Fiber Composite Rotor for Double Stator Machine
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Solution Overview
Problem
Rotating electrical machines with double-stator arrangements face challenges in maintaining concentric alignment and preventing contact between the rotor and stators due to eccentricities or imbalances, which can lead to damage or seizing, especially at high RPMs.
Innovation Solution
The rotor is constructed from fiber composite material, shaped as a hollow cylinder with radially disposed magnet cavities and aligned magnetic bars, and assembled from pultruded segments to ensure stiffness and maintain coaxial alignment, reducing the risk of contact with stators and enhancing electromagnetic interaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the rotor is made from traditional materials, then it can be manufactured easily, but it lacks sufficient stiffness to resist distortion or displacement at high RPMs
Solution Approach 1:
The rotor is constructed from fiber composite material that provides high stiffness-to-weight ratio, enabling the rotor to resist distortion and displacement at high rotational speeds while maintaining manufacturability through pultrusion processes
2Reliability
If the rotor is made stiffer to prevent contact with stators, then reliability improves, but device complexity increases
Solution Approach 1:
The fiber composite construction achieves the required stiffness and rotational stability without increasing structural complexity, as the composite material itself provides the necessary mechanical properties through its inherent strength-to-weight characteristics
3Productivity
If the rotor weight is reduced, then productivity and efficiency improve, but strength and stiffness may be compromised
Solution Approach 1:
The fiber composite material provides high specific strength and stiffness (strength-to-weight ratio), allowing the rotor to be significantly lighter while maintaining or improving structural integrity and resistance to distortion at high rotational speeds
Solution Approach 2:
The rotor is divided into multiple segments that can be manufactured separately and assembled, allowing for optimized fiber orientation and material distribution that maximizes strength where needed while minimizing weight
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 fiber composite rotor maintains concentric spacing with stators, preventing distortion and improving rotational balance, thus avoiding contact and enhancing the machine's efficiency and output by minimizing annular gaps and reducing weight and complexity.
Implementation Method 1
the rotor is sufficiently stiff to resist distortion or displacement with respect to the axis line
Implementation Method 2
the rotor and stator are electromagnetic components that include magnets and electrical conductors called windings or coils arranged to electromagnetically interact with each other
Implementation Method 3
a small annular air gap that is traversed by the magnetic flux associated with the magnets
Data Source
AI summary
A rotating electrical machine of the double stator configuration includes a rotor shaped as a hollow cylinder disposed concentrically between an outer stator and an inner stator. The rotor can include plurality of radially spaced magnet cavities configured to receive permanent magnetic bars. To provide sufficient stiffness and rigidity, the rotor may be made from fiber composite material. To simplify construction, the rotor can be assembled from a plurality of rotor segments radially arranged about an axis line in which the magnet cavities are disposed.