Rotor Cooling Passage Layout for Tolerant Shaft-End Plate Alignment
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Solution Overview
Problem
The existing cooling structure for electric motors requires precise alignment and high machining and assembly accuracy, leading to increased manufacturing time and cost due to the need for precise alignment of the rotation shaft and end plates.
Innovation Solution
A rotor design with a hollow shaft and end plates featuring ribs and refrigerant passages, where the refrigerant entry portion has a larger circumferential length than the supply hole, allowing for easier alignment and reduced machining and assembly precision requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If precise alignment of rotation shaft and end plates is required for refrigerant passage connection, then coil cooling performance is improved, but manufacturing time and cost increase
Solution Approach 1:
The invention changes the dimensional parameters of the refrigerant passage system by making the circumferential length of the refrigerant entry portion larger than that of the supply hole. This parameter change creates an overlapping area that accommodates alignment deviations, thereby maintaining cooling performance while reducing assembly precision requirements and manufacturing time
Solution Approach 2:
The design anticipates potential alignment deviations during assembly by pre-designing a larger entry portion that acts as a buffer zone. This beforehand cushioning ensures that even if alignment is not perfectly precise, the refrigerant passages will still connect properly, maintaining cooling effectiveness without requiring strict tolerance control
2Reliability
If precise alignment of rotation shaft and end plates is required for refrigerant passage connection, then refrigerant flow connection is improved, but machining accuracy and assembling accuracy requirements increase
Solution Approach 1:
The invention modifies the geometric parameters of the refrigerant passage components by enlarging the circumferential dimension of the entry portion relative to the supply hole. This creates a dimensional buffer that tolerates assembly variations, ensuring reliable refrigerant flow connection without demanding high assembling accuracy
Solution Approach 2:
The design incorporates a built-in alignment buffer by making the entry portion larger than the supply hole opening. This beforehand cushioning anticipates and compensates for potential misalignment during assembly, ensuring that refrigerant passages connect properly even with moderate assembly precision
3Reliability
If precise alignment of rotation shaft and end plates is required for refrigerant passage connection, then cooling system effectiveness is improved, but device complexity increases
Solution Approach 1:
The invention simplifies the device by changing the dimensional parameters of the refrigerant passage - specifically making the entry portion larger than the supply hole. This parameter change eliminates the need for complex alignment mechanisms or procedures, reducing device complexity while maintaining cooling effectiveness through the created alignment tolerance buffer
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 manufacturing costs and time while maintaining high coil cooling performance by allowing for more forgiving alignment tolerances and efficient refrigerant flow, thereby reducing the complexity and cost of producing rotary electric machines.
Implementation Method 1
the refrigerant is supplied from the rotation shaft to the coils of the stator, via the end plates
Implementation Method 2
a passage through which a refrigerant flows, between the end plate and the rotor core
Data Source
AI summary
A rotor for a rotary electric machine includes: a rotor core; a shaft that is hollow and that supports the rotor; and an end plate that is disposed on an end of the rotor in a rotational axis direction, and that forms a passage through which a refrigerant flows, between the end plate and the rotor core, in which the end plate includes a plurality of ribs that come into contact with the shaft, the passage includes a refrigerant entry portion that is provided between the plurality of ribs, and a refrigerant exit portion that communicatively connects the refrigerant entry portion to an outer peripheral surface of the end plate, the shaft has a refrigerant supply hole communicatively connecting the refrigerant entry portion to internal of the shaft, and a circumferential length of the refrigerant entry portion along an innermost diameter is larger than a circumferential length of the refrigerant supply hole.