comprising a mounting arm fixedly attached to the mounting block and defining a first end and a second end spaced apart from the first end, the first grounding bar, and the second grounding bar attached to the first end and the second end and spaced apart from the first grounding bar by a non-zero distance in the mounting direction.

17. The generator grounding module of claim 16, wherein the mounting arm includes a first arm defining the first end and a separate second arm defining the second end.

18. The generator grounding module of claim 14, further comprising a sensor positioned to generate a signal in response to a failure of the first grounding bar and the second grounding bar.

19. The generator grounding module of claim 14, wherein the biasing assembly includes a biasing member that applies a constant biasing force to the mounting block as the mounting block moves between the disengaged position and the engaged position.

20. The generator grounding module of claim 19, wherein the biasing member comprises a coiled metal strip having a coiled end attached to the plate member and a free end attached to the mounting block.

21. The generator grounding module of claim 14, further comprising a plate member movable along the mounting axis between a first position and a second position in which the plate member is substantially fixed relative to the support bracket.

22. The generator grounding module of claim 21, further comprising a handle coupled to the plate member and operable to move the plate member along the mounting axis between the first position and the second position.

23. The generator grounding module of claim 22, wherein the handle includes a locking member selectively engageable with the support bracket to lock the plate member in the second position.

24. The generator grounding module of claim 21, further comprising a sensor positioned to detect displacement of the mounting block toward the plate member when the plate member is in the first position.

25. The generator grounding module of claim 24, wherein the sensor comprises a switch positioned to be activated in response to a failure of the grounding bar.

Technical Field

The present disclosure relates generally to modular assemblies for generator grounding bars, and more particularly to modular grounding bars including redundant bars and sensors.

Background

Large rotating shafts, such as those in generators, must be continuously grounded to prevent damage to the bearings from the charge accumulated in the shaft or rotor during operation. The shaft itself rests on a thin film of oil or other suitable lubricant in a pair of bearings and is therefore electrically insulated from ground potential. However, the accumulation of excess charge on the shaft can result in discharge through the oil film, resulting in damage to the bearings. To prevent such discharge and to ground the rotating shaft, a Shaft Grounding Device (SGD) is placed in continuous contact with the rotating shaft while the rotating shaft rotates to provide a discharge path to ground.

Disclosure of Invention

The generator grounding module selectively mountable to the support bracket and selectively engageable with the rotor includes a plate member movable along a mounting axis to selectively attach the generator grounding module to the support bracket, the plate member movable between a first position and a second position in which the plate member is substantially fixed relative to the support bracket. The mounting block is movable relative to the plate member along a mounting axis, the ground access strip is coupled to the mounting block and movable between a disengaged position and an engaged position (in which the ground access strip contacts the rotor), and a biasing assembly is connected to the plate member and the mounting block and is operable to bias the mounting block toward the plate member along the mounting axis, wherein the plate member is fixedly attached to the support bracket and the biasing assembly biases the ground access strip into the engaged position when in the second position.

In another configuration, the generator grounding module is selectively mountable to the support bracket and selectively engageable with the rotor and includes a mounting block movable relative to the support bracket along a mounting axis, a first grounding bar, a second grounding bar, and an attachment assembly operable to connect the first and second grounding bars to the mounting block, the mounting block movable between a disengaged position and an engaged position in which the first grounding bar contacts the rotor and the second grounding bar is spaced apart from the rotor. A biasing assembly is connected to the support bracket and the mounting block and is operable to bias the mounting block along the mounting axis toward the rotor, wherein the biasing assembly biases the first grounding bar into the engaged position.

In another configuration, a generator grounding module is selectively mountable to the support bracket and selectively engageable with the rotor, the generator grounding module including a plate member, a mounting block, a first grounding bar, a second grounding bar, and a biasing assembly connected to the plate member and the mounting block to generate a constant biasing force to bias the mounting block and the plate member toward each other. The attachment assembly is operable to connect the first and second grounding bars to the mounting block. The handle, the plate member, the mounting block, the first ground engaging strip, the second ground engaging strip, the biasing assembly, the attachment assembly, and the handle are movable as a unit along the mounting axis from a free position to a contact position where the first ground engaging strip contacts the rotor, the handle being movable to a locked position where the biasing assembly generates a first biasing force engaging the first ground engaging strip and the rotor and the attachment assembly generates a second biasing force that balances the first biasing force, and wherein failure of the first ground engaging strip reduces the second biasing force and moves the second ground engaging strip into engagement with the rotor.

