Squirrel-Cage Rotor Metal Composite Discs
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Solution Overview
Problem
Existing squirrel-cage rotor designs for asynchronous machines face challenges in achieving reliable and efficient connections between short-circuit rings and rotor bars, particularly in terms of electrical conductivity, mechanical stability, and cost optimization, especially under high rotational speeds.
Innovation Solution
The use of metal composite discs, comprising two different materials connected in a planar and electrically conductive manner, with adjacent discs facing each other, allows for a single connection process such as welding, reducing connection costs and improving conductivity and stability by using materials like aluminum and copper alloys.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional soldering processes are used to connect short-circuit rings to rotor bars, then reliable electrical connection is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies composite materials by using metal composite discs comprising a copper disc and an aluminum disc connected in a planar and electrically conductive manner. The copper disc provides excellent electrical conductivity for connection to rotor bars, while the aluminum disc offers mechanical stability and cost optimization. This composite structure enables reliable welding connections while maintaining electrical conductivity, eliminating the need for complex soldering processes.
2Reliability
If multiple connection processes are used for short-circuit rings and rotor bars, then connection reliability is improved, but manufacturing cost and time increase
Solution Approach 1:
The patent merges multiple functions into a single connection process. The metal composite disc structure allows both electrical connection and mechanical stabilization to be achieved through one welding operation. The copper disc ensures electrical conductivity for the connection to rotor bars, while the aluminum disc provides mechanical support, combining what would traditionally require separate processes into a single efficient operation.
3Reliability
If copper metal sheets are used for short-circuit rings, then electrical conductivity is improved, but mechanical stability deteriorates due to expansion at high rotational speeds
Solution Approach 1:
The patent uses a composite structure with a copper disc and an aluminum disc connected in a planar and electrically conductive manner. The copper disc ensures excellent electrical conductivity for current flow, while the aluminum disc provides mechanical stability and resistance to expansion at high rotational speeds. This composite approach allows both electrical and mechanical requirements to be satisfied simultaneously.
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 enables a reliable, efficient, and cost-effective connection between short-circuit rings and rotor bars, enhancing electrical conductivity and mechanical stability while reducing the complexity and cost of the connection process.
Implementation Method 1
The rotor bars are bonded, preferably welded, to the first metal discs in the region of the slots
Data Source
AI summary
A squirrel-cage rotor having at least one laminated rotor core and a method of manufacturing the same are provided. Short-circuit rings in the squirrel-cage rotor are provided with at least two metal composite discs. A metal composite disc includes at least a first metal disc and a second metal disc connected to the first metal disc, where the second metal disc is made of a different material from the first metal disc. Adjacent metal composite discs are arranged such that the first metal discs face one another. The short-circuit rings are attached at an end face to the rotor core. Conductive rotor bars are attached to the first metal disc in the region of slots arranged in the outer periphery of the short-circuit rings.