Composite Rotor Support for Winding Stability Under High Loads
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Solution Overview
Problem
Rotors for current-excited synchronous machines face issues with mechanical stabilization of windings due to high loadings, leading to potential cracks in potting compounds, which are not adequately addressed by existing production methods.
Innovation Solution
A rotor design incorporating a support element composed of composite material, comprising matrix and fiber materials, which is shaped around the winding and solidified to provide mechanical stabilization, allowing for a weight-optimized structure with reduced crack formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rotor laminated core with wound rotor windings is overmolded under high pressure with a plastics compound for mechanical stabilization, then the winding stability is improved, but cracks can form in the potting compound which compromises reliability
Solution Approach 1:
The invention replaces the homogeneous plastics compound with a composite material consisting of fiber reinforcement (such as glass fibers) embedded in a matrix material. This composite structure provides both the mechanical stabilization needed to secure the windings and the crack resistance required for reliable operation under high centrifugal forces and temperature variations.
Solution Approach 2:
The invention changes the material parameters by transitioning from a pure plastics compound to a fiber-reinforced composite material. This parameter change fundamentally alters the mechanical properties, providing enhanced tensile strength, stiffness, and crack resistance while maintaining the stabilizing function.
2Strength
If a solid support element is used to mechanically stabilize the winding, then the mechanical strength is improved, but the rotor weight increases
Solution Approach 1:
The fiber-reinforced composite material provides high mechanical strength with lower density compared to traditional solid metal or homogeneous plastic support structures. The fibers carry the primary loads while the matrix material distributes stresses and binds the fibers together, achieving high strength-to-weight ratio.
Solution Approach 2:
The composite material structure provides localized reinforcement where needed - the fiber orientation and distribution can be optimized to provide strength specifically in the directions of highest stress, rather than uniformly throughout the entire support element, reducing unnecessary material and weight.
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 composite support element effectively stabilizes the winding, reducing crack formation and enabling a lightweight rotor that withstands high mechanical loads while maintaining electrical insulation and structural integrity.
Implementation Method 1
a support element composed of a composite material, comprising matrix material and fiber material
Implementation Method 2
Only after a drying and/or curing process does it achieve its final strength
Data Source
AI summary
A rotor, in particular for a current-excited electric machine, comprising a winding, wherein on or against the winding is arranged a support element made of a composite material comprising matrix material and fiber material.