Finite Element Analysis Design of a Split Rotor Bracket for a Bulb Turbine Generator

The rotor bracket is a key component of the generator rotor with cracks in the rotor bracket leading to rubbing between the rotor and stator, which threatens safe operation of the unit. The rotor rim is so complicated that the equivalent radial stiffness of rim was determined by numerical simulation other than engineering experience. A comprehensive numerical method including finite element analyses and the contact method for multibody dynamics has been used to design the split rotor bracket. The com-putational results showed that cracks would occur in the initial design of the bracket when the turbine operated at the runaway speed, and the bracket design should be improved. The improved design of the bracket was strong enough to avoid cracks and rub between the rotor and stator. This design experience will help improve the design of split rotor brackets for bulb turbine generators.