Wedge for electric motor

Abstract

The rotor includes a laminated core defining magnetic poles and pole shoes. The pole shoe defines a slot for the coil. An outer wedge is disposed in the slot. The outer wedge includes a top portion disposed at an outer diameter of the rotor. The top portion includes an upper surface and a lower surface. The upper and lower surfaces form a continuous curve that presses against the pole shoe. The upper surface creates a first seal and the lower surface creates a second seal. The outer wedge also includes a bottom portion continuously connected to the top portion and in contact with the coil wire. The bottom includes a winding support surface and a wedge tip surface. The winding support surface is connected to the lower surface of the top. The wedge tip surface extends along the wedge center axis toward the laminated core.

Description

Technical Field

[0001] This disclosure relates to a wedge for an electric motor. More specifically, this disclosure relates to a wedge for an independently excited rotor in an electric motor, the wedge compressing a coil and sealing it to the rotor to retain cooling fluid therein. Background Technology

[0002] Independently driven synchronous motors (SESMs) typically consist of a stator and a rotor. Instead of permanent magnets in the rotor, SESMs include coils that generate the rotor's magnetic field. Therefore, the rotor's magnetic field can be adjusted by the level of current applied to the coils.

[0003] The rotor comprises a laminated iron core with magnetic poles and pole shoes defining slots. Coils are disposed within the slots and wound around the magnetic poles. As current is applied to the coils, the rotor begins to rotate at high speed. As it rotates, the coils undergo strain through radial forces and may become misaligned.

[0004] One solution is to insert a wedge into the slot. The wedge presses against the coil, protecting it and maintaining alignment. While effective, there is a need in the art for an improved wedge design that provides a stronger seal between the wedge and the pole shoe, and that allows additional coils to be placed in the slot while maintaining compression of the coil during high rotational speeds. Summary of the Invention

[0005] According to several aspects, a wedge-shaped member for a rotor is provided. The rotor includes a laminated iron core defining a rotation axis, magnetic poles, and pole shoes, wherein the rotor defines slots for receiving coils. The wedge-shaped member includes an outer wedge-shaped member defining a wedge-shaped central axis perpendicular to the rotation axis. The outer wedge-shaped member is disposed in the slot. The outer wedge-shaped member includes a top disposed at the outer diameter of the rotor. The top includes an upper surface that is inclined away from the wedge-shaped central axis and moves radially outward and vertically from the rotor axis. The upper surface presses against the pole shoes to form a seal. The outer wedge-shaped member also includes a lower surface that is inclined toward the wedge-shaped central axis and moves radially outward and vertically from the rotor axis. The lower surface seals to the pole shoes when a radial load is present. The upper and lower surfaces form a continuous curve. The outer wedge-shaped member also includes a bottom continuously connected to the top. The bottom includes a winding support surface connected to the lower surface of the top. The bottom also includes a wedge-shaped tip surface. The wedge-shaped tip surface extends along the wedge-shaped central axis toward the laminated iron core. The winding support surface and the wedge tip surface are adjacent to the coil.

[0006] In another aspect of this disclosure, the outer wedge includes a protrusion disposed between a lower surface at the top and a winding support surface at the bottom.

[0007] In another aspect of this disclosure, the varnish manifold is defined by a raised portion and a pole shoe. The varnish manifold enables the varnish to cover the sealing space between the coil and the laminations forming the laminated core.

[0008] In another aspect of this disclosure, the outer wedge includes a flexible hinge located where the lower surfaces of the top and bottom of the outer wedge meet. The flexible hinge allows the top to move independently relative to the bottom.

[0009] In another aspect of this disclosure, the winding support surface forms an inclined plane away from the central axis of the wedge, while moving radially outward and perpendicular to the rotor axis.

[0010] In another aspect of this disclosure, the wedge also includes an inner wedge. The inner wedge is disposed within a groove of the outer wedge. The inner wedge matches the contour of the inner surface of the outer wedge and compresses the pole shoe and winding support surface.

[0011] In another aspect of this disclosure, the inner wedge defines a shaped hole along its axial length. This shaped hole increases the absorption of radial loads. The shaped hole also allows for adjustable compressive stiffness from one magnetic pole to the adjacent magnetic pole.

