Motor Rotor Copper Sheet Flat Inner Ends
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Solution Overview
Problem
The complexity and cost of producing conventional motor rotors are increased due to the need for copper bars to be inserted between copper sheets with varying distances, requiring cutting and the use of holding rings to prevent separation under centrifugal force.
Innovation Solution
The motor rotor design features copper sheets with flat inner ends and outer ends, allowing copper bars to be inserted between adjacent sheets without extending beyond the outer ends, reducing the need for cutting and holding rings, and enhancing stability against centrifugal force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If copper sheets have curved inner ends with varying distances, then the copper bars can be inserted between adjacent sheets, but the manufacturing complexity and production cost increase due to needing cutting and holding rings
Solution Approach 1:
The patent changes the geometric parameters of the copper sheet inner ends from curved surfaces with varying distances to flat surfaces with uniform distances. This parameter change allows copper bars to be inserted without extending beyond the outer ends, eliminating the need for cutting operations and holding rings, thus reducing manufacturing complexity and production cost
2Ease of operation
If copper bars extend beyond the outer ends of copper sheets, then insertion is easier, but holding rings are needed to prevent separation under centrifugal force during rotation
Solution Approach 1:
The patent modifies the distance parameter between adjacent copper sheets at their inner ends to be uniform, which allows the copper bars to be fully contained within the outer ends of the copper sheets. This eliminates the need for holding rings to prevent centrifugal separation while maintaining ease of bar insertion
3Reliability
If holding rings are mounted around copper sheets and copper bars, then separation under centrifugal force is prevented, but production cost and manufacturing complexity increase
Solution Approach 1:
The patent changes the geometric parameters of the copper sheet inner ends to flat surfaces with uniform distances, allowing copper bars to be fully contained without extending beyond the outer ends. This design change maintains bar retention reliability under centrifugal force while eliminating the need for holding rings, thereby reducing production cost and manufacturing complexity
Data Source
AI summary
A motor rotor has an outer casing, multiple silicon-steel sheets, multiple copper sheets and multiple copper bars. The silicon-steel sheets are stacked and mounted in the outer casing and each has multiple through holes formed through the silicon-steel sheet at intervals. The copper sheets are mounted in the through holes, extend out of the silicon-steel sheets and each has two side faces. Each side face of the copper sheet has a flat inner end and an outer end. The flat inner end of the side face of the copper sheet is flat to enable a distance between the outer ends of two adjacent copper sheets to be smaller than a distance between the flat inner ends of the adjacent copper sheets. The copper bars are inserted into the copper sheets from the flat inner ends to the outer ends of the side faces of the copper sheets.