Underfloor generator repair and test station

The station combines workplaces for the complete repair cycle of passenger car underfloor generators — DC and AC machines rated up to 35 kW, including the generators of air-conditioned cars. Disassembly, inspection, bearing replacement, assembly and final load testing with a test report are all carried out in one area.

The repair part is built around a tilter with an electromechanical rotation drive: a generator weighing up to 1200 kg is clamped by its feet or flange and rotated through 360° with locking every 90°, giving access to the bearing end shields, commutator or slip rings and terminal box without re-slinging. Next to it are a table with a hydraulic press for pressing bearings off and on, and a rack for storing assemblies in disassembly order.

The test rig drives the generator from an electric motor through a V-belt transmission with a tensioner; the speed is set by a frequency converter across the whole working range, including the minimum excitation speed. The load bank — a sectional resistor block with forced cooling — loads the generator in steps up to rated power. The measuring system records voltage, current, speed, winding and bearing temperatures and the excitation cut-in point; the results are written to the test report.

The station is configured for the customer's range of generators: adapter plates for different flanges, pulleys for the standard sizes, fixtures for winding insulation checks and rotor balancing. Individual modules — the tilter or the test rig — can be supplied separately.