[0012] In another aspect of this disclosure, the inner wedge includes pockets. Each pocket is of a different size to adjust stiffness along the length of the wedge's axis.

[0013] In another aspect of this disclosure, the pocket is located on the upper surface of the inner wedge. The upper surface of the inner wedge is positioned at the outer diameter of the rotor.

[0014] In another aspect of this disclosure, the pocket is located on the side of the inner wedge. The side of the inner wedge contacts the inner surface of the outer wedge.

[0015] According to several aspects, a wedge-shaped member for a rotor is provided. The rotor includes a laminated iron core defining a rotation axis, magnetic poles, and pole shoes, wherein the rotor defines slots for receiving coils. The wedge-shaped member includes an outer wedge-shaped member defining a wedge-shaped central axis perpendicular to the rotation axis. The outer wedge-shaped member is disposed in the slot. The outer wedge-shaped member includes a top disposed at the outer diameter of the rotor. The top includes an upper surface that is inclined away from the wedge-shaped central axis while moving radially outward and vertically from the rotor axis. The upper surface presses against the pole shoes to form a seal. The top also includes a lower surface that is inclined toward the wedge-shaped central axis while moving radially outward and vertically from the rotor axis. When a radial load is present, the lower surface seals to the magnetic poles. The upper and lower surfaces form a continuous curve. The outer wedge-shaped member also includes a bottom. The bottom is continuously connected to the top. The bottom includes a winding support surface connected to the lower surface of the top. The bottom also includes a wedge-shaped tip surface. The wedge-shaped tip surface extends along the wedge-shaped central axis toward the laminated iron core. The winding support surface and the wedge tip surface are adjacent to the coil. The wedge also includes an inner wedge. The inner wedge is disposed within a groove of the outer wedge. The inner wedge generates compression in the pole shoe and the winding support surface.

[0016] In another aspect of this disclosure, a varnish manifold is provided. The varnish manifold is defined by pole shoes, and the lower surfaces of the top and bottom of an outer wedge are connected to the pole shoes. The varnish manifold enables varnish to cover the sealing space between the coil and the laminations forming the laminated core.

[0017] In another aspect of this disclosure, the outer wedge includes a flexible hinge, wherein the lower surfaces of the top and bottom of the outer wedge are connected. The flexible hinge allows the top to move independently relative to the bottom.

[0018] In another aspect of this disclosure, the winding support surface forms an inclined plane away from the central axis of the wedge, while moving radially outward and perpendicular to the rotor axis.

[0019] In another aspect of this disclosure, the inner wedge defines a shaped hole along its axial length. This shaped hole increases the absorption of radial loads. The shaped hole also allows for adjustable compressive stiffness from one magnetic pole to the adjacent magnetic pole.

[0020] In another aspect of this disclosure, the inner wedge matches the contour of the inner surface of the outer wedge.

[0021] In another aspect of this disclosure, the inner wedge includes pockets. Each pocket is of a different size to adjust stiffness along the length of the wedge's axis.

[0022] In another aspect of this disclosure, the pocket is located on the upper surface of the inner wedge. The upper surface of the inner wedge is positioned at the outer diameter of the rotor.

[0023] In another aspect of this disclosure, the pocket is located on the side of the inner wedge, wherein the side of the inner wedge contacts the inner surface of the outer wedge.

[0024] According to several aspects, a rotor for an independently excited synchronous motor is provided. The rotor includes a laminated iron core, copper windings, and a wedge. The laminated iron core includes magnetic poles defining slots and pole shoes. The copper windings are wound with multiple magnetic poles. The wedge includes an outer wedge. The outer wedge defines a wedge central axis perpendicular to the axis of rotation. The outer wedge is disposed in a slot. The outer wedge includes a top disposed at the outer diameter of the rotor. The top includes an upper surface. The upper surface presses against the pole shoes to create a first seal. The top also includes a lower surface. The lower surface presses against the pole shoes to create a second seal. The outer wedge also includes a bottom. The bottom is continuously connected to the top. The bottom includes a winding support surface connected to the lower surface of the top. The bottom also includes a wedge tip surface. The wedge tip surface extends along the wedge central axis toward the laminated iron core. The wedge also includes an inner wedge. The inner wedge is disposed within a groove of the outer wedge. The inner wedge compresses the pole shoes and the winding support surface.

