Rotor Bar Protrusion Clamping for Induction Motor Core Fixation

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Solution Overview

Problem

Conventional induction motor rotor mechanisms face challenges in securely fixing the rotor core during manufacturing, particularly in forming end rings without auxiliary support and avoiding welding, which can lead to inefficiencies and increased costs.

Innovation Solution

The rotor mechanism incorporates rotor bars with protruding portions that are deformed to clamp and fix the rotor core, allowing for the elimination of auxiliary supports and the formation of end rings through casting aluminum, which reduces manufacturing costs and improves starting performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional methods are used to fix the rotor core during manufacturing, then the rotor core can be securely positioned, but auxiliary supports are required which increase device complexity and manufacturing cost

Engineering Contradiction:

Improverotor core fixationVSAvoidauxiliary support structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The rotor bar's protruding portions serve dual functions: as structural extensions for positioning and as clamping elements that deform to secure the rotor core. The rotor bar itself performs the fixation function without requiring separate auxiliary support structures, achieving self-service and eliminating additional components.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The protruding portions of the rotor bar are designed to perform multiple functions: they extend from the rotor bar body for positioning, clamp the rotor core during manufacturing, and become part of the final rotor structure. This multi-functionality eliminates the need for dedicated auxiliary support components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If welding is used to form end rings, then strong structural bonds are achieved, but manufacturing cost and complexity increase

Engineering Contradiction:

Improveend ring bond strengthVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent replaces the welding process (thermal/mechanical joining) with a deformation-based clamping mechanism. The protruding portions are deformed to clamp the rotor core, and end rings are formed through casting rather than welding, substituting a simpler manufacturing process that achieves sufficient structural integrity without the complexity of welding operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the joining parameter from welding (high temperature, complex process) to deformation and casting (lower temperature, simpler process). The protruding portions are deformed to create clamping force, and end rings are cast in place, representing a parameter change that simplifies manufacturing while maintaining structural strength.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If rotor bars are inserted without deformation, then insertion is simple, but the rotor core cannot be securely clamped

Engineering Contradiction:

Improveinsertion processVSAvoidrotor core clamping

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The rotor bars are designed with pre-formed protruding portions that extend beyond the rotor bar body before insertion. This preliminary configuration allows the bars to be inserted easily through the rotor core slots, and the protruding portions are then deformed to create the clamping action, separating the insertion and clamping actions for optimal ease and reliability.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The rotor bar protruding portions transition from a rigid insertion state to a deformed clamping state. The dynamic deformation process allows the same structural element to serve both insertion and clamping functions, achieving ease of manufacture during insertion and reliable clamping after deformation.

Inventive Principle:

Principle #15Dynamics

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 solution effectively secures the rotor core in place without additional supports and enables the formation of end rings through casting, enhancing the motor's starting performance and reducing vibration and noise.

Implementation Method 1

deforming the protruding portions of the plurality of rotor bars that penetrate through two opposite sides of the rotor core, such that the rotor core is clamped and fixed by the protruding portions

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS10804761B2Rotor mechanism and method for manufacturing the same

Publication Date: 2020.10.13 IND TECH RES INST

AI summary

The present disclosure provides a rotor mechanism includes a rotor core and a plurality of rotor bars. The rotor core has a plurality of insertion slots arranged along an edge of the rotor core. Each of the plurality of rotor bars has an insertion portion and two protruding portions. The insertion portions are respectively located in the plurality of insertion slots, wherein in each of the plurality of rotor bars, the two protruding portions are respectively connected to two opposite ends of the insertion portion and respectively protrude from two opposite sides of the rotor core, and the two protruding portions each has an extension direction, that has an angle with respect to an extension direction of the insertion portion, in order to clamp and fix the rotor core therebetween. In addition, the present disclosure also provides a method for manufacturing the rotor mechanism.