Drive-End Rotor Lock Structure for High-Load Electrical Machines
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Solution Overview
Problem
As electric machines, particularly those in wind turbines, increase in size and load, existing rotor locks face increased manufacturing complexity and costs due to larger components and loads, necessitating a more efficient and cost-effective construction.
Innovation Solution
The rotor lock is mounted at the drive end, utilizing a stator plate to manage torque loads, eliminating the need for a structure at the non-drive end and incorporating a pin that engages both stator and rotor holes, with optional sandwich structures of stationary and rotary plates for optimized radial positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the rotor lock is mounted on thick steel plates on both sides of the brake disc, then the rotor lock can provide sufficient structural strength to handle increasing loads, but the manufacturing complexity and costs increase
Solution Approach 1:
The rotor lock is extracted from the brake disc structure and mounted separately on the stator plate. This separation allows the brake disc to be reduced in size while the rotor lock maintains its load-bearing capability through the stator plate mounting, thereby reducing manufacturing complexity without compromising strength
Solution Approach 2:
The stator plate serves multiple functions: it provides the mounting surface for the rotor lock, handles torque loads from the torque input, and eliminates the need for a separate structure at the non-drive end. This multi-functionality reduces overall device complexity while maintaining structural strength
2Force
If the rotor lock structure is enlarged to handle increased loads, then the load-bearing capacity improves, but the manufacturing costs and complexity increase
Solution Approach 1:
The stator plate is designed to perform multiple functions simultaneously: it mounts the rotor lock, absorbs torque loads, and eliminates the need for additional structures at the non-drive end. This consolidation reduces manufacturing costs while maintaining load-bearing capacity
Solution Approach 2:
The rotor lock system is segmented into distinct functional components: the pin mechanism for locking, the stator plate for load bearing, and the brake disc for size reduction. This segmentation allows each component to be optimized independently, reducing overall manufacturing complexity and cost
3Reliability
If a structure is provided at both ends of the brake disc for the rotor lock, then the rotor lock can be securely mounted, but the brake disc size and machining costs increase
Solution Approach 1:
The rotor lock mounting is extracted from the brake disc and relocated to the stator plate. This extraction allows the brake disc to be minimized in size while the rotor lock remains securely mounted through the stator plate, achieving both compactness and reliability
Solution Approach 2:
The mounting function and torque load-bearing function are merged into the stator plate. This consolidation eliminates the need for separate structures at both ends of the brake disc, reducing brake disc size while maintaining secure mounting through the integrated stator plate design
Data Source
Figure 1
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AI summary
An electrical machine (10) including a stator (20) and a rotor (30) and extending along a longitudinal axis (Y) between a drive end (21) and an axially opposite non-drive end (22), the drive end (21) being attachable to a torque input, the rotor (30) being rotatable with respect to the stator (20) about the longitudinal axis (Y), the electrical machine (10) comprising a rotor lock (100) engaging the stator (20) and the rotor (30) for preventing the rotor (30) from rotating with respect to the stator (20), the rotor lock (100) being provided at the drive end (21).