Rotor Cup-Hub Structure for Rigid Shaft Support
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Solution Overview
Problem
Existing rotor shaft-hub connections lack sufficient support and radial force transmission, leading to instability and undesirable deformation, particularly with plastic connections where the material can protrude from the yoke.
Innovation Solution
A rotor design where the shaft is supported by a hub bushing within a receptacle of the rotor pot, with an edge section of the receptacle extending parallel or angled to the axis of rotation, and the rotor pot and shaft are encapsulated in plastic, enhancing rigidity and force conduction through knurling and recesses, and using a metallic rotor pot for improved stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a plastic shaft-hub connection is used, then the rotor can be manufactured with simpler processes, but the shaft support rigidity and radial force transmission are insufficient
Solution Approach 1:
The invention uses a composite structure combining plastic and metal components. The hub is made of plastic for ease of manufacturing, while metal inserts are embedded in the plastic to provide the necessary rigidity and radial force transmission. This composite approach allows the plastic hub to be easily manufactured while the metal inserts ensure sufficient mechanical strength and stability for the shaft connection.
2Strength
If metal inserts are used for shaft-hub connection, then shaft support rigidity is improved, but the complexity of manufacturing increases
Solution Approach 1:
The invention merges the plastic hub and metal inserts into a single integrated component. The metal inserts are embedded directly into the plastic hub during the manufacturing process, creating a unified structure that provides both the manufacturing simplicity of plastic and the mechanical strength of metal. This merging eliminates the need for separate assembly steps and reduces overall structural complexity.
3Strength
If the receptacle edge section extends parallel to the rotational axis, then shaft support rigidity is maximized, but the installation space for the electric motor is reduced
Solution Approach 1:
The invention applies local quality by extending the receptacle edge section parallel to the rotational axis only in the specific region where the shaft connection requires maximum rigidity. This localized extension provides enhanced shaft support where needed, while the rest of the rotor pot maintains its original design to accommodate the electric motor. The solution optimizes the balance between connection strength and motor installation space by applying the structural reinforcement only where mechanically necessary.
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
The solution significantly increases the rigidity and strength of the shaft-hub connection, effectively transferring radial forces and reducing imbalance and deformation, while optimizing space usage and force conduction.
Implementation Method 1
the hub is made of a plastic and is molded onto at least the receptacle by means of an injection molding process
Implementation Method 2
The knurling and the recesses transmit the radial forces via the hub to the rotor cup or optimize their transmission
Data Source
Figure 1
AI summary
The invention relates to a rotor (10) comprising a rotor cup (1), a hub (2), and a shaft (3), wherein the rotor cup (1), the hub (2), and the shaft (3) are rotatable about an axis of rotation (A) of the rotor (10), the shaft (3) being received in a hub bushing (21) of the hub (2) to form a shaft-hub connection, the rotor cup (1) having a receptacle (11) for the hub (2), and the hub (2) being attached to the rotor cup (1) at least in the region of the receptacle (11), wherein an edge section (111) of the receptacle (11) of the rotor cup (1) extends at least partially parallel to the axis of rotation (A). The invention further relates to a method for manufacturing the rotor (10).