Overmolded Rotor Hub Structure for Stronger Shaft Support
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Solution Overview
Problem
Existing shaft-hub connections in rotors provide insufficient support to the shaft and inadequate transmission of radial forces to the rotor pot, particularly in applications where plastic materials are used, leading to potential lifting issues.
Innovation Solution
A rotor design where the rotor pot and shaft are overmolded with plastic, featuring a receptacle edge that extends partially or angled to the axis of rotation, enhancing the rigidity of the shaft-hub connection, and incorporating recesses and knurls to improve force transmission and prevent lifting, with the hub being made of plastic and the rotor pot of metallic material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional shaft-hub connections are used, then the structure is simple, but the shaft support and radial force transmission are insufficient
Solution Approach 1:
The hub is constructed as a composite structure combining a metallic rotor pot with an overmolded plastic hub portion. This composite design provides both the structural support of metal and the bonding advantages of plastic, creating a shaft-hub connection that delivers sufficient shaft support and radial force transmission while maintaining manufacturing efficiency through integrated molding processes
Solution Approach 2:
The receptacle edge portion extends at an angle (0° to 75°) relative to the axis of rotation, creating a geometric configuration that provides mechanical support in multiple directions. This angular extension of the receptacle edge into the accommodation space adds dimensional complexity to the connection geometry, enhancing rigidity and force transmission capabilities
2Ease of manufacture
If plastic material is used for shaft-hub connection, then manufacturing is simplified, but hub lifting occurs to an undesirable extent
Solution Approach 1:
The rotor pot surface is pre-treated with a coupling agent before overmolding the plastic hub material. This preliminary chemical treatment creates a bonding interface that prevents hub lifting while maintaining the manufacturing simplicity of the injection molding process. The coupling agent layer is applied in advance to ensure reliable adhesion between the metallic rotor pot and plastic hub
Solution Approach 2:
The combination of metallic rotor pot with overmolded plastic hub creates a composite structure where each material contributes its advantageous properties. The plastic hub provides ease of manufacture through injection molding while the metal substrate with coupling agent treatment ensures bonding reliability and prevents lifting
3Volume of moving object
If the receptacle edge extends into the accommodation space, then space utilization is improved, but the structure becomes more complex
Solution Approach 1:
The receptacle edge portion extends at an angle (0° to 75°) relative to the axis of rotation, creating a geometric configuration that provides mechanical support in multiple directions. This angular extension of the receptacle edge into the accommodation space adds dimensional complexity to the connection geometry, enhancing rigidity and force transmission capabilities
Solution Approach 2:
The angularly extended receptacle edge serves multiple functions: it provides structural support for the shaft-hub connection, transmits radial forces effectively, and optimizes space utilization within the accommodation space. This multi-functional design element reduces the need for separate components while achieving multiple technical objectives
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 design significantly enhances the rigidity and strength of the shaft-hub connection, effectively transmits radial forces, reduces the risk of hub lifting, and minimizes rotor imbalance, while optimizing space usage and force transmission.
Implementation Method 1
the rotor pot and the shaft are overmolded, preferably with a plastic material, to form the hub
Implementation Method 2
The knurl and the grooves transmit the radial forces via the hub to the rotor pot or optimize the transmission
Data Source
AI summary
A rotor (10) with a rotor pot (1), a hub (2) and a shaft (3) are provided,wherein the rotor pot (1), the hub (2) and the shaft (3) are rotatable about an axis of rotation (A) of the rotor (10).The shaft (3) is accommodated in a hub bushing (21) of the hub (2) to form a shaft-hub connection.The rotor pot (1) has a receptacle (11) for the hub (2) and the hub (2) is secured to the rotor pot (1) at least in the region of the receptacle (11).An edge portion (111) of the receptacle (11) of the rotor pot (1) extends at least partially parallel to the axis of rotation (A).A method is also provided for producing the rotor (10).