Electrically Excited Rotor End-Plate Layout for Compact Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electrically excited rotors face challenges in manufacturing complexity and size due to the attachment of electric components, which complicates assembly and increases the rotor's dimensions.
Innovation Solution
An electrically excited rotor design featuring a rectifier board attached to an end-plate, allowing simultaneous assembly with the end-plate, and a contactless transformer device for power transfer, along with a winding attachment interface for secure electrical connections, enhancing compactness and manufacturing ease.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electric components (rectifier board, transformer) are attached to the rotor using conventional methods, then the rotor can function as an electrically excited rotor, but the rotor size increases and manufacturing/assembling complexity increases
Solution Approach 1:
The rectifier board is integrated directly into the end plate structure, merging two previously separate components (rectifier board and end plate) into a single unified component. This integration eliminates separate attachment steps and reduces the number of parts, thereby simplifying manufacturing and assembly processes while maintaining the electrical excitation function
Solution Approach 2:
The end plate is designed to serve multiple functions: it provides structural closure for the rotor, serves as a mounting substrate for the rectifier board, and acts as a support structure for the transformer device. This multi-functionality reduces the need for additional dedicated mounting components, simplifying the overall rotor structure and assembly
2Ease of operation
If electric components are attached to the rotor using conventional methods, then the rotor can operate with proper power transmission, but the rotor dimensions increase
Solution Approach 1:
The transformer device is positioned within the space between the end plate and the rotor core, utilizing otherwise unused internal volume. The rectifier board is embedded in the end plate itself. This nesting approach allows electric components to be housed within the existing rotor envelope rather than adding external protrusions, maintaining compact dimensions while ensuring proper power transmission functionality
3Ease of manufacture
If multiple electric components are assembled separately and then attached to the rotor, then each component can be manufactured independently, but the assembly process becomes more complex
Solution Approach 1:
The rectifier board is pre-integrated into the end plate during end plate manufacturing, rather than being attached as a separate component during rotor assembly. This preliminary integration reduces the number of assembly steps required and improves productivity, while the rotor core and winding arrangement can still be manufactured independently and assembled in a simplified sequence
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 design facilitates easier assembly, secure electrical connections, and compact rotor structure, while enabling efficient power transfer and electromagnetic shielding, with potential for early fault detection and improved cooling through integrated cooling channels.
Implementation Method 1
a transformer device (30) comprising a rotary part (31) and a static part (32), the static part (32) being configured to contactless transfer AC power to the rotary part (31)
Implementation Method 2
The rectifier board (40) may be configured to rectify said AC power to DC power so to power said winding arrangement (10) with said DC power
Implementation Method 3
the end-plate to act as a support structure and heat sink for two parts, i.e. the rectifier board and the rotary part
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present disclosure relates to an electrically excited rotor (1) comprising an annular rotor core (2) comprising a circumferentially distributed winding arrangement (10). Further, the rotor (1) comprises an end plate (20) attached to a base (2a) of said rotor core (2), a transformer device (30) comprising a rotary part (31) and a static part (32), the static part (32) being configured to contactless transfer AC power to the rotary part (31). Further, the rotor (1) comprises a rectifier board (40) connected to said rotary part (31), wherein the rectifier board (40) is attached to a first surface (20a) of said end-plate (20).