- Conference Article
- 10.1109/pcic47468.2025.11289158
Maintaining and Monitoring Stator End-Windings on Electrical Rotating Machines
- Sep 22, 2025
- Alexandre B Romanato + 2 more +2
The stator end-windings are critical focus area in large electrical rotating machines, particularly in medium and high voltage motors and generators. These components face numerous challenges due to the elevated voltage gradients, exposure to cooling media, vibration, and the manual, handcrafted nature of their construction. The intricacies involved in forming and connecting the end-windings make them susceptible to more variation than other parts of the winding, potentially introducing imperfections that can impact the reliability and performance of the machines over time. The importance of maintaining and monitoring end-windings cannot be overstated, as they are vital for the overall health and reliability of electrical rotating machines. Continuous improvement and focus on potential interventions are essential for owners, operators, and service engineers. This paper aims to share practical experiences in assessing end-windings, identifying early indications of potential issues, and presenting case studies where corrective actions were successfully implemented to avert catastrophic failures and to improve the service life. The discussion will emphasize also on challenges associated with on-site repairs. Often, there is a pressing need to design specialized tools and engineer processes that can be executed in-situ, ensuring the quality of repairs matches that expected from a dedicated service shop facility. The paper will cover various assessment techniques, both visual and measurable, to highlight areas where existing literature is sparse. This information aims to support engineering and technical consultants in determining the ideal timing for interventions and improving the overall maintenance strategy for stator. By focusing on real-world problems and solutions, this paper intends to provide valuable insights into the end-winding maintenance and repair process. It will offer practical guidance to those involved in the operation/servicing of rotating machines.
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