Rotor Shaft Assembly Device for Electric Machine Laminated Core Centering
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Solution Overview
Problem
Existing methods for assembling rotor segments of electric machines face challenges in centering and angular orientation of laminated cores on the rotor shaft, leading to nonuniform torque transmission due to radial play and varying magnetic flux, which impairs optimal torque transmission and results in nonuniform torques during operation.
Innovation Solution
A method and assembly device that utilize orienting means and clamping means to position and orient laminated cores relative to the rotor shaft, using pressure elements and markings for precise angular positioning, allowing for coaxial alignment and interference fits to ensure accurate angular offset and centering, thereby enabling efficient torque transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If radial play is formed between shaft outer diameter and laminated core inner diameter to enable gap formation, then ease of assembly is improved, but manufacturing precision deteriorates due to inability to use interference fit or form fit for centering
Solution Approach 1:
A centering element is introduced as an intermediary component between the shaft and laminated core. This centering element has a first end that contacts the shaft outer diameter and a second end that contacts the laminated core inner diameter, enabling precise centering without requiring interference fit or form fit between the shaft and core directly.
2Adaptability or versatility
If geometric elements are added to individual stack disks for angular orientation, then angular position adjustability is improved, but device complexity increases due to multiple laminated core geometries
Solution Approach 1:
The angular orientation function is extracted from the laminated core geometry itself and transferred to a separate angular orientation element. This allows the laminated core to maintain a single standardized geometry while the angular orientation element provides the necessary angular positioning capability through features like teeth and grooves.
3Measurement precision
If multiple laminated core geometries are used for angular offset positioning, then angular position precision is improved, but manufacturing cost increases due to non-uniform magnetic flux
Solution Approach 1:
All laminated cores are designed with identical geometry and magnetic properties, ensuring uniform magnetic flux distribution. The angular positioning is achieved not by varying the laminated core geometry, but by using a standardized angular orientation element that can be configured to provide the required angular offsets without affecting magnetic uniformity.
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 allows for simple and economical centering and angular orientation of laminated cores, ensuring uniform torque transmission and improved magnetic flux distribution, resulting in enhanced operational performance of electric machines.
Implementation Method 1
orienting means for orienting the rotor shaft in a defined assembly position
Implementation Method 2
clamping means for positioning the at least one laminated core as well as at least one of the pressure elements relative to the rotor shaft
Implementation Method 3
two pressure elements, which clamp the at least one laminated core
Data Source
AI summary
A device may be used to assemble a rotor segment of an electric machine. The rotor segment may include a rotor shaft, a laminated core joined to the rotor shaft, and two pressure elements that clamp the laminated core. A method for assembling the rotor segment may involve positioning the rotor shaft in the device and orienting the rotor shaft using an orienting means of the assembly device, positioning the laminated core and at least one of the first or second pressure elements within a clamping means of the device, orienting the laminated core by means of a positioning module of the clamping means, and moving the rotor shaft relative to the clamping means such that the laminated core is pushed onto the rotor shaft and the at least one of the first or second pressure elements is connected to the rotor shaft.