Rotor Shaft Structural Elements for Core Stack Connection
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Solution Overview
Problem
The existing methods for producing rotors with a core stack firmly connected to a rotor shaft are time-consuming and expensive, requiring extensive machining and a complex shrinking process to prevent relative rotation during normal use.
Innovation Solution
A rotor design featuring a rotor shaft with a circular cylinder surface region and radially outward structural elements allows the core stack to be pushed over and pressed against the shaft, causing plastic deformation to create a reliable, torsion-proof connection, thereby simplifying the production process and ensuring a positive closure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the core stack is shrunk onto the rotor shaft using conventional methods, then a firm connection is achieved, but the production process becomes time-consuming and expensive due to extensive machining requirements
Solution Approach 1:
The rotor shaft is prepared in advance with structural elements (protrusions or deformable regions) that will engage with the core stack during assembly. This preliminary preparation eliminates the need for extensive machining of the shaft after assembly, as the connection features are built-in from the start.
Solution Approach 2:
The connection method transitions from thermal shrinking (heat-based parameter change) to mechanical deformation (force-based parameter change). The core stack is pressed axially to plastically deform the structural elements, creating a firm connection without requiring thermal processes or complex machining operations.
2Reliability
If extensive machining of the rotor shaft is performed prior to shrinking, then a reliable connection is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The structural elements are incorporated into the rotor shaft design before assembly. These elements (protrusions or deformable regions) are positioned and sized in advance to ensure reliable engagement with the core stack, eliminating the need for post-assembly machining or complex shrinking fixtures.
Solution Approach 2:
Instead of machining the entire rotor shaft surface, only specific localized regions are designed with structural elements. This localized approach maintains connection reliability at the interface between shaft and core stack while simplifying the overall manufacturing process and reducing complexity.
3Ease of manufacture
If the core stack is pressed against structural elements causing plastic deformation, then a simple production process is achieved, but the structural elements must be precisely designed
Solution Approach 1:
The connection is achieved through controlled plastic deformation of the structural elements during pressing. The elements are designed with specific geometric parameters (protrusion height, radius, spacing) that enable reliable engagement when the core stack is pressed axially, simplifying the assembly process while maintaining precision through design rather than complex manufacturing.
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
This approach enables a cost-effective and efficient production of rotors with a stable, torsion-resistant connection between the rotor shaft and core stack, reducing manufacturing costs while maintaining reliability.
Implementation Method 1
the core stack is plastically deformed and by this means a positive connection between the rotor shaft and the core stack is generated
Data Source
AI summary
The invention relates to a rotor that exhibits a rotor shaft, by which a rotor axis is defined, and also a core stack that is arranged around the rotor shaft along a longitudinal portion of the rotor axis. Along the longitudinal portion the rotor shaft exhibits a first surface region, the shape of which describes a circular cylinder, and also a second surface region which is constituted by structural elements that with respect to the rotor axis rise radially outwardly above the first surface region. For the purpose of producing the rotor, the core stack can be pushed over the rotor shaft and in the process can be pushed against the structural elements) in such a manner that it is deformed and by this means a positive connection between the rotor shaft and the core stack is generated. In this way, in particularly simple manner in terms of production engineering a reliable and torsion-proof connection between the core stack and the rotor shaft can be formed.