Cold Gas Sprayed Connecting Layer for Rotating Electrical Machine Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rotating electrical machines require numerous mechanical connecting elements and sealing elements, which complicate assembly, increase component variance, and can lead to media penetration, making them complex and difficult to clean.
Innovation Solution
A continuous connecting layer produced by cold gas spraying is used to firmly connect machine components, eliminating the need for mechanical connecting elements and serving as a seal, thereby simplifying assembly and design while reducing component complexity and media penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical connecting elements and sealing elements are used to connect machine components, then the connection strength and sealing function are ensured, but the number of components increases and assembly complexity increases
Solution Approach 1:
The patent combines multiple functions (connection and sealing) into a single integrated layer. The connecting layer is applied continuously across machine components, simultaneously providing mechanical bonding and sealing against media penetration, thereby eliminating the need for separate mechanical fasteners and sealing elements
Solution Approach 2:
The patent replaces traditional mechanical connection systems (screws, bolts, clips) and sealing systems (gaskets, O-rings) with a cold gas sprayed connecting layer. This coating-based system uses material deposition and adhesion mechanisms rather than mechanical interlocking, achieving both connection and sealing functions
2Strength
If mechanical connecting elements are used to connect machine components, then the connection strength is ensured, but the assembly process becomes more complex
Solution Approach 1:
The patent replaces complex mechanical assembly operations (threading, fastening, positioning) with a coating application process. The connecting layer is applied continuously over the machine components, creating bonds as the coating is deposited, thereby eliminating the need for separate fastening operations and complex positioning procedures
Solution Approach 2:
The connecting layer is applied in advance to machine components before final assembly operations. This preliminary coating creates pre-bonded surfaces that simplify subsequent assembly steps, as components are already partially secured and sealed by the connecting layer before final positioning
3Reliability
If machine components have interfaces for mechanical connecting elements and sealing elements, then the connection and sealing functions are achieved, but the design complexity increases
Solution Approach 1:
The patent merges multiple functional interfaces (threaded connections, sealing recesses, gasket mounting surfaces) into a single continuous connecting layer application area. This eliminates the need for diverse interface geometries and allows machine components to be designed with simpler, more uniform surfaces
Solution Approach 2:
The connecting layer serves multiple functions simultaneously: mechanical bonding, sealing against media penetration, and surface protection. This multi-functionality eliminates the need for specialized interfaces for each function, allowing machine components to have more universal, simplified designs
4Reliability
If numerous mechanical connecting elements and sealing elements are used, then the connection and sealing functions are ensured, but the outer surface becomes rougher and harder to clean
Solution Approach 1:
The connecting layer creates a continuous, unified surface that integrates the machine components into a smoother overall structure. By eliminating protruding fasteners, sealing grooves, and interface features, the outer surface becomes more uniform and easier to clean
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 solution reduces the number of components, simplifies assembly, improves heat dissipation, and enhances sealing, making the machine surface smoother and easier to clean, with cost-effective material usage and improved heat dissipation using aluminum or steel alloys for the connecting layer.
Implementation Method 1
A continuous coating with a connecting layer produced by cold gas spraying, by means of which several machine components of the electric machine are firmly connected to one another
Data Source
Figure 1
AI summary
The invention relates to a rotating electric machine (1) which has a continuous coating containing a joining layer (15) which is created using cold spraying and by means of which a plurality of machine components (5, 7, 11, 13) of the electric machine (1) are fixedly joined to each other and an outer surface (25) of the electric machine (1) is formed.