Blade-Arm Rotor Structure for Strength and Winding Ventilation

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Solution Overview

Problem

Existing rotors for electromagnetic retarders and generators are not robust enough and lack effective ventilation for the windings, leading to potential mechanical deformation and inadequate cooling.

Innovation Solution

A rotor design featuring fixing arms with a blade shape and specific inclinations, along with cooling fins and a ring structure, enhances mechanical strength and ventilation, directing air to improve cooling and reduce deformation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the rotor uses a conventional structure with interior ring, flange and cylindrical body, then the structure is simple, but the mechanical strength is insufficient and severe deformation can occur

Engineering Contradiction:

Improvemechanical strengthVSAvoidstructure complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The rotor structure is segmented into interior ring, cylindrical body, and multiple fixing arms. The fixing arms are further divided into proximal portion and distal portion with different functions. This segmentation allows each part to be optimized independently for strength and function.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The fixing arms extend in the radial direction from the interior ring to the cylindrical body, adding a radial dimension to the structure. The distal portion is inclined at an angle between 10° and 30° relative to the radial direction, introducing angular orientation to enhance mechanical strength and ventilation.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Temperature

If the rotor uses conventional design, then manufacturing is easier, but ventilation for windings is inadequate leading to poor cooling

Engineering Contradiction:

Improvecooling efficiencyVSAvoidmanufacturing ease

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The fixing arms have different properties in different sections: the proximal portion is curved to facilitate ventilation, while the distal portion is inclined to provide structural strength. The blade shape with specific dimensions creates localized ventilation channels without compromising overall structural integrity.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The fixing arms create ventilation channels that allow air flow through the rotor structure. The curved proximal portion and inclined distal portion work together to guide air flow for effective cooling of windings while maintaining mechanical strength.

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Strength

If fixing arms are added for strength and ventilation, then mechanical strength and cooling improve, but aerodynamic losses increase

Engineering Contradiction:

Improvemechanical strengthVSAvoidaerodynamic losses

Core Design Contradiction:

StrengthVSLoss of energy

Solution Approach 1:

The fixing arms are designed with specific curvature and inclination angles to optimize performance. The distal portion inclination angle between 10° and 30° is optimized to balance structural strength with aerodynamic efficiency, reducing turbulence and energy losses.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The geometry parameters of the fixing arms are precisely controlled: the proximal portion has a radius of curvature between 5mm and 15mm, the distal portion has length between 30mm and 60mm, and the inclination angle is between 10° and 30°. These parameter optimizations reduce aerodynamic losses while maintaining strength.

Inventive Principle:

Principle #35Parameter changes

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

The new rotor design increases mechanical strength and cooling efficiency, reducing plastic deformation and aerodynamic losses while enhancing the electrical performance of the rotating electrical machine.

Implementation Method 1

The fixing arms advantageously make it possible to increase the cooling of the cylindrical body by ventilation

Methodology Applied

Scientific EffectForced Convection: Forced Convection

Implementation Method 2

each fixing arm being inclined so that the first edge of the distal end of the fixing arm is at an inclination angle between 40 degrees and 60 degrees inclusive, preferably 45 degrees, to the straight line segment

Methodology Applied

Scientific EffectAerodynamic flow direction:

Data Source

PatentUS20250219483A1Rotating electrical machine rotor and electromagnetic retarder and generator assembly

Publication Date: 2025.07.03 TELMA SA

AI summary

A rotating electrical machine rotor, the rotor being able to turn about a rotation axis, with a transverse plane being perpendicular to the rotation axis, the rotor including: an interior fixing ring; a cylindrical body having a peripheral face, wherein the cylindrical body and the interior fixing ring being coaxial; and fixing arms having a blade shape having two main faces, wherein the fixing arms comprising a distal portion connected to the cylindrical body, the distal portion being inclined so that the main faces of the distal end of the fixing arms are at an inclination angle between 40 degrees and 60 degrees inclusive to the radial plane.