In another configuration, a method of installing a generator grounding module includes: attaching a first ground strip and a second ground strip to a mounting block; attaching a mounting block to a plate member; and biasing the mounting block toward the plate member using a biasing member, the first ground strip, the second ground strip, the mounting block, the plate member, and the biasing member defining a unit. The method further comprises the following steps: attaching the unit to a fixed support bracket, the unit being movable relative to the support bracket along a mounting axis; moving the unit into an engaged position in which the first mounting bar engages the rotor and applies a first biasing force to the mounting block to bias the mounting block away from the plate member; and applying a second biasing force to the mounting block using the biasing member, the second biasing force and the first biasing force balancing each other.

The biasing member generates a second biasing force and wherein the second biasing force is constant when the unit is between the engaged and disengaged positions.

The method may also include sensing movement of the mounting block from the engaged position in response to failure of one or both of the first and second grounding bars.

The method may further comprise: attaching a handle to the plate member; moving the plate member along the mounting axis by moving the handle along the mounting axis to position the plate member in the locked position; and rotating the handle about the mounting axis to fixedly attach the plate member to the block member.

The foregoing has outlined rather broadly the features of the present disclosure so that those skilled in the art may better understand the detailed description that follows. Additional features and advantages of the disclosure will be described hereinafter which form the subject of the claims. Those skilled in the art will appreciate that they may readily use the conception and the specific embodiment disclosed as a basis for modifying or designing other structures for carrying out the same purposes of the present disclosure. Those skilled in the art will also realize that such equivalent constructions do not depart from the spirit and scope of the disclosure in its broadest form.

Further, before proceeding with the following detailed description, it is to be understood that various definitions of certain words and phrases are provided throughout this specification, and one of ordinary skill in the art will understand that such definitions apply in many, if not most, instances to prior as well as future uses of such defined words and phrases. Although some terms may include a wide variety of embodiments, the appended claims may expressly limit these terms to particular embodiments.

Drawings

FIG. 1 is a side view of a generator rotor.

Fig. 2 is a perspective view of a generator grounding bar module attached to a stationary component adjacent to the rotor of fig. 1.

Fig. 3 is a perspective view of the generator grounding bar module of fig. 2.

Figure 4 is a perspective view of a support bracket for the generator grounding bar module of figure 3.

Fig. 5 is a perspective view of a portion of the support bracket of fig. 4.

Figure 6 is a perspective view of a portion of the grounding bar module of figure 3.

Figure 7 is a perspective view of a handle of the grounding bar module of figure 3.

Figure 8 is a perspective view of a biasing assembly of the grounding bar module of figure 3.

Fig. 9 is a perspective view of a plate member of the grounding bar module of fig. 3.

Fig. 10 is a cross-sectional view of the plate member of fig. 9 taken along line 10-10 of fig. 11.

Fig. 11 is another perspective view of the plate member of fig. 9.

Fig. 12 is a perspective view of a mounting block of the grounding bar module of fig. 3.

Fig. 13 is another perspective view of the mounting block of fig. 12.

Figure 14 is a perspective view of a mounting arm and ground bar assembly of the ground bar module of figure 3.

Figure 15 is a perspective view of a partial assembly of the grounding bar module of figure 3.

Figure 16 is a side view of a portion of the grounding bar module of figure 3 in an engaged position.

Fig. 17 is a perspective view of a portion of the generator grounding bar module of fig. 3.

Fig. 18 is a perspective view of a portion of the generator grounding bar module of fig. 3 in a first configuration.

Fig. 19 is a perspective view of a portion of the generator grounding bar module of fig. 3 in a second configuration.

