Reverse Engineered Collector Ring Standoff

  • 40+ years old
  • Insulators had failed & spares no longer existed
  • OEM would recreate the parts but many months to retool and expensive ($200k+)
  • Project had been on hold with the utility for months holding up $100k+ in billings for service center
  • Other fabricators similar to CMI had declined to take on the project
  • CMI solution:
  • Reverse engineered standoff by dissecting previous construction
  • Develop drawings for individual components and recommend alternate materials and construction
  • Identified 3rd party independent lab for essential mechanical and electrical testing requirements
  • Coordinated with service center and end utility on construction, schedule and testing
  • Delivered product successfully within 8 weeks of drawing and 3rd party testing approval

    Stator end support rings

    Stator End Support Rings

  • Factory Lead time too long for scheduled outage.
  • Another fabricators attempt was too flimsy for casting process.
  • CMI created temporary tooling for faster turnaround and utilized one of our existing resins.
  • Tooling, molding and machining completed in 3 weeks.
  • More permanent and universal tooling is being designed for downstream requirements.

  • CMI was approached by a local large motor repair facility because of some problems they were having with some composite end turn encapsulation rings critical to the insulation system of the end turn windings used on a large 1000hp motor. The product that had been initially procured from another supplier had severely distorted most likely due to the nature of the final processing that IPS has to perform which includes a high temperature bake cycle. Coupled with this problem was that IPS was under pressure to get the project back on schedule with their customer. CMI put into action its engineering and fabrication expertise to come up with a viable solution. CMI engineers used their vacuum infusion experience while also coming up with a high temperature resin system to tackle this problem and not only hit the deadline that IPS was requesting, but put the entire project ahead of the original schedule originally committed to by IPS to the end user.

    Amtrack Success Story

    Amtrak has purchased a substation to be installed in Philadelphia. Siemens Energy & Automation is building the Static Frequency converter for this station. The static frequency converter will be five times larger than the largest converter currently in operation. The substation will power the trains from Washington, DC to New York. The drip pan is used on all inverter cubicles and chopper cubicles. There are 40 inverter cubicles and 5 chopper cubicles. The pan is used to help protect the lower module from water should there be a leak in the upper module. The initial design created problems with the sidepieces breaking off of the actual pan. Your design of the pan solved the problem and created a quality product. Without this pan the risk of module failure caused by water leaks would have created a serious safety issue. As shown in the photo below the pan fits between the bottom module and the capacitor bank. Thank you for the innovative design and the quality product. We could not have made this work without your help.