Rotating Machine Monolithic Flange Bearing Mount

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Solution Overview

Problem

Rotating machines face challenges due to increased distance between dynamic and load-carrying elements, which leads to higher component mass and load on anti-friction mechanisms, as well as difficulties in maintaining a small air gap, resulting in increased costs and potential plastic deformation under asymmetric loading.

Innovation Solution

A rotating machine design where the stator and rotor have a mounting flange, with bearings directly mounted to the flange, and the rotor is pre-loaded to reduce the distance between load-carrying elements and maintain a consistent air gap, thereby reducing component mass and assembly costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If anti-friction mechanisms are spaced apart from the static element along the shaft, then the dynamic element can be positioned, but the distance between the dynamic element and load-carrying elements increases, requiring increased component mass

Engineering Contradiction:

Improvepositioning of dynamic elementVSAvoidmass of components

Core Design Contradiction:

Ease of operationVSWeight of moving object

Solution Approach 1:

The patent merges the shaft and mounting flange into a single monolithically formed component. This integration eliminates the need for separate shaft and flange parts, reducing the number of mechanical interfaces and tolerances that would otherwise increase component mass and complexity while maintaining proper positioning of the dynamic element relative to load-carrying elements

Inventive Principle:

Principle #5Merging (Combining)

2Ease of manufacture

If multiple components and mechanical interfaces are used, then the rotating machine can be assembled, but the number of tolerances affecting the air gap increases

Engineering Contradiction:

Improveassembly of rotating machineVSAvoidair gap tolerance

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The mounting flange is formed monolithically with the shaft, reducing the number of separate components and mechanical interfaces. This integration directly reduces the number of tolerances that would otherwise accumulate and affect the air gap between permanent magnets and conductors, improving manufacturing precision while maintaining ease of assembly

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If a shaft is required to support components, then the rotating machine can be assembled, but material, manufacturing, and assembly costs increase

Engineering Contradiction:

Improveassembly of rotating machineVSAvoidshaft and component structure

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The shaft and mounting flange are combined into a single monolithically formed component, reducing the overall device complexity. This integration eliminates the need for separate shaft and flange assemblies, reducing material requirements, simplifying manufacturing processes, and reducing assembly steps while maintaining the structural support function

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The monolithic shaft-flange component performs multiple functions simultaneously: it provides rotational support, structural mounting capability, and load transmission. This multi-functionality reduces the need for separate specialized components, lowering overall device complexity and cost

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Reliability

If additional anti-friction mechanisms are incorporated to prevent unintended contact, then component protection is improved, but the number of mechanical interfaces and tolerances affecting the air gap increases

Engineering Contradiction:

Improveprevention of unintended contactVSAvoidair gap tolerance

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

By integrating the mounting flange with the shaft, the patent reduces the total number of mechanical interfaces in the system. This reduction in interfaces decreases the cumulative tolerance stack-up that would affect the air gap, while the monolithic structure provides inherent stability that prevents unintended contact, maintaining reliability without additional anti-friction mechanisms

Inventive Principle:

Principle #5Merging (Combining)

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 reduces the mass of components, minimizes plastic deformation, and decreases assembly costs by directly mounting bearings to the stator, enhancing the stability and efficiency of the rotating machine.

Implementation Method 1

one or more anti-friction mechanisms (e.g., bearings)

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

generating a magnetic field with a magnetized material

Methodology Applied

Scientific EffectMagnetic field: Magnetic Field

Implementation Method 3

interacting a conductor with the magnetic field to generate a rotational force

Methodology Applied

Scientific EffectElectromagnetic interaction: Lorentz Force

Data Source

PatentUS11637477B2Rotating machine

Publication Date: 2023.04.25 GENTILE JOSEPH

AI summary

Example aspects of a rotating machine, a method for pre-loading a rotating machine, and a method for using a rotating machine are disclosed. The rotating machine can comprise a stator; a rotor, wherein one of the stator and the rotor comprises a mounting flange formed monolithically therewith; a bearing directly mounted to the mounting flange; and the other of the stator and the rotor directly mounted to the bearing.