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

Detailed Description

Various technologies pertaining to systems and methods will now be described with reference to the drawings, where like reference numerals represent like elements throughout. The drawings discussed below, and the various embodiments used to describe the principles of the present disclosure in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the disclosure. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any suitably arranged device. It should be understood that functions described as being performed by certain system elements may be performed by multiple elements. Similarly, for example, one element may be configured to perform functions described as being performed by multiple elements. The numerous innovative teachings of the present application will be described with reference to exemplary, non-limiting embodiments.

Further, it is to be understood that the words or phrases used herein are to be interpreted broadly, unless expressly limited in some instances. For example, the terms "including," "having," and "containing," as well as derivatives thereof, mean including, but not limited to. The singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. Further, as used herein, the term "and/or" refers to and encompasses any and all possible combinations of one or more of the associated listed items. The term "or" is inclusive, meaning and/or, unless the context clearly dictates otherwise. The phrases "associated with … …" and "associated therewith," as well as derivatives thereof, may mean including, included within … …, interconnected with … …, contained within … …, connected to or with … …, coupled to or with … …, communicable with … …, cooperative with … …, staggered, juxtaposed, proximate, bonded to or in conjunction with … …, having the nature of … …, or the like.

Furthermore, although the terms "first," "second," "third," etc. may be used herein to refer to various elements, information, functions, or actions, these elements, information, functions, or actions should not be limited by these terms. Rather, these numerical adjectives are used to distinguish one element, information, function, or action from another. For example, a first element, information, function, or action may be termed a second element, information, function, or action, and, similarly, a second element, information, function, or action may be termed a first element, information, function, or action, without departing from the scope of the present disclosure.

Furthermore, the term "adjacent" may mean: one element is relatively close to but not in contact with the other element; or that the element is in contact with another part, unless the context clearly dictates otherwise. Further, the phrase "based on" is intended to mean "based, at least in part, on" unless explicitly stated otherwise. The term "about" or "substantially" or similar terms are intended to encompass variations in value that are within normal industry manufacturing tolerances for that dimension. If no industry standard is available, a 20% variation would fall within the meaning of these terms unless otherwise indicated.

Fig. 1 illustrates a generator rotor 10 of the type commonly used in large scale power generation, such as fossil fuel power plants, nuclear power plants, and the like. The rotor 10 includes an elongate central portion 15 in which coils are disposed to define one or more windings. Each end includes a retaining ring 20 positioned to support and constrain the ends of the windings. The rotor 10 extends beyond the central portion 15 in both directions to define a bearing surface 25 where the bearing engages and supports the rotor 10 for rotation and engages and supports other surfaces and features required for proper operation of the rotor 10. One or more couplings 30 are provided at each end to connect the rotor 10 to other rotating equipment, such as gas turbine engines, evaporative turbines, water turbines, wind turbines, and the like. The stator and other stationary components 35 surround the rotor 10 and remain substantially stationary during operation of the rotor.

Turning to fig. 2, a perspective end view better illustrates two support brackets 40 attached to the stationary component 35 located near the rotor 10 and including two generator grounding modules 45 (sometimes referred to as generator grounding bar modules), each generator grounding module 45 being attached to one of the two support brackets 40. The stationary component 35 may be a bearing housing, a stator housing, a generator housing, a seal housing, and the like. Obviously, a single generator grounding module 45 or more than two grounding modules 45 may be used at one or both ends of the rotor 10, as desired.

Fig. 3 illustrates one support bracket 40 and generator grounding module 45 of fig. 2. As illustrated in fig. 3 and better illustrated in fig. 4, the support bracket 40 includes a mounting plate 50 and a support bracket 55 attached to the mounting plate 50. The mounting plate 50 includes an elongated rectangular section 60 and two smaller rectangular extensions 65 at a first end. The smaller rectangular extension 65 is positioned to receive a fastener 70 that facilitates attachment of the mounting plate 50 to the stationary component 35. Other shapes or arrangements may be used for the mounting plate 50 depending on the arrangement of the stationary component 35 to which the mounting plate 50 must be attached.

