Deformable Bearing Cage Rotor Thermal Contraction

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Solution Overview

Problem

Existing cage rotors in electric machines face challenges with high electrical resistance due to the contraction of the short-circuit ring during cooling, which affects the efficiency of the machine, as the bar cannot follow the contraction, leading to suboptimal joint characteristics between the bar and the short-circuit ring.

Innovation Solution

A deformable bearing device is integrated into the laminated rotor core, allowing the bar to be supported in a slot and follow the contraction of the short-circuit ring during solidification, thereby maintaining a low electrical resistance and ensuring a mechanically solid connection between the bar and the cast-on short-circuit ring.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If the bar is rigidly fixed in the slot, then the structural stability is improved, but the electrical resistance between the bar and short-circuit ring increases due to contraction mismatch

Engineering Contradiction:
Improvestructural stabilityVSAvoidelectrical connection reliability
Core Design Contradiction:
Stability of the object's compositionVSReliability

Solution Approach 1:

The patent applies the dynamics principle by making the bearing deformable rather than rigid. The deformable bearing allows the bar to move dynamically in response to thermal contraction of the short-circuit ring during cooling, maintaining continuous contact and low electrical resistance while still providing structural support. This resolves the contradiction by replacing a static rigid connection with a dynamic adaptive connection.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent applies parameter changes by modifying the physical state of the bearing material to be deformable. The bearing's material properties are selected to allow controlled deformation under thermal stress, enabling the bar to follow the contraction of the short-circuit ring. This changes the parameter of bearing rigidity to an optimal intermediate state that provides both support and adaptability.

Inventive Principle:
Principle #35Parameter changes

2Reliability

If the bar is allowed to move freely in the slot, then the electrical resistance is reduced, but the mechanical support and positioning of the bar deteriorates

Engineering Contradiction:
Improveelectrical connection reliabilityVSAvoidmechanical positioning stability
Core Design Contradiction:
ReliabilityVSStability of the object's composition

Solution Approach 1:

The deformable bearing provides a dynamic support system that adapts its rigidity based on operational conditions. During normal operation, it provides sufficient mechanical support to maintain bar positioning, while during thermal contraction, it deforms to allow bar movement. This dynamic behavior resolves the contradiction between free movement and mechanical support.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The bearing acts as an intermediary element between the rigid slot and the bar. It mediates the interaction by providing controlled deformation, allowing the bar to move when necessary while maintaining mechanical support. The bearing absorbs the thermal stress and transfers it to the slot in a controlled manner, protecting both the bar and slot from damage.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Reliability

If a deformable bearing is introduced to allow bar movement, then the electrical resistance is reduced, but the device complexity increases

Engineering Contradiction:
Improveelectrical connection reliabilityVSAvoidbearing structure complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent simplifies the bearing structure by focusing on material property changes rather than complex mechanical designs. The deformable bearing achieves its function through careful selection of material properties (viscoelastic or plastic deformation characteristics) rather than through complex geometries or multiple components. This reduces device complexity while maintaining the required functionality.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The bearing is designed as a flexible element that can be made from thin-walled structures or flexible materials. This approach simplifies the overall structure compared to rigid mechanical assemblies with multiple moving parts. The flexible nature of the bearing allows it to deform smoothly under thermal stress without requiring complex mechanisms.

Inventive Principle:
Principle #30Flexible shells and thin films

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 results in a highly efficient electric machine with reduced wear on bearings, improved mass distribution, and lower friction losses, leading to increased efficiency and extended service life of the machine.

Implementation Method 1

the bar is able to follow a contraction of the first material upon solidification of the molten mass of the first material after or during a casting-on of the short-circuit ring

Methodology Applied
Scientific EffectThermal contraction: Thermal Contraction

Data Source

PatentUS10476361B2Cage rotor comprising a deformable bearing
Publication Date: 2019.11.12 INNOMOTICS GMBH
  • US10476361B2 patent drawing
  • US10476361B2 patent drawing
  • US10476361B2 patent drawing

AI summary

A cage rotor for an electric machine, has a laminated rotor core having a groove, a rotor end ring that is cast on to one axial end of the laminated core and has a first material and a bar situated in the groove and supported by a deformable bearing having a bearing device. A laminated rotor core for a cage rotor includes a groove and a bearing device, an electric machine with a cage rotor, a method for producing a laminated rotor core by producing a bearing device on the laminated rotor core, and a method for producing a cage rotor by supporting a bar in a groove by a deformable bearing having a bearing device.