Hollow Rotor Shaft Modular Segmentation for Weight Reduction
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Solution Overview
Problem
The existing methods for manufacturing rotor shafts for brushless rotating electrical machines are complex and weight-intensive, requiring intricate threading and winding operations, which complicate production and increase inertia, making it necessary to produce new shafts for each modification in electrical and mechanical characteristics.
Innovation Solution
A hollow rotor shaft comprising two parts, with a first hollow cylindrical element for accommodating rotor windings and a second hollow cylindrical element with perforated holes for diode plates, secured by bosses and threaded elements that allow for modular assembly and weight reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a solid shaft is used for the rotor, then the structural strength is sufficient, but the weight and inertia of the rotor increase
Solution Approach 1:
The rotor shaft is divided into multiple segments (first shaft segment, second shaft segment, third shaft segment) that are assembled together. The first and third segments form a hollow structure while the second segment is solid, creating a lightweight yet strong configuration. This segmentation allows weight reduction while maintaining structural integrity through proper joint design.
2Adaptability or versatility
If threading and winding operations are performed on the shaft to modify electrical and mechanical characteristics, then the machine characteristics can be adjusted, but the production complexity increases and no pre-assembly is possible
Solution Approach 1:
The shaft is segmented into multiple independently manufacturable parts that can be pre-assembled with windings and diode plates before final assembly. This allows different segments to be produced with specific characteristics and then combined, reducing production complexity while maintaining adaptability.
Solution Approach 2:
The shaft segments can be pre-assembled with windings and other components before final rotor assembly. This preliminary action allows for easier modification of electrical and mechanical characteristics without requiring complex operations on the complete rotor.
3Weight of moving object
If the interior of the shaft is reamed to reduce weight, then the rotor weight decreases, but additional machining operations are necessary and the interior of the shaft may be degraded
Solution Approach 1:
Instead of reaming the entire shaft interior, the design uses a hollow structure formed by assembling segmented shaft parts. The hollow configuration is achieved through the segmentation itself rather than post-manufacturing removal of material, avoiding degradation from additional machining operations.
4Speed
If the rotor shaft weight is reduced by hollowing, then the inertia decreases and dynamic response improves, but the manufacturing process becomes more complex
Solution Approach 1:
The hollow shaft structure is achieved through segmentation rather than complex hollowing operations. Multiple shaft segments are assembled to form the hollow configuration, which reduces inertia and improves dynamic response while keeping manufacturing relatively simple through standard assembly processes.
Data Source
AI summary
The hollow rotor shaft for a rotating electrical machine includes two parts. A first part includes a first hollow cylindrical element and a second part includes a second hollow cylindrical element, whereby sections of a first end of the first and second elements are in contact and secured by securing means.