Separately Excited Rotor Electrical Connecting Assembly
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Solution Overview
Problem
The existing electrical connecting methods for separately excited rotors in rotary electric machines, such as wound or slip ring rotors, face challenges in mechanical holding and production complexity due to high-speed rotation and the need for deformable connectors, which are difficult to shape and stabilize.
Innovation Solution
The use of separate axial and radial electrical conductors connected through a slip ring assembly, which is embedded in a holding element and overmolded with insulation, providing a robust and stable electrical connection that reduces production complexity and enhances mechanical holding, eliminating the need for deformable connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If deformable electrical connectors are used to connect the field coil to the slip rings, then the electrical connection can be established, but the manufacturing complexity increases and the mechanical stability deteriorates under high-speed rotation
Solution Approach 1:
The electrical connection is divided into two separate rigid conductors: an axial electrical conductor connected to the slip ring and a radial electrical conductor connected to the field coil. These two conductors are electrically connected through a holding element rather than using a single deformable connector, thereby eliminating the need for complex deformation operations while maintaining electrical connectivity.
Solution Approach 2:
The patent replaces the mechanical deformation process (shaping deformable connectors) with a straightforward assembly process where two rigid conductors are positioned and electrically connected. This substitution eliminates complex manual shaping operations and improves mechanical stability under centrifugal forces.
2Ease of manufacture
If a single wire is used to connect the field coil through the rotor shaft, then the electrical connection is simplified, but the shaping operation becomes complex and time-consuming
Solution Approach 1:
Instead of using a single wire that requires complex shaping and deformation operations, the patent segments the electrical connection into two separate rigid conductors (axial and radial) that are easier to manufacture and assemble. This segmentation eliminates time-consuming shaping operations while maintaining the electrical connection function.
Solution Approach 2:
The axial and radial electrical conductors are prepared as separate pre-formed components before assembly. This preliminary preparation eliminates the need for complex on-site shaping operations, thereby reducing production time and improving ease of manufacture.
3Reliability
If deformable electrical connectors are used, then the electrical connection can be made, but the positioning stability deteriorates during high-speed rotation due to centrifugal forces
Solution Approach 1:
The electrical connection is segmented into two rigid conductors (axial and radial) that are separately positioned and secured. This segmentation allows each conductor to be independently held in place, improving positioning stability under centrifugal forces compared to a single deformable connector.
Solution Approach 2:
Instead of using a deformable connector that must be shaped and held in place, the patent uses two rigid conductors that are naturally stable and require minimal holding mechanisms. This inversion of the approach (from deformable to rigid) improves positioning stability while reducing the complexity of holding mechanisms.
Data Source
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Figure 3
Figure 4~5
AI summary
The invention concerns a rotor (1) comprising a rotor shaft (4) configured to rotate around an axis (X) of rotation, a rotor body (2) formed of a stack of laminations, a field coil (3) wound around the rotor body (2), at least one slip ring (110) configured to exchange electric power with an external power supply, the at least one slip ring (110) being electrically connected to an end (31) of the field coil (3) through an electrical connecting assembly (10) comprising an axial electrical conductor (120) and a radial electrical conductor (130), the axial electrical conductor (120) passing through an axial bore (41) of the rotor shaft (4), the radial electrical conductor (130) passing through a radial bore (42) of the rotor shaft (4), the axial electrical conductor (120) and the radial electrical conductor (130) being two separate pieces configured to be electrically connected together.