[0025] Further areas of application will become clear from the description provided herein. It should be understood that the specification and specific embodiments are for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description

[0026] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of this disclosure in any way.

[0027] Figure 1 This is an isometric view of a SESM rotor with wedge-shaped elements according to the principles of this disclosure.

[0028] Figure 2 It is along Figure 1 Cross-sectional view of the rotor viewed in the direction of the middle arrow 2-2.

[0029] Figure 3 This is an enlarged cross-sectional view of the wedge-shaped part.

[0030] Figure 4A This is an enlarged cross-sectional view of an alternative embodiment of a wedge-shaped member with a flexible hinge.

[0031] Figure 4B This is an enlarged cross-sectional view of another alternative embodiment of the wedge-shaped member with a flexible hinge.

[0032] Figure 5A This is an isometric view of the inner wedge-shaped part.

[0033] Figure 5B It is along Figure 5A The cross-sectional view of the inner wedge-shaped part is observed in the direction of arrow 5B-5B.

[0034] Figure 6A This is an enlarged cross-sectional view of another alternative embodiment of the wedge with an inner wedge having a shaped hole.

[0035] Figure 6B This is an enlarged cross-sectional view of another alternative embodiment of the wedge with an inner wedge having a shaped hole.

[0036] Figure 7 This is a cross-sectional view of an alternative embodiment of the inner wedge. Detailed Implementation

[0037] The following description is merely exemplary in nature and is not intended to limit this disclosure, application, or use.

[0038] refer to Figure 1 and Figure 2 The diagram illustrates a plurality of wedge-shaped members 10 according to the principles of this disclosure, having an exemplary rotor 12. The rotor 12 is part of an independently excited synchronous motor (SESM) (not shown). When current is applied to the rotor 12, the SESM converts electrical energy into mechanical energy. The rotor 12 includes a laminated iron core 14 and copper windings 16.

[0039] The laminated core 14 supports the copper winding 16 and includes a plurality of laminations 18. The laminations 18 are stacked together to form the laminated core 14. The laminated core 14 is connected to the output shaft 20 of the rotor 12. The output shaft 20 defines the axis of rotation 22 of the rotor 12 about which the rotor 12 rotates.

[0040] like Figure 2 As shown, the laminated iron core 14 includes a plurality of magnetic poles 24 extending radially away from the axis of rotation 22. Each magnetic pole 24 has a curved exterior 34. Adjacent magnetic poles 24 define slots 26 within the laminated iron core 14. Each magnetic pole 24 also includes a pole shoe 28. The pole shoe 28 is disposed at the radially distal end 30 of the magnetic pole 24 and extends circumferentially away from the magnetic pole 24. Adjacent pole shoes 28 define gaps 32 in the curved exterior 34 of the laminated iron core 14. The gaps 32 communicate with the slots 26 and are sized to receive wedges 10, which will be described in more detail below.

[0041] The copper winding 16 is the conductor wound around the laminated iron core 14. A portion of the copper winding 16 is wound around each magnetic pole 24 to form a coil 36. The coil 36 is disposed within the slot 26. When current is applied to the copper winding 16, the rotor 12 begins to rotate at high speed.

[0042] Now for reference Figure 3An enlarged view of one of the plurality of wedges 10 is shown. It should be understood that each wedge 10 is identical, therefore only one wedge 10 is described here. For clarity, the coil 36 to the left of the slot 26 is not shown. The wedge 10 is used to compress adjacent coils 36 and form a seal against the laminated core 14. The wedge 10 includes an outer wedge 40 and an inner wedge 42 disposed within the outer wedge 40.

[0043] The outer wedge 40 includes a top 44 and a bottom 46. The top 44 is disposed radially outward from the bottom 46. The top 44 and the bottom 46 define a central axis 48 of the wedge, which extends from the bottom 46 to the top 44 along the center line of the wedge 10. The central axis 48 of the wedge is perpendicular to the rotor 12 (e.g., Figure 1-2 (as shown) and output shaft 20 (as shown) Figure 1-2 The rotation axis 22 (as shown) extends.