The support member 55 is substantially L-shaped and includes an attachment portion 75 attached to the mounting plate 50 and a support portion 80 oriented at approximately ninety degrees relative to the attachment portion 75, the support portion 80 supporting the generator grounding module 45, as will be described. With continued reference to fig. 4, the attachment portion 75 includes a slot 85 or other aperture sized to receive a fastener 90 that facilitates attachment of the support member 55 to the mounting plate 50. The fasteners 90 may alternatively pass through the mounting plate 50 and engage the stationary component 35 to complete the attachment of the mounting plate 50 and the support member 55 to the stationary component 35, as desired. In other configurations, the fastener 70 attaching the mounting plate 50 is the only fastener attached to the stationary component 35, and a pin or other alignment member is provided between the mounting plate 50 and the stationary component 35 to provide the desired positional stability of the mounting plate 50 and the support member 55.

The support portion 80 of the support member 55 includes a circular aperture 95 passing through the support portion 80 from the first surface 100 to the second surface 105 and a first slot 110 also passing through the support portion 80. A mounting axis 115 is defined to extend along a centerline of the circular aperture 95. Referring to fig. 5, the second surface 105 of the support portion 80 includes a larger circular counterbore 120 that extends partially through the support portion 80 and has a diameter equal to the length of the first slot 110. The second slot 125 is arranged orthogonal to the first slot 110, has the same length as the first slot 110, and extends from the surface of the counterbore 120 partially through the support portion 80.

Also visible in fig. 4 and 5 are a pair of guide rods 130. The guide bar 130 is attached to the first surface 100 and extends parallel to the mounting axis 115 in a direction from the first surface 100 and away from the second surface 105. In the illustrated construction, fasteners 135 attach each rod 130 to the support portion 80 of the support member 55, and other attachment mechanisms are possible.

Also visible in fig. 4 and 5 is a sensor 140, which is in the form of a switch 140 or a microswitch. The switch 140 is fixedly attached to the attachment portion 75 and includes an actuation arm 145 that extends from the switch 140 to a position where it can be actuated, as will be discussed in more detail below.

Referring to fig. 6, the generator grounding module 45 includes a handle 150 (fully illustrated in fig. 3) extending along the mounting axis 115, the plate member 155, the mounting block 160, the biasing assembly 165, the grounding bar assembly 170, and the mounting arm 175. As illustrated in fig. 7, the handle 150 includes a shaft 180, a grip portion 185 fixedly attached to one end of the shaft 180, a first pin 190, a second pin 195, a biasing element 200, and a locking member 205. Grip portion 185 is sized and shaped to be easily grasped by a user to allow the user to manipulate handle 150 and generator grounding module 45 as desired. The first pin 190 passes through the shaft 180 near the second end of the shaft 180 and is fixed relative to the shaft 180. Roll or solid pins may be used as desired and secured using any suitable arrangement, including welding, soldering, brazing, adhesives, friction, and the like. A second pin 195 passes through the shaft 180 at a point between the grip portion 185 and the first pin 190 and is fixed relative to the shaft 180, much like the first pin 190. The second pin 195 is arranged orthogonal to the first pin 190, but may be arranged at other angles to the first pin as desired. Further, the first pin 190 has a length less than or equal to the length of the first slot 110 and the second slot 125.

The groove 208 is formed around the shaft 180 at a first distance from the first pin 190. The groove 208 is sized and shaped to receive the locking member 205, which in the illustrated construction includes a C-clip 210. The C-clip 210 and/or another member, such as a washer, defines a first stop for the biasing element 200, which includes a coil spring 215 disposed on the shaft 180 between the C-clip 210 and the first pin 190. In other constructions, other components may be used in place of the coil spring 215. For example, other configurations may use belleville springs formed from a stack of belleville washers, and still other configurations use other components.

