Rotor End Ring Reinforcement via Cold Spray
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Solution Overview
Problem
High-speed operation of electric motors leads to deformation or breakage of conductive end rings due to centrifugal force, and existing reinforcing solutions are costly and limited by the shape of the rotor, increasing complexity and cost.
Innovation Solution
A rotor design featuring a cylindrical iron core with a squirrel-cage conductive body and conductive reinforcing layers formed by spraying solid-phase conductive particles, such as stainless steel or titanium, onto the outer surfaces of the conductive end rings and iron core, using the cold spray process to enhance structural strength without additional fixing means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a reinforcing member is attached to the conductive end ring to prevent deformation at high speeds, then the structural strength is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The reinforcing function is merged with the conductive end ring itself by forming a conductive reinforcing layer directly on the outer surface of the conductive end ring. This integration eliminates the need for separate reinforcing members, reducing component count while maintaining the strength enhancement needed for high-speed operation
Solution Approach 2:
A composite structure is created by combining the base conductive end ring material with a conductive reinforcing layer formed through cold spray process. This composite approach provides enhanced structural strength to resist centrifugal forces at high speeds while maintaining electrical conductivity, avoiding the need for additional reinforcing components
2Adaptability or versatility
If a reinforcing member is specially designed according to the rotor shape, then the adaptability is improved, but the manufacturing cost increases
Solution Approach 1:
The cold spray process used to form the conductive reinforcing layer is a universal manufacturing technique that can accommodate various rotor shapes and conductive end ring geometries without requiring custom-designed reinforcing members. This universal approach reduces manufacturing complexity and cost while maintaining adaptability to different rotor configurations
Solution Approach 2:
The conductive reinforcing layer can be applied with varying thicknesses and coverage areas depending on the specific rotor shape and performance requirements. By adjusting process parameters such as spray distance, number of passes, and particle size, the same manufacturing process adapts to different geometries without increasing cost
3Productivity
If the rotor is operated at high speed, then the productivity is improved, but the conductive end ring deforms or breaks due to centrifugal force
Solution Approach 1:
The conductive reinforcing layer is applied in advance to the conductive end ring before high-speed operation begins. This preliminary strengthening creates a protective composite structure that resists the centrifugal forces generated during high-speed rotation, preventing deformation or breakage and enabling reliable high-speed operation
Solution Approach 2:
The combination of the base conductive end ring material and the cold-sprayed conductive reinforcing layer creates a composite structure with enhanced mechanical strength and electrical conductivity. This composite construction allows the rotor to operate at high speeds by withstanding the centrifugal forces that would otherwise cause failure
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 provides enhanced structural strength to prevent deformation and breakage at high speeds, reduces the need for complex reinforcing members, and allows for operation of electric motors at high speeds without shape-related limitations, extending the motor's service life and reducing production costs.
Implementation Method 1
a conductive reinforcing layer extends on at least a part of an outer surface of the conductive end ring, the conductive reinforcing layer being formed by spraying conductive particles in a solid phase onto the outer surface of the conductive end ring
Data Source
AI summary
A rotor including a cylindrical iron core having a through hole for receiving a rotational shaft, and a squirrel-cage conductive body including a plurality of conductive bars and a pair of annular conductive end rings provided at both ends of the plurality of conductive bars is provided. The conductive bars extend along a direction in which the rotational shaft is received and are arranged at an outer circumference of the iron core at certain intervals. The rotor further includes a conductive reinforcing layer extends on at least a part of an outer surface of the conductive end ring. The conductive reinforcing layer is formed by spraying conductive particles in a solid phase onto the outer surface of the conductive end ring.