Layered Sheet Metal Wheel for Electrical Machinery Radial Deformation
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Solution Overview
Problem
In electrical machinery, large generator diameters face challenges in minimizing radial deformations and maintaining dynamic performance due to the need for efficient stator and rotor wheel structures that resist forces while minimizing mass and air gap.
Innovation Solution
The use of layered sheet metal elements forming slanted spokes and rims, which provide structural integrity and damping through friction between stacked layers, eliminating the need for thick steel welds and allowing for lightweight, low-deformation wheel structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional thick steel wheel structures are used, then structural strength is improved, but weight increases and radial deformation is not minimized
Solution Approach 1:
The wheel structure is segmented into multiple thin sheet metal layers stacked together, replacing traditional thick steel construction. Each layer can be independently formed and assembled, allowing the structure to achieve required strength through layered configuration rather than increasing individual layer thickness or overall weight.
Solution Approach 2:
The invention uses composite construction by stacking multiple sheet metal layers with potentially different material properties or treatments. This layered composite structure provides enhanced strength-to-weight ratio compared to monolithic thick steel, as each layer contributes to overall structural integrity while maintaining low individual mass.
2Power
If wheel diameter is increased for larger generators, then power capacity is improved, but radial deformation increases and dynamic performance deteriorates
Solution Approach 1:
By dividing the wheel into multiple thin stacked layers, the structure achieves better radial stability in larger diameter wheels. The segmented layered construction allows each layer to resist radial forces independently while collectively maintaining the wheel's circular geometry, preventing excessive radial deformation in large-scale applications.
Solution Approach 2:
The invention transitions from considering wheel strength in a single dimensional sense (thick steel) to a multi-dimensional approach by stacking layers in the axial dimension. This layered arrangement provides radial stability through axial stacking, enabling larger diameter wheels to maintain structural integrity without proportionally increasing radial deformation.
3Use of energy by moving object
If air gap is reduced to optimize efficiency, then energy efficiency is improved, but structural precision requirements increase
Solution Approach 1:
The segmented layered structure provides inherent dimensional stability and precision. Each thin sheet layer can be manufactured with tight tolerances, and the stacked configuration maintains consistent spacing and alignment, ensuring the wheel meets the high precision requirements necessary for small air gap installations in efficient electrical machines.
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 solution achieves minimal radial deformation and enhanced dynamic performance with reduced weight and manufacturing costs, addressing the challenges of large-scale wheel structure integrity and damping in electrical machinery.
Implementation Method 1
the layered sheet metal elements, when bound, establish structural integrity with an increase in structural damping perpendicular to the stack due to friction between the layers
Data Source
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AI summary
A wheel of an electrical machine, comprising a hub and a rim (115) connected by spokes (111), the rim (115) being formed by layered sheet metal elements (110) assembled together. Also disclosed is an electrical machine comprising said wheel.