As best illustrated in fig. 8, the biasing assembly 165 includes two individual springs 220 formed from coiled metal strip. Each spring 220 includes a coiled portion 225, an extended portion 230, and a free end 235, wherein the spring 220 creates a biasing force that attempts to pull the free end 235 toward the coiled portion 225. The use of coiled metal strip as the springs 220 results in the biasing force of each spring 220 being substantially constant (plus or minus ten percent) regardless of the distance of the free end portion 235 from the coiled portion 225 (i.e., the length of the extension portion 230). Of course, the biasing force is most constant when a small portion of the total length of the coiled metal strip extends between the coiled portion 225 and the free end portion 235. For example, in a preferred construction, the extension portion 230 of each spring 220 extends between one and three inches (25-75 millimeters), and at least eight to ten inches (203 and 255 millimeters) of the springs 220 are disposed in the coiled portion 225. Accordingly, the coiled portion 225 includes between about two and ten times as much metal strip as the extension portion 230. In another configuration, the coiled portion 225 includes about twelve full coils and no more than one coil is required to move the biasing assembly 165 between the fully retracted and fully extended positions. This arrangement ensures a substantially constant biasing force at all desired operating points.

Fig. 9-11 illustrate the plate member 155 in more detail than is visible in fig. 3. As illustrated, the plate member 155 includes a biasing assembly mount 240, a pair of guide rod apertures 245, and a first handle aperture 250. The biasing assembly mount 240 includes two recesses 255, each arranged to receive one of the coiled metal springs 220 of the biasing assembly 165. More specifically, the recess 255 is arranged to retain the coiled portion 225 and maintain it in a coiled shape while also allowing the free end 235 and the extension portion 230 to extend from the plate member 155. In some configurations, the biasing assembly mount 240 can include a blocking element that covers the recess 255 to inhibit undesired removal of the coiled portion 225 from the recess 255.

The guide rod aperture 245 is a generally straight aperture sized to receive the guide rod 130 while allowing the plate member 155 to move freely along the guide rod 130. As best illustrated in fig. 10, the first handle aperture 250 includes a large counterbore 260 that is sized to receive a portion of the coil spring 215 of the handle 150. A third slot 265 is formed in a surface opposite the counterbore 260 and is sized to receive the first pin 190.

The guide screw 270 illustrated in fig. 9 and 11 threadedly engages the plate member 155 and is fixed relative to the plate member 155. The lead screw 270 comprises an elongated screw including a head 275 and a shoulder 280 adjacent to a threaded portion 285. The shoulder 280 is arranged to engage or partially constrain the bushing 290 or plate member 155 to attach the bushing 290 to the plate member 155 and at least partially fix its position relative to the plate member 155. In other constructions, the bushing 290 and/or the guide screw 270 are formed as a single piece, are formed as part of the plate member 155, and/or are permanently attached to the plate member 155.

The mounting block 160 is best illustrated in fig. 12 and 13 and includes two guide rod bores 295, a second handle bore 300, and a bearing bore 305. The guide rod aperture 295 is a generally straight through hole sized to receive the guide rod 130 and allow the mounting block 160 to move freely relative to the guide rod 130.

The bearing holes 305 are straight holes that pass through the mounting block 160 and are sized to receive the bearing members 310 illustrated in fig. 12. The bearing member 310 is bolted to the mounting block 160 or otherwise attached to fix its position relative to the mounting block 160. The bearing member 310 preferably includes an insert or inner member 315 that tightly engages the guide screw 270 for movement of the mounting block 160 relative to the plate member 155. The insert 315 may be a bushing, linear bearing, or flexible package that allows the desired linear movement while maintaining the desired alignment.

The second handle aperture 300 includes a through hole sized to allow passage of the shaft 180 and a fourth slot 320 sized to allow passage of the second pin 195. A fourth slot 320 passes through the mounting block 160. As illustrated in fig. 13, a counterbore 325 can be provided to reduce the thickness of the mounting block 160 in the region of the fourth slot 320.

Two mounting apertures 330 are provided on opposite sides of the mounting block 160 and are arranged to receive fasteners 335 that attach the free end 235 of the coiled metal spring 220 to the mounting block 160. In the illustrated construction, a threaded aperture 330 is used. However, other configurations may use other attachment mechanisms as desired.

