Hollow-Shaft Rotor Rectifier Layout for Heat and Vibration Control
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Solution Overview
Problem
Inductively electrically excited synchronous machines face issues with electrical component damage due to centrifugal forces and vibrations, limited component selection due to strength requirements, and high cooling challenges, leading to increased costs and reduced operational limits.
Innovation Solution
A rotor assembly with a hollow shaft and a rectifier aligned transversely to the axis of rotation, housed within the shaft's cavity, reduces centrifugal forces and provides effective cooling through a cooling body and fluid circulation, enhancing rotational stability and reducing mechanical and thermal stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the rectifier is positioned close to the shaft and close to the rotor, then the structural compactness is improved, but the temperature limit is constrained by the electrical component parts' upper temperature limit
Solution Approach 1:
The rotor assembly is divided into functionally independent modules: the rectifier assembly with electrical components is separated from the rotor assembly with windings, and further separated from the shaft. This spatial segmentation allows each module to operate within its optimal temperature range without mutual thermal interference, resolving the contradiction between compactness and temperature constraints.
Solution Approach 2:
The patent transitions from a two-dimensional planar arrangement to a three-dimensional distributed spatial configuration. The rectifier is positioned in a radial plane at a specific distance from the shaft center, creating a three-dimensional layout that optimizes both compactness and thermal management by utilizing spatial distribution rather than planar proximity.
2Stability of the object's composition
If the electrical component parts are arranged in a diameter around the shaft, then the rotational stability is improved, but the centrifugal forces and vibrations cause damage to the electrical component parts and soldered joints
Solution Approach 1:
A non-conductive support structure serves as an intermediary between the rotating shaft and the electrical component parts. This mediator provides mechanical support and electrical isolation, allowing the rectifier assembly to maintain rotational stability while being protected from excessive centrifugal forces and vibrations that would otherwise damage the components and their connections.
Solution Approach 2:
The support structure is designed with cushioning characteristics to absorb and mitigate the effects of centrifugal forces and vibrations before they can damage the electrical components and soldered joints. This preventive design approach protects the fragile connections from mechanical stress during rotation.
3Volume of moving object
If the rectifier is positioned close to the shaft, then the space utilization is improved, but the cooling of the shaft and rotor becomes more challenging
Solution Approach 1:
The rectifier assembly is extracted from the immediate vicinity of the shaft and positioned at an optimized distance on the rotor assembly. This extraction creates dedicated cooling spaces and thermal zones, allowing independent cooling strategies for the shaft, rotor, and rectifier without the thermal interference that would result from close positioning.
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 enhances rotational speed stability, reduces mechanical damage, and improves cooling efficiency, allowing higher operational speeds and lower costs while maintaining component integrity.
Implementation Method 1
a cooling body (12) fastened to the printed circuit board (10) so as to face away from the electrical component parts (11) and so as to conduct heat
Implementation Method 2
The hollow shaft (3) has a cavity (9) and the secondary-side circuit (5), thus the rectifier (7) and the secondary coil (8), are arranged in the cavity (9)
Data Source
AI summary
A rotor assembly for an inductively electrically excited synchronous machine may include a hollow shaft, a rotor connected to the hollow shaft, and a secondary-side circuit of an energy transmitter. The secondary-side circuit may be arranged in a rotationally fixed manner in the rotor assembly. The secondary-side circuit may include a rectifier. The rectifier may include a printed circuit board and at least one electrical component part fastened to the printed circuit board and a secondary coil. The rectifier may be aligned transversely to an axis of rotation of the hollow shaft and may be arranged in a rotationally fixed manner in a cavity of the hollow shaft. The rectifier may include a cooling body abutting against the printed circuit board such that the cooling body faces away from the at least one electrical component part and transmits heat.