Non-Through Shaft Rotor for Larger Conductive Bars and Rigidity
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Solution Overview
Problem
Rotors with non-through shafts for rotating electrical machines face challenges in increasing the section of conductive bars without compromising the compaction of the magnetic mass, leading to reduced critical speed and flexibility issues due to decompaction at the periphery.
Innovation Solution
A rotor design with cylindrical magnetic mass clamped between half-shafts, featuring axial housings and insertion holes that allow for the insertion of conductive bars and coils, with screws and tie rods maintaining compaction, and a fixing flange with chamfers and countersinks to facilitate bar insertion and removal without dismantling, ensuring uniform compaction and increased critical speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If the diameter of the fixing flanges is reduced to increase the cross-section of conductive bars, then the cross-section of conductive bars is improved, but the compaction of magnetic mass deteriorates
Solution Approach 1:
The rotor is divided into two half-shafts that can be assembled separately. The magnetic mass is segmented into multiple laminations that can be stacked and compacted independently. This segmentation allows conductive bars to be inserted into housings before final assembly, enabling larger bar cross-sections without compromising magnetic mass compaction.
Solution Approach 2:
The invention transitions from a through-shaft design to a non-through shaft design with blind holes in the fixing flanges. This dimensional change allows conductive bars to be inserted axially into housings and secured from the side, enabling larger bar cross-sections while maintaining flange diameter for proper magnetic mass compaction.
2Area of moving object
If the fixing flange diameter is reduced to accommodate larger conductive bars, then the conductive bar size is improved, but the critical speed of rotor deteriorates
Solution Approach 1:
By segmenting the rotor into two half-shafts with separate assembly, the invention maintains the full diameter of the fixing flanges for proper magnetic mass compaction and rotor rigidity, while still accommodating larger conductive bars through the blind hole insertion method. This preserves the critical speed characteristics.
Solution Approach 2:
Conductive bars are preliminarily inserted into housings and secured with retention elements before the final assembly of the rotor. This preliminary action allows for larger bar cross-sections without requiring reduced flange diameter, thereby maintaining rotor rigidity and critical speed.
3Device complexity
If conductive bars are inserted into compacted magnetic mass, then the rotor assembly is simplified, but the conductive bars cannot be removed without dismantling tie rods
Solution Approach 1:
The rotor is segmented into two half-shafts that can be separated. The blind holes in the fixing flanges allow conductive bars to be accessed and removed from one side only, eliminating the need to dismantle tie rods or disassemble the entire rotor structure for maintenance.
Solution Approach 2:
The conductive bars are extracted from the magnetic mass and placed in separate housings that are accessible through blind holes in the fixing flanges. This extraction allows bars to be removed independently without affecting the magnetic mass compaction or requiring dismantling of structural components like tie rods.
4Area of moving object
If the fixing flange diameter is reduced to fit larger conductive bars, then the conductive bar cross-section is improved, but the rotor flexibility increases causing reduced operating speed range
Solution Approach 1:
The rotor is divided into two half-shafts with separate assembly procedures. This segmentation allows the fixing flanges to maintain their full diameter for proper magnetic mass compaction and rotor rigidity, while conductive bars with larger cross-sections are inserted into housings through blind holes, preventing rotor flexibility issues.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The rotor (18) with a non-through shaft for a rotary electric machine comprises a cylindrical magnetic body (19) clamped between two half-shafts (20), each comprising an attachment flange (21) connected to the magnetic body, axial housings (22) being uniformly provided in the magnetic body on at least one diameter (D22) of the magnetic body in order to house conductive bars (25). At least one attachment flange comprises insertion holes (23), each arranged facing a housing for inserting the conductive bars into the housings and the exterior diameter (D21) of the attachment flange is substantially equal to the exterior diameter (D19) of the magnetic body, the attachment flange comprising as many insertion holes (23) as housings.