3D-Printed Electric Machine Rotor Conductors With Diffusion Bonding
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Solution Overview
Problem
The existing methods for producing active parts of electrical machines, such as rotors in asynchronous machines, are complex and expensive due to the need for high-strength connections to withstand centrifugal forces, particularly in high-speed applications, and require processes like Hot Isostatic Pressing or thermal spraying.
Innovation Solution
The use of additive printing techniques, specifically 3D printing, to create electrical conductors and intermediate bodies with a contact layer, forming a diffusion zone between materials like copper, nickel, and steel, which enhances the mechanical strength and stability of the rotor, allowing for a simpler and more cost-effective production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional metallurgical bonding methods (HIP process) are used to create high-strength connections between copper conductors and steel rotor, then mechanical strength is improved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent changes the fundamental parameters of the manufacturing process by replacing the HIP process (high temperature and pressure) with additive manufacturing parameters (layer-by-layer deposition). This allows direct creation of metallurgically bonded structures without requiring external bonding equipment, thus reducing device complexity while maintaining strength
Solution Approach 2:
The patent replaces the mechanical HIP bonding system with an additive manufacturing system that builds structures layer-by-layer. The additive process inherently creates metallurgical bonds between materials during deposition, eliminating the need for separate mechanical bonding equipment and processes
2Strength
If HIP process is used for bonding copper and steel, then mechanical strength is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges the conductor formation and bonding processes into a single additive manufacturing operation. The multimaterial printer deposits copper and steel layers that are metallurgically bonded during the printing process itself, eliminating the need for separate bonding operations and reducing manufacturing cost
Solution Approach 2:
The additive manufacturing process creates self-bonded structures where the deposition process itself generates the metallurgical bond between materials. The built structure serves its own bonding function, eliminating the need for external bonding equipment and reducing manufacturing cost
3Productivity
If conventional manufacturing methods are used, then production process is established, but automation level and customization capability are limited
Solution Approach 1:
The patent implements a dynamic, programmable manufacturing process where the additive manufacturing parameters (layer thickness, deposition path, material selection) can be dynamically adjusted through software control. This enables high automation levels while maintaining flexibility for customization of rotor geometries and conductor configurations
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 approach simplifies the production process, increases automation levels, and enables the creation of customized rotor geometries with improved mechanical strength, effectively addressing the challenges of centrifugal forces and reducing production costs compared to traditional methods.
Implementation Method 1
The electrical conductors are printed, in particular additively printed. This means that an additive printing process is used, has been used, or was used to print the electrical conductors
Implementation Method 2
The subsequent application of an isostatic hot pressing (HIP) process creates a diffusion zone between the copper of the rods and the nickel of the coating, as well as between the nickel of the coating and the steel of the solid rotor
Implementation Method 3
The intermediate body insulates two adjacent electrical conductors from each other when positioned between them
Data Source
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AI summary
The invention relates to an active part (1) of an electric machine (10), having electrical conductors (3, 3', 3' ', 3' ' '), wherein the electrical conductors (3, 3', 3' ', 3' ' ') are additively printed, and an additively printed spacer element (4, 4', 4' ', 4' ' ') is located between the electrical conductors (3, 3', 3' ', 3' ' '). In a method for producing an active part (1) of an electric machine, electrical conductors (3, 3', 3' ', 3' ' ') are additively printed, and a spacer element (4, 4', 4' ', 4' ' ') is additively printed between electrical conductors (3, 3', 3' ', 3' ' '), wherein printing alternates between at least one electrical conductor (3, 3', 3' ', 3' ' ') and a spacer element (4, 4', 4' ', 4' ' ').