As illustrated in fig. 14, the mounting arm 175 is attached to the mounting block 160 between the mounting block 160 and the bearing member 310 and extends from the mounting block 160 to define a first end 340 and a second end 345. The mounting arm 175 is substantially arcuate and is formed of a metallic material such as copper, brass, bronze, steel or aluminum and the like. While the illustrated construction includes a single piece mounting arm 175, other constructions may use two or more pieces defining the mounting arm as desired. The mounting arm 175 and the ground bar assembly 170 have a length and size that ensures that only the ground bar assembly 170 touches the rotor 10 when the ground bar assembly 170 is engaged with the rotor 10. The mounting arm 175 remains spaced from the rotor 10 regardless of the position or configuration of the generator grounding module 45.

Ground bar assembly 170 is preferably formed of a braided metallic material such as copper, brass, bronze, steel or aluminum and the like. In one configuration, a length of ground strip material is folded onto itself such that two free ends 350 are disposed adjacent to the first end 340 of the mounting arm 175 and the loop end 355 is positioned adjacent to the second end 345 of the mounting arm 175. The first end 340 of the mounting arm 175 includes a first clamp 360 that engages the two free ends 350 of the folded ground strip material. The second end 345 includes a second clamp 365 that engages a top end bar 370 of the ground bar assembly 170 before the ring 355. Attaching the grounding bar material in this manner results in two separate grounding bars 370, 375 adjacent to each other. Further, if the first grounding bar 375 wears out or otherwise fails, the second grounding bar 370 will still be securely mounted in the mounting arm 175 and may engage the rotor 10 with the desired contact pressure. The mounting arm 175, the first clamp 360, and the second clamp 365 cooperate to define an attachment assembly that supports the ground strip assembly 170.

To assemble the support bracket 40, a user first attaches the mounting plate 50 to the stationary component 35. As best illustrated in fig. 2, two fasteners 70 attach one end of the mounting plate 50 to the stationary component 35. Circular projections 380 extending from the stationary component 35 engage opposite ends of the mounting plate 50 and act as pins to maintain the position of the mounting plate 50. The support member 55, including the guide bar 130 and the sensor 140, is attached to the mounting plate 50 before or after it is attached to the stationary component 35. This assembly provides a mounting point on which the entire generator grounding module 45 can be placed or removed as desired and does not require any special tools, processes or procedures.

Referring to fig. 15, to assemble the generator grounding module 45, a user first positions the locking member 205 on the shaft 180 and positions the biasing element 200 adjacent to the locking member 205. The plate member 155 is then placed over the shaft 180 and the biasing element 200 is at least partially seated within the counterbore 260 of the first handle aperture 250 of the plate member 155. The first pin 190 is then positioned in the shaft 180 such that the plate member 155 is sandwiched between the first pin 190 (on one side) and the biasing element 200 and the locking member 205 (on the opposite side). The mounting block 160 is then positioned with the shaft 180 through the second handle aperture 300, as illustrated in fig. 15. The second pin 195 is then placed in the shaft 180 or has been positioned in the shaft 180 and passes freely through the second handle aperture 300. The grip portion 185 is then attached to the end of the shaft 180 to complete the assembly of the handle 150 into the generator grounding module 45. Once the grip portion 185 and the first pin 190 are in place, the handle 150, the plate member 155, and the mounting block 160 are connected to one another and cannot be separated without removing at least the grip portion 185 and/or the first pin 190.

Thereafter, the metal coil springs 220 are positioned in the respective recesses 255 and the free ends 235 extend toward the mounting block 160 at the mounting aperture 330 and are coupled to the mounting block 160. Once attached, the metal coil spring 220 defines a biasing assembly 165 and creates a biasing force that attempts to pull the mounting block 160 toward the plate member 155. In a preferred construction, threaded fasteners attach the free end 235 to the mounting block 160 and other attachment mechanisms (e.g., pins, rivets, adhesives, welding, soldering, brazing, etc.) are possible.

