Bearingless Machine Portal for Fixture Alignment

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Solution Overview

Problem

Bearingless machines, such as permanent magnet motors and generators, face challenges in storage, transportation, and assembly due to the magnetic attraction between rotor and stator subassemblies, which can cause damage and misalignment, especially when integrated into drivelines where access to the air gap is limited.

Innovation Solution

The implementation of a rotating machine design with a stationary subassembly and a rotating subassembly, featuring a first circumferential track defined by a rotor track portion and a stator track portion, along with a portal in the stator casing, allows for the insertion and removal of assembly fixtures to maintain axial and radial alignment, reducing the need for separate support bearings and simplifying assembly, storage, and transportation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the rotor and stator subassemblies are transported separately, then shipping space is wasted, but if they are transported together, then magnetic attraction causes damage and misalignment

Engineering Contradiction:

Improveshipping space utilizationVSAvoidsubassembly alignment and damage prevention

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

A portal is provided in the stator subassembly that serves as an intermediary access point, allowing insertion and removal of fixtures through the stator without requiring disassembly. This mediator structure enables secure fixation of rotor and stator together during transport while maintaining the ability to separate them when needed, thus optimizing both space utilization and reliability

Inventive Principle:

Principle #24Intermediary (Mediator)

2Stability of the object's composition

If support bearings are used to maintain alignment, then assembly stability is improved, but device complexity increases

Engineering Contradiction:

Improveaxial and radial alignment stabilityVSAvoidnumber of support bearings and structures

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The invention extracts and eliminates the need for separate support bearings by integrating the alignment function directly into the stator-rotor assembly structure. The portal-based fixture system provides the necessary alignment stability without requiring additional bearing components, thus reducing device complexity while maintaining assembly stability

Inventive Principle:

Principle #2Taking out (Extraction)

3Manufacturing precision

If fixtures are inserted through the air gap, then alignment is maintained, but access to the air gap is required which is not available in integrated drivelines

Engineering Contradiction:

Improvealignment precision during assemblyVSAvoidaccessibility for fixture installation

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

Instead of accessing the air gap directly (the conventional approach), the invention inverts the approach by providing a portal through the stator subassembly. This allows fixtures to be inserted from the outside through the stator, bypassing the need to access the air gap, thus maintaining alignment precision while improving ease of operation in integrated driveline configurations

Inventive Principle:

Principle #13The other way round (Inversion)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution enables efficient and compact transportation and assembly of bearingless machines by maintaining subassembly alignment, preventing damage from magnetic forces and reducing the complexity of integration into drivelines, while eliminating the need for additional support structures.

Implementation Method 1

a fixture band (40A, 40B) disposed within the circumferential track (54A, 54B) to maintain axial and radial alignment of the rotor subassembly (22) relative to the stator subassembly (24)

Methodology Applied

Scientific EffectMechanical constraint: Mechanical Force

Implementation Method 2

the rotating magnetic fields generate an electrical current in one or more adjacent winding circuits disposed circumferentially around the outer stator assembly

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 3

currents induced in the winding circuits induce magnetic fields that can cause rotation of the shaft

Methodology Applied

Scientific EffectElectromagnetic force: Lorentz Force

Data Source

PatentEP2485373B1Bearingless machine

Publication Date: 2018.11.07 HAMILTON SUNDSTRAND CORP

Figure 1A
Figure 1B
Figure 2A~2C

AI summary

A rotating machine (16) comprises a stationary subassembly (24;124), a rotating subassembly (22; 122), and a first circumferential track (62A, 62B). The stationary subassembly (24; 124) includes a plurality of stator elements (30; 130) disposed proximate an inner circumference of a portion of the stationary subassembly (24; 124), and a casing having a first portal (34A). The rotating subassembly (22; 122) includes a plurality of rotor elements (28; 128) disposed proximate an outer circumference of a portion of the rotating subassembly (22; 122). The rotating subassembly (22; 122) is aligned coaxially within the stationary subassembly (24; 124) and is rotatable relative to the stationary subassembly (24; 124) without the aid of support bearings. The first circumferential track (62A, 62B) is defined by a first rotor track portion (62A) on the rotating subassembly (22; 122) and a first stator track portion (62B) on the stationary subassembly (24; 124), and is in communication with a first portal (34A) on the casing.