Introduction
A HOUCHIN AEROSPACE generator rated at 140 kW and operating at 400 Hz was brought into our workshop after a failed repair attempt by an external service provider. At first glance, the makeshift connection terminals indicated poor workmanship and improper handling.
Issues Identified
During our in-depth diagnostic inspection, the following issues were found:
- The bearing housing was damaged, and the bearing seat was worn out.
- A short circuit was present in the stator windings.
- Several diodes were defective.
Repair Work Performed
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Complete Disassembly and Diagnosis:
- The generator was fully disassembled to conduct a detailed inspection of all components.
- All previously mentioned issues were confirmed: damaged bearing housing, shorted stator windings, and failed diodes.
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Replacement of the Diode Bridge:
- The faulty diodes were removed and replaced, and a new diode bridge was installed to restore proper generator function.
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Stator Rewinding and Impregnation:
- The stator windings were completely rewound using high-quality materials.
- After rewinding, the stator was impregnated to enhance insulation and long-term durability.
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Restoration of the Bearing Seat and Bearing Replacement:
- The worn bearing seat was restored to its original dimensions and specifications.
- A new bearing, matching the manufacturer’s requirements, was installed.
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Full Reassembly and Electrical Testing:
- The generator was reassembled completely and subjected to a series of electrical tests.
- Testing included short circuit checks, load tests, and a full operational performance evaluation.
Result
Upon completion of all repairs and testing, the HOUCHIN AEROSPACE 140 kW 400 Hz generator was fully restored and ready for operation. Testing confirmed stable and reliable performance, validating the quality of the repair work.
Conclusion
The restoration of the HOUCHIN AEROSPACE 140 kW 400 Hz aircraft generator involved complete disassembly, thorough diagnostics, replacement of the diode bridge, stator rewinding and impregnation, restoration of the bearing seat, and installation of a new bearing. Each step was executed with precision and high-quality materials, resulting in a fully functional generator that meets performance expectations for reliable and long-lasting use.