To complete the assembly of the generator grounding module 45, the conductor 400 includes a wire 405, two end connections 410, and two fasteners 415 attached at one end to the mounting block 160 and at the other end to the plate member 155. The conductor 400, best illustrated in fig. 16, ensures electrical connection between the mounting block 160 and the plate member 155 during operation.

The grounding bar assembly 170 is attached to the mounting arm 175 as described with respect to fig. 14. Mounting arm 175 is then positioned adjacent mounting block 160, and bearing member 310 is inserted into bearing aperture 305 with mounting arm 175 sandwiched therebetween. The bearing member 310 is fixedly attached to the mounting block 160 using fasteners that also attach the mounting arm 175 and the ground strip assembly 170 to the mounting block 160. In a preferred construction, the mounting arm 175 includes an aperture that allows passage of the bearing member 310 and any fasteners used to attach the bearing member 310. The lead screw 270 is then inserted through the bearing member 310 and the bushing 290 and screwed into the plate member 155. The guide screw 270 provides a guide for movement of the mounting block 160 relative to the plate member 155.

To complete the assembly, the generator grounding module 45 is attached to the support bracket 40 by passing the guide rods 130 through the guide rod holes 245, 295 in the plate member 155 and mounting block 160, as illustrated in fig. 3.

To assist or simplify assembly, prior to placing the generator grounding module 45 on the guide bar 130, a user first manipulates the handle 150 to configure the generator grounding module 45 into the first configuration (as shown in fig. 17 and 18). In the first configuration, the second pin 195 of the handle 150 is aligned with the fourth slot 320, passes through the fourth slot 320, and the handle 150 is then rotated to lock the position of the handle 150. As illustrated in fig. 17, in this position, the second pin 195 is disposed in the counterbore 325, but is rotated 90 degrees relative to the fourth slot 320 and is biased against the mounting block 160. The first pin 190 is disposed in the second slot 125 such that the first pin 190 and the shaft 180 do not extend below the plate member 155. In this configuration, the entire mounting block 160 is locked between the second pin 195 and the grip portion 185 such that the mounting block 160 and the plate member 155 are at their maximum separation distance. In this position, the grounding bars 370, 375 are retracted as far as possible from the rotor 10 and the biasing assembly 165 is fully extended.

While in this first configuration, the generator grounding module 45 is placed on the guide bar 130 and the plate member 155 is free to slide into contact with the support portion 80 of the support member 55. This configuration also advantageously pre-aligns the first pin 190 with the first slot 110, which allows a user to simply push the shaft 180 toward the support member 55 in order to move the first pin 190 through the first slot 110.

In the second or operating configuration illustrated in fig. 19, the second pin 195 of the handle 150 is disposed between the grip portion 185 and the mounting block 160. In this position, biasing assembly 165 pulls plate member 155 and mounting block 160 to their closest possible proximal position, thereby pulling biasing assembly 165 to its most retracted position. One of the bushing 290 and the coil spring 215, both disposed between the mounting block 160 and the plate member 155, engages both the plate member 155 and the mounting block 160 to stop any additional movement and define a proximal position between the mounting block 160 and the plate member 155.

To move the generator grounding module 45 from the first configuration to the second or operational configuration, a user first positions the generator grounding module 45 in the first configuration and places it on the guide bar 130 until the plate member 155 contacts the support member 55.