[0044] The outer wedge 40 includes an inner surface 50 and an outer surface 52. The inner surface 50 defines a groove for receiving the inner wedge 42. The groove extends lengthwise along the axis of the outer wedge 40. The outer surface 52 of the top 44 includes a plurality of features configured to seal to the pole shoe 28 under various conditions. The top 44 includes an upper surface 54 and a lower surface 56.

[0045] The upper surface 54 is inclined away from the central axis 48 of the wedge and moves toward the outer diameter of the rotor 12. The upper surface 54 presses against the pole shoe 28, creating a first seal. The first seal is maintained when the rotor 12 is stationary, and the first seal decreases as the rotational speed increases.

[0046] The lower surface 56 is inclined toward the central axis 48 of the wedge and moves toward the outer diameter of the rotor 12. The lower surface 56 presses against the pole shoe 28, creating a second seal. The second seal remains stationary and is also maintained under radial force when the rotor 12 rotates.

[0047] The bottom 46 presses against the coil 36, maintaining the alignment of the coil 36 within the slot 26. The bottom 46 includes a winding support surface 58 and a wedge tip surface 60. The winding support surface 58 connects to the lower surface 56 and forms an inclined plane away from the wedge's central axis 48, while moving towards the outer diameter of the rotor 12. The wedge tip surface 60 extends towards the output shaft 20 (e.g., ...). Figure 1-2 (As shown).

[0048] The top 44 and the bottom 46 are continuously connected together by a protrusion 62. The protrusion 62 connects the lower surface 56 of the top 44 to the winding support surface 58 of the bottom 46.

[0049] In an alternative embodiment, the top 44 and the bottom 46 are continuously connected together by a flexible hinge 70, such as Figure 4A As shown. The flexible hinge 70 includes a flexible region that allows independent compression between the pole shoe 28 and the coil 36. The flexible hinge 70 contacts the coil 36 and allows the winding support surface 58 to exert greater compression on the coil 36. The coil 36 has looser tolerances and lower stiffness.

[0050] exist Figure 4B An alternative embodiment of the flexible hinge 70, indicated by reference numeral 72, is shown. The flexible hinge 72 is similar to... Figure 4A The flexible hinge 70 is shown. However, Figure 4B The flexible hinge 72 shown contacts the pole shoe 28. The flexible hinge 72 allows for independent compression between the pole shoe 28 and the coil 36. The coil has looser tolerances and lower stiffness, allowing for greater compression of the coil conductor 36 by the winding support surface 58.

[0051] Back Figure 3 An inner wedge 42 is disposed within a groove of an outer wedge 40. The inner wedge 42 matches the contour of the outer wedge 40 and extends lengthwise along the axis of the outer wedge 40, thereby generating contact pressure against the outer wedge 40. The inner wedge 42 includes... Figure 5A and Figure 5B The pocket 74 is shown. This pocket 74 is disposed on the inner wedge 42 at the outer diameter of the rotor 12. The length and depth of the pocket 74 vary, thereby providing customized stiffness for the outer wedge 40.

[0052] In an alternative embodiment, pocket 74 is... Figure 7 Pocket 76 is shown instead. Pocket 76 is similar to... Figure 5A and 5B Pocket 74 is shown. Pocket 76 provides customized stiffness for the outer wedge 40. However, pocket 76 is located on the side 78 of the inner wedge 42 and is positioned with respect to the outer wedge 40 (as shown). Figure 1-3 The protruding portion 62 (as shown) Figure 3 (As shown) Contact.

[0053] In another alternative embodiment, the inner wedge 42 defines a forming hole 80, such as... Figure 6A and Figure 6B As shown. The shape of the forming hole 80 can vary and extends lengthwise along the axis of the inner wedge 42. The forming hole 80 helps to absorb winding tolerances and hold the wedge 10 (as shown). Figure 2-3 (as shown) and extreme boot 28 (as shown) Figure 2-3 The forming hole also allows for adjustable compressive stiffness from magnetic pole 24 to adjacent magnetic pole 24. The forming hole 80 can be elliptical (as shown). Figure 6A ) or teardrop-shaped ( Figure 6B ).

