Non-Through Shaft Rotor Flange Layout for Larger Conductive Bars

Solution Overview

Problem

Existing rotary electric machines with non-through shaft rotors face challenges in increasing the section of conductive bars or coils without compromising the compaction of the magnetic mass, leading to reduced critical speed and flexibility issues due to decompaction at the periphery.

Innovation Solution

The rotor design includes attachment flanges with insertion holes matching the housings, allowing for uniform compaction and insertion of conductive bars or coils, with features like screws and tie rods maintaining magnetic mass integrity, and optional chamfers, countersinks, and seals to enhance insertion and compaction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If the exterior diameter of the attachment flange is reduced to insert larger conductive bars, then the section of conductive bars is increased, but the magnetic mass becomes decompacted at the periphery

Engineering Contradiction:

Improvesection of conductive barsVSAvoidcompaction of magnetic mass

Core Design Contradiction:

Quantity of substanceVSStability of the object's composition

Solution Approach 1:

The attachment flange is segmented by providing multiple insertion holes distributed around its circumference, allowing conductive bars to be inserted at multiple locations without requiring a reduction in the overall exterior diameter of the flange. This segmentation enables the magnetic mass to maintain its compaction while accommodating larger conductive bars.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of increasing the conductive bar section by reducing the flange diameter (one-dimensional approach), the invention distributes multiple insertion holes around the flange circumference, utilizing the radial dimension to accommodate multiple conductive bars. This dimensional approach allows larger bar sections while maintaining flange diameter and magnetic mass compaction.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Quantity of substance

If the exterior diameter of the attachment flange is reduced to accommodate larger conductive bars, then the conductive bar section is increased, but the critical speed of the rotor decreases

Engineering Contradiction:

Improvesection of conductive barsVSAvoidcritical speed of rotor

Core Design Contradiction:

Quantity of substanceVSSpeed

Solution Approach 1:

The attachment flange is segmented by providing multiple insertion holes distributed around its circumference, allowing conductive bars to be inserted at multiple locations without requiring a reduction in the overall exterior diameter of the flange. This segmentation enables the magnetic mass to maintain its compaction while accommodating larger conductive bars.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of increasing the conductive bar section by reducing the flange diameter (one-dimensional approach), the invention distributes multiple insertion holes around the flange circumference, utilizing the radial dimension to accommodate multiple conductive bars. This dimensional approach allows larger bar sections while maintaining flange diameter and magnetic mass compaction.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Stability of the object's composition

If tie rods are used to compact the magnetic mass, then the magnetic mass is kept compacted, but the conductive bars cannot be inserted or removed without removing the tie rods

Engineering Contradiction:

Improvecompaction of magnetic massVSAvoidinsertion and removal of conductive bars

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The attachment flange is segmented by providing multiple insertion holes distributed around its circumference, allowing conductive bars to be inserted at multiple locations without requiring a reduction in the overall exterior diameter of the flange. This segmentation enables the magnetic mass to maintain its compaction while accommodating larger conductive bars.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insertion holes are pre-formed in the attachment flange before the magnetic mass is compacted and before the conductive bars are inserted. This preliminary action allows conductive bars to be inserted through the flange without requiring disassembly of the compaction structure, enabling easy maintenance and replacement.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11923735B2Rotor with non-through shaft and associated rotary electric machine

Publication Date: 2024.03.05 GE ENERGY POWER CONVERSION TECHNOLOGY LTD(GB)

AI summary

The rotor with a non-through shaft for a rotary electric machine comprises a cylindrical magnetic body clamped between two half-shafts, each comprising an attachment flange connected to the magnetic body, axial housings being uniformly provided in the magnetic body on at least one diameter of the magnetic body in order to house conductive bars. At least one attachment flange comprises insertion holes, each arranged facing a housing for inserting the conductive bars into the housings and the exterior diameter of the attachment flange is substantially equal to the exterior diameter of the magnetic body, the attachment flange comprising as many insertion holes as housings.