Electric Machine Rotor Assembly with Pre-Balanced Parts
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Solution Overview
Problem
The existing rotor balancing method for electric machines often results in costly scrap due to unbalances that cannot be rectified after assembly, as balancing is done post-assembly.
Innovation Solution
The method involves individually balancing the parts of an electric machine rotor before assembly, allowing for pre-assembly balancing of parts into groups, reducing the risk of unbalance and enabling counterbalancing of minor imbalances during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If balancing is performed after complete rotor assembly, then the rotor can be balanced as a whole system, but the scrap rate increases due to uncorrectable unbalances
Solution Approach 1:
The patent applies preliminary action by balancing individual rotor parts (end pieces, shaft center piece) before they are assembled into the complete rotor. This pre-balancing allows detection and correction of unbalances in individual components, preventing the need to scrap entire assembled rotors due to uncorrectable unbalances.
Solution Approach 2:
The patent segments the rotor into individual parts (end pieces, shaft center piece) that can be balanced separately. This segmentation enables independent balancing of each component, allowing faults to be identified and corrected at the component level rather than requiring disposal of the entire rotor assembly.
2Loss of substance
If individual parts are balanced separately before assembly, then the scrap rate is reduced, but the production process becomes more complex
Solution Approach 1:
The production process is segmented into distinct phases: individual part balancing and subsequent assembly. While this adds a step, it simplifies the overall process by allowing standard balancing procedures to be applied to individual components rather than requiring complex post-assembly balancing of the complete rotor.
Solution Approach 2:
By performing balancing actions preliminarily on individual parts, the patent eliminates the need for complex rework or scrapping after assembly. The preliminary balancing of components simplifies the final assembly process, as parts are already balanced and require minimal adjustment.
3Productivity
If individual parts are balanced separately, then production cost-effectiveness improves, but the assembly process requires additional alignment steps
Solution Approach 1:
The preliminary balancing of individual parts during manufacturing reduces the need for expensive scrapping and rework later in production. Although assembly requires alignment steps, the overall productivity improves because balanced components assemble more efficiently with fewer adjustments needed after completion.
Data Source
AI summary
A method for producing a rotor of an electric machine is disclosed. The method may include providing at least two individual parts and individually balancing the at least two individual parts. The method may also include, subsequently to balancing the at least two individual parts, connecting the at least two balanced individual parts to one another such that the rotor is at least unbalance-low.