[0054] Now back Figure 1-3 The outer wedge 40 is inserted into the slot 26 using a tool (not shown). Once inserted, the outer wedge 40 presses against the pole shoe 28 and the coil 36. The top 44 forms two seals on the pole shoe 28. The upper surface 54 of the top 44 creates a first seal, which is maintained when the rotor 12 is stationary. The lower surface 56 of the top 44 creates a second seal, which is maintained when the rotor 12 is subjected to high rotational speeds. The inner wedge 42 is inserted into the outer wedge 40 and further reinforces the first and second seals by applying contact pressure to the outer wedge 40.

[0055] The bottom 46 compresses and maintains the alignment of the coil 36. Wire varnish is inserted to further maintain the alignment of the wire coil 36 and to protect it from strain due to the presence of radial loads. The insertion of the wire varnish also seals the space between the laminations 18 that form the laminated core 14. The wire varnish is inserted through the varnish manifold 64 (as shown). Figure 2-3 (As shown). The varnish manifold 64 is defined by the protrusion 62 of the outer wedge 40, the pole shoe 28, and the coil 36.

[0056] The advantages of the wedge 10 design include forming two seals with the pole shoe 28, with the second seal maintained during high rotational speeds. Additionally, the wedge 10 creates a strong seal with the pole shoe 28 while covering a small surface area of ​​the groove 26. This allows for the use of an additional coil 36 or a thicker coil 36.

[0057] The description in this disclosure is exemplary in nature only, and variations thereof without departing from the spirit of this disclosure are intended to be within the scope of this disclosure. Such variations should not be considered as a departure from the scheme and scope of this disclosure.

Claims

1. A wedge for a rotor, the rotor including a laminated iron core defining an axis of rotation, magnetic poles, and pole shoes, wherein the rotor defines slots for receiving coils, the wedge comprising: An outer wedge, the outer wedge defining a wedge-shaped central axis perpendicular to the axis of rotation, wherein the outer wedge is disposed in the groove, the outer wedge comprising: The top, located at the outer diameter of the rotor, comprises: The upper surface, inclined away from the central axis of the wedge and moving radially outward and vertically from the rotor axis, wherein the upper surface is compressed against the pole shoe to create a seal; and The lower surface is inclined toward the central axis of the wedge and moves radially outward and vertically from the rotor axis, wherein the lower surface seals to the pole shoe under radial load. The upper surface and the lower surface form a continuous curve; and The bottom, which is continuously connected to the top, includes: A winding support surface, the winding support surface being connected to the lower surface of the top; and The wedge tip surface, wherein the wedge tip surface extends along the central axis of the wedge toward the laminated iron core. The winding support surface and the wedge tip surface are adjacent to the coil.

2. The wedge according to claim 1, wherein the outer wedge includes a protrusion disposed between the lower surface at the top and the winding support surface at the bottom.

3. The wedge of claim 2, further comprising a varnish manifold defined by the protrusion and the pole shoe, wherein the varnish manifold allows varnish to cover the coils and sealing spaces between the laminations forming the laminated core.

4. The wedge of claim 1, wherein the outer wedge includes a flexible hinge, the lower surface of the top of the outer wedge and the bottom of the outer wedge are connected at the flexible hinge, the flexible hinge allowing the top to move independently relative to the bottom.

5. The wedge according to claim 1, wherein the winding support surface forms an inclined surface away from the central axis of the wedge, and moves radially outward and perpendicular to the rotor axis.

6. The wedge member according to claim 1, further comprising an inner wedge member disposed within a groove of the outer wedge member, wherein the inner wedge member matches the contour of the inner surface of the outer wedge member and generates compression on the pole shoe and the winding support surface.

7. The wedge of claim 6, wherein the inner wedge defines a shaped hole along the axial length of the wedge, the shaped hole increasing the absorption of the radial load and allowing adjustable compressive stiffness from the magnetic pole to the adjacent magnetic pole.

8. The wedge of claim 6, wherein the wedge further comprises pockets located on the inner wedge, the pockets being of different sizes to adjust stiffness along the axial length of the wedge.

9. The wedge of claim 8, wherein the pocket is located on the upper surface of the inner wedge, wherein the upper surface of the inner wedge is disposed at the outer diameter of the rotor.

10. The wedge of claim 8, wherein the pocket is located on the side of the inner wedge, wherein the side of the inner wedge contacts the inner surface of the outer wedge.

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