Rotor Contact Element Positioning for Tool Accessibility
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Solution Overview
Problem
The connection of winding ends to a slip ring module in rotor production is complicated due to limited structural space, making it difficult to access tools required for connection, such as crimping or welding tools.
Innovation Solution
A rotor design that allows a contact element to be positioned along the rotor axis in an intermediate position offset from the end position, enabling better accessibility and using methods like crimping, soldering, or welding, with a guide element and support elements to facilitate the connection of conductor ends to the slip ring module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the contact element is positioned close to the rotor (end position) to reduce structural space, then the rotor becomes more compact, but accessibility for tools required for connection is significantly limited
Solution Approach 1:
The contact element is designed to be displaceable along the rotor axis, transitioning between an intermediate position during connection operations and an end position during operation. This dynamic positioning allows the system to optimize for accessibility during manufacturing and for compactness during operation, resolving the contradiction between these two requirements.
Solution Approach 2:
The contact element is positioned in an intermediate position before the connection operation is performed, providing adequate space for tool engagement. After the connection is established, the contact element is then displaced to the end position. This preliminary positioning ensures that accessibility requirements are met before the compact configuration is activated.
2Ease of operation
If the contact element is positioned far from the rotor (intermediate position) to improve accessibility for tools, then tool engagement is facilitated, but the structural space requirement increases
Solution Approach 1:
The contact element's ability to move along the rotor axis allows it to occupy an intermediate position during connection operations, providing the necessary accessibility for tools. After the connection is complete, it transitions to the end position to minimize structural space. This dynamic behavior resolves the contradiction by allowing both configurations at different times.
Solution Approach 2:
The contact element is preliminarily positioned in the intermediate position to enable tool access for connection operations. Once the connection is established, it is then moved to the compact end position. This sequential positioning strategy allows the system to prioritize accessibility when needed and compactness when operational.
3Ease of manufacture
If the contact element is fixed in position to simplify structure, then manufacturing is easier, but adaptability for different connection methods and positions is limited
Solution Approach 1:
The contact element is designed with displacement capability along the rotor axis, allowing it to move between intermediate and end positions. This dynamic feature provides versatility for different connection methods and positions while maintaining a relatively simple overall structure, balancing ease of manufacture with adaptability.
Solution Approach 2:
The contact element is separated from the rotor body as a distinct, movable component rather than being fixed integrally. This segmentation allows the contact element to be independently positioned and displaced, providing adaptability for different connection operations while keeping the rotor structure itself simple and easy to manufacture.
Data Source
AI summary
The invention relates to a rotor for an electric machine, comprising at least one first (22) and a second (32) conductor end and a contact element, which provides a connection between the at least two conductor ends (22, 32), and wherein the contact element can be positioned along a rotor axis (R) of the rotor in such a way that the connection can be established in an intermediate position, which is offset away from the rotor in relation to an end position of the contact element.