Molded Wire Support for Aircraft Rotor Assemblies

Solution Overview

Problem

The high cost and time-consuming machining process of using solid TORLON material for wire supports in rotor assemblies of rotary electromechanical devices, such as aircraft starter/generators, necessitates a more efficient manufacturing method.

Innovation Solution

A molded wire support design with a body having a hole for the shaft and end turn supports for wire wrapping, incorporating molded pockets to prevent cracking and featuring cooling fluid communication, manufactured using injection molding to reduce material waste and production time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If wire supports are machined from solid TORLON material, then structural integrity is ensured, but production cost and time increase significantly

Engineering Contradiction:

Improvestructural integrityVSAvoidproduction time

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent changes the manufacturing parameter from mechanical machining to injection molding, transforming the production process from subtractive to additive manufacturing. This parameter change maintains structural integrity while dramatically reducing production time and cost.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical machining system with an injection molding system. Instead of removing material through cutting tools, the wire support is formed by injecting molten TORLON material into a mold cavity, eliminating time-consuming machining operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If wire supports are machined from solid TORLON material, then structural integrity is ensured, but manufacturing cost increases

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent changes the manufacturing parameter from mechanical machining to injection molding, transforming the production process from subtractive to additive manufacturing. This parameter change maintains structural integrity while dramatically reducing production time and cost.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical machining system with an injection molding system. Instead of removing material through cutting tools, the wire support is formed by injecting molten TORLON material into a mold cavity, eliminating time-consuming machining operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If traditional machining processes are used, then precision is achieved, but material waste and production time increase

Engineering Contradiction:

Improvedimensional accuracyVSAvoidmaterial waste

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The patent replaces the mechanical machining system with an injection molding system. Instead of removing material through cutting tools, the wire support is formed by injecting molten TORLON material into a mold cavity, eliminating time-consuming machining operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent incorporates cooling channels and pockets directly into the mold during the injection molding process setup. This preliminary action ensures that cooling features are built-in from the start, eliminating the need for subsequent machining operations and reducing both material waste and production time.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS8339011B2Rotor assembly wire support

Publication Date: 2012.12.25 HAMILTON SUNDSTRAND CORP

AI summary

A rotor assembly for an electromechanical device includes a molded wire support. The wire support has a body including a first side spaced from a second side and a hole extending through the sides and configured to receive a shaft. The body includes a wall about the hole extending to the first side. At least one end turn support extends outwardly from the wall and is configured to support wires. A molded pocket extends into the wall from the second side without penetrating through to the first side.