Electric Motor Rotor Segmentation for Flexible Configurations
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Solution Overview
Problem
Conventional electric motor production is limited by high costs and inflexibility in design variations, as existing technologies often require a large number of parts and fixed configurations, making it difficult to produce a variety of motor variants efficiently.
Innovation Solution
The electric motor design incorporates a rotor with a rotor shaft part and two shaft parts, each with a bearing seat, allowing for a torsionally fixed connection and enabling the use of different sizes and configurations, such as pinion attachments and fan or brake connections, while minimizing distortions and using a laminated stator core with a squirrel cage for asynchronous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a rotor is made up of multiple parts (rotor shaft part, first shaft part, second shaft part), then a high variety of rotors can be produced with different configurations, but the device complexity increases
Solution Approach 1:
The rotor is divided into three main segments: rotor shaft part, first shaft part, and second shaft part. Each segment can be independently designed and manufactured, then assembled together. This segmentation enables flexible configuration variations (with or without pinion, fan, brake) while maintaining a manageable number of standardized components.
Solution Approach 2:
The rotor design incorporates universal interfaces and standardized connection sections that can accommodate different attachments (pinion, fan, brake) on the same basic rotor structure. The first and second shaft parts provide universal mounting capabilities for various mechanical interfaces, allowing one rotor base design to serve multiple application purposes.
2Strength
If the rotor is mounted via bearings in bearing shields connected to stator housing, then high transverse moment can be derived with minimal distortions, but the device complexity increases
Solution Approach 1:
Bearing shields serve as intermediary components between the rotor mounting system and the stator housing. These shields accommodate the bearings and provide a structured interface for rotor support, distributing mechanical loads and minimizing direct contact between rotor and housing to reduce distortions while maintaining structural strength.
3Strength
If journal regions are pressed into rotor shaft part with elastic deformation, then torque-proof connection is achieved, but manufacturing precision requirements increase
Solution Approach 1:
The connection method utilizes elastic deformation of the journal regions during the press-fit process. By controlling the press-fit parameters (force, temperature, timing), the journal regions undergo temporary elastic deformation to accommodate the interference fit, then maintain permanent dimensional changes that ensure torque-proof connection. This parameter-controlled approach balances connection strength with manufacturability.
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 design allows for the cost-effective production of a high variety of electric motor variants with minimal distortion, enabling flexible mechanical interfaces and efficient torque transmission, suitable for applications like transmission, fan, or brake motors, while maintaining a precise cylindrical outer contour.
Implementation Method 1
the gear-tooth region being pressed into a region, provided with internal teeth, of the first recess, in particular under an elastic deformation
Data Source
AI summary
An electric motor includes a rotor having a rotor shaft part and a first shaft part and a second shaft part. The rotor shaft is situated axially between the first and the second shaft parts. The first shaft part includes a first bearing seat and is connected to the rotor shaft part in a torsionally fixed manner, and the second shaft part includes a second bearing seat and is connected to the rotor shaft part in a torsionally fixed manner.