Integrated Rotor Shaft and Slip Ring Module for Higher Load Capacity
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Solution Overview
Problem
The use of a multiple-part rotor shaft for current-energized rotors in electric machines leads to reduced stability and mechanical load-bearing capability due to separate bearing seats, which compromises the robustness and reliability of the rotor shaft.
Innovation Solution
A single-part, metallic rotor shaft with a circular-cylindrical shaft part that integrates a rotor body region for an interference fit, a support element, and a slip ring module with electrically isolating plastics material, ensuring efficient and reliable assembly and electrical connection while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a multiple-part rotor shaft with separate bearing seats is used, then the ease of manufacture and assembly is improved, but the stability and mechanical load-bearing capability deteriorate
Solution Approach 1:
The patent merges the bearing seat and the shaft into a single integral structure. The bearing seat is formed as an inherent part of the shaft body through machining operations, eliminating the need for separate bearing seat components. This integration strengthens the overall structure while maintaining manufacturing feasibility through standard machining processes.
2Ease of manufacture
If a multiple-part rotor shaft with separate bearing seats is used, then the ease of assembly is improved, but the mechanical load-bearing capability deteriorates
Solution Approach 1:
The shaft and bearing seat are combined into a single monolithic component. The bearing seat is machined directly from the shaft material, creating continuous grain structure and eliminating weak interfaces. This integration significantly enhances mechanical load-bearing capability while the component can still be manufactured using conventional machining techniques.
3Stability of the object's composition
If a single-part metallic rotor shaft is used, then the stability and mechanical load-bearing capability are improved, but the ease of manufacture and assembly deteriorates
Solution Approach 1:
The shaft is designed with functionally segmented features (bearing seat, connecting region, support element) that are machined from a single material block. This approach combines the stability of monolithic construction with the manufacturing advantages of feature segmentation, allowing each functional region to be optimized independently through machining operations.
Solution Approach 2:
The shaft material parameters and geometric parameters are optimized to balance manufacturing ease with structural performance. The bearing seat diameter, connecting region dimensions, and support element geometry are carefully selected to enable conventional machining while achieving the required mechanical strength and stability.
4Strength
If a single-part metallic rotor shaft is used, then the mechanical load-bearing capability is improved, but the ease of assembly deteriorates
Solution Approach 1:
The bearing seat is integrated directly into the shaft body, eliminating the need for separate bearing seat components and their associated assembly steps. This integration maintains high mechanical load-bearing capability while actually simplifying assembly by reducing the number of parts that need to be fitted together.
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 a robust, durable, and efficiently producible rotor shaft with enhanced stability and mechanical load-bearing capability, ensuring reliable operation and preventing fluid and metallic dust leakage between the rotor windings and slip rings.
Implementation Method 1
the shaft part can be joined to the rotor body by means of an interference fit in the rotor body region
Data Source
AI summary
Please substitute the new Abstract submitted herewith for the original Abstract: A rotor shaft has a shaft part extending along the axis of rotation of the rotor and which has a rotor body region for arrangement in the rotor body. The shaft part has a carrier element that follows in the axial direction. The shaft part has grooves extending in the axial direction from an attachment region of the shaft part to the carrier element. The rotor shaft includes a slip ring module having a base element with slip rings arranged on the carrier element of the shaft part. The slip ring module electrically conductive module lines extending from the corresponding slip rings inside the corresponding grooves to the attachment region of the shaft part. The rotor shaft also includes a bearing surface, on the shaft part and/or on the slip ring module, for mounting of the rotor shaft.