Elastic Rotor Wire Guide for High-Speed Generator Windings
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Solution Overview
Problem
Existing high-speed generator rotors face challenges in maintaining windings under high mechanical stresses and centrifugal forces, with existing holding devices being complex and difficult to adapt to manufacturing tolerance errors.
Innovation Solution
A single-piece guide device with radially and angularly deformable branches connected by elastic means, featuring notches and guide grooves for wire positioning, allows for reliable and inexpensive attachment and adaptation to the rotor's conductive block, accommodating radial and angular movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a holding device with multiple distinct parts is used to maintain windings under high mechanical stresses, then the reliability of wire positioning is improved, but the device complexity increases and manufacturing cost rises
Solution Approach 1:
The patent combines multiple distinct holding parts into a single integrated guide device that encompasses all functional elements (supports, caps, and positioning features) in one monolithic structure, thereby reducing assembly complexity while maintaining the reliability of wire positioning under high mechanical stresses
Solution Approach 2:
The guide device is designed as a universal component that simultaneously performs multiple functions: supporting coils, positioning wires, accommodating thermal expansion, and compensating for manufacturing tolerances, thereby replacing several separate components with one multi-functional element
2Manufacturing precision
If a rigid holding device is used to maintain precise wire positioning, then the manufacturing precision is improved, but the adaptability to thermal expansion and radial movements deteriorates
Solution Approach 1:
The guide device incorporates dynamic characteristics by allowing controlled radial movements and rotations to accommodate thermal expansion of the rotor, while maintaining precise wire positioning through its geometric design and elastic connection features that adapt to dimensional changes during operation
3Ease of manufacture
If a single-piece guide device is used to simplify construction and reduce cost, then the ease of manufacture is improved, but the ability to adapt to manufacturing tolerance errors deteriorates
Solution Approach 1:
The guide device incorporates geometric parameters and elastic connections that allow it to adapt to manufacturing tolerance variations, enabling the single-piece structure to accommodate dimensional deviations while maintaining functional performance and wire positioning accuracy
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 guide device simplifies construction and installation, provides tolerance to manufacturing errors, and maintains wire windings effectively under operational conditions, including thermal expansion, while being cost-effective and adaptable.
Implementation Method 1
at least two branches extending radially away from the shaft and arranged at 90° to one another, said branches being connected by an elastic connection means
Implementation Method 2
The elastic connection also allows independent movement of each pole of the electric machine, as well as of each branch of the guide device in the radial direction. This allows, in addition to the ease of installation, to adapt to radial movements during the operation of the rotor, such as for example, to the movements of the poles due to the thermal expansion of the poles...
Data Source
Figure 1
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Figure 4~5
AI summary
Guiding device (12) for coiling electrically conducting wires (8, 9) around an electrically conducting block (3) of a rotor (1) of an electric motor comprising a shaft (2) extending axially in the rotor (1), said electrically conducting block (3) being provided with at least four notches (4a, 4b, 5a, 5b) for receiving wires (8, 9). The guiding device (12) comprises at least two branches (13, 14) extending radially away from the shaft (2) and disposed at 90° to one another, said branches (13, 14) being connected by an elastic linking means (18).