To move the generator grounding module 45 into operative engagement with the rotor 10 (i.e., engagement with the desired contact pressure between the bars 370, 375 and the rotor 10), the user begins with the generator grounding module 45 in the first configuration illustrated in fig. 17 and 18. In this configuration, the shaft 180 is positioned such that the first pin 190 is aligned with the first slot 110. The second pin 195 is preferably oriented at a ninety degree angle relative to the first pin 190 and can be used as a guide to properly orient the shaft 180. The user then pushes the shaft 180 toward the plate member 155. The locking member 205 and spring 215 urge the plate member 155 into engagement with the support portion 80 of the support member 55. Further pressure compresses the coil spring 215 against the plate member 155 and allows the user to push the shaft 180 until the first pin 190 passes through the first slot 110 and is disposed in the counterbore 120 of the support portion 80. The user then rotates the shaft 180 ninety degrees such that the first pin 190 engages the second slot 125 and the coil spring 215 holds the plate member 155 against the support member 55. Rotation of the handle 150 also aligns the second pin 195 with the fourth slot 320, which allows the biasing assembly 165 to pull the mounting block 160 toward the plate member 155 with a desired constant biasing force as the second pin 195 passes through the fourth slot 320. However, before the mounting block 160 reaches the fully retracted position (i.e., the second configuration shown in fig. 19), the ground bar assembly 170 contacts the rotor 10 and generates a force in the mounting arm 175 that opposes the biasing force. Once these forces are balanced, the generator grounding module 45 has reached an operating position in which the grounding bar assembly 170 is in contact with the rotor 10 at the desired contact pressure, as illustrated in fig. 16. In the operating position, the mounting block 160 is still spaced a non-zero distance from the actuation arm 145 of the switch 140.

Once the grounding bars 170 contact the rotor 10, the grounding path is fully established. The ground path begins at the ground strip 170 and flows into the mounting arm 175. From mounting arm 175, any current flows into mounting block 160, through conductor 400 into plate member 155, and finally into support member 55. The support member 55 can be grounded to the stationary component 35 by fasteners or additional wires, or the grounding path can continue to a current measuring device via wires for monitoring.

During operation, the rotor 10 attempts to wear the grounding bars 375 in contact with the rotor 10 such that the bars 375 will fail. The arrangement of the grounding bar assembly 170 provides a second grounding bar 370 that engages the rotor 10 upon failure of the first bar 375. The first grounding bar 375 engages the rotor 10 in a position maintained by a balance of forces between the mounting arm 175 and the biasing assembly 165. When the first grounding bar 375 fails, the force generated by the mounting arm 175 will drop because the desired contact pressure is no longer maintained. The biasing force created by biasing assembly 165 remains constant and thus causes mounting block 160 to move toward plate member 155 until second ground bar 370 contacts rotor 10 and the forces created by biasing assembly 165 and mounting arm 175 are again balanced.

Referring to fig. 16, movement of the mounting block 160 toward the plate member 155 may be measured or an indication of the movement may be provided. For example, the length of the guide screw 270 above the mounting block 160 may be measured periodically, with any increase in the measurement indicating that the first grounding bar 375 has failed. In other constructions, the guide screw 270 may include a colored strip that may be hidden under the mounting block 160 when both ground strips 370, 375 are intact. Once the first ground strip 375 fails, the colored strip will become visible. A second color may be provided to indicate when the two bars 370, 375 have failed.

As discussed above, the sensor 140 is provided in the form of a switch 140 and can be used to indicate when both ground bars 370, 375 have failed. Once the second grounding bar 370 fails, the biasing assembly 165 pulls the mounting block 160 toward the plate member 155 to a fully retracted position. In this position, the mounting block 160 contacts and actuates the actuation arm 145 of the switch 140. The switch 140 can be connected to an indicator (e.g., a visual device such as a light, an audible device such as an alarm, etc.) or to a control system to provide a direct indication that both grounding bars 370, 375 have failed upon actuation of the actuation arm 145.

In another configuration, the sensor 140 includes a position measuring sensor, such as an RVDT or an LVDT, which is capable of accurately measuring position changes. These sensors 140 may provide a signal to indicate a failure of the first grounding bar 375 and the second grounding bar 370 when the position changes by more than a fixed amount. In still other configurations, non-contact sensors, such as hall effect sensors and the like, may be used to detect movement of the mounting block 160 relative to the plate member 155.

Although exemplary embodiments of the present disclosure have been described in detail, those skilled in the art will understand that various changes, substitutions, variations and modifications disclosed herein may be made without departing from the spirit and scope of the present disclosure in its broadest form.

None of the description in this application should be read as implying that any particular element, step, or function is an essential element which must be included in the claim scope: the scope of patented subject matter is defined only by the allowed claims. Furthermore, unless the exact word "means" followed by a word claim, these claims are not intended to invoke a means-plus-function claim construct.