Integrated Rotor Slip Ring Layout for Coolant-Tight Sealing
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Solution Overview
Problem
Existing rotors with slip ring devices lack a fluid-tight seal between the rotor and the rubbing contacts, which is problematic in oil-cooled systems, allowing oil to penetrate the slip rings.
Innovation Solution
A rotor design with a slip ring device integrated within the shaft section, featuring a continuous outer shell surface and a bearing device, ensuring a fluid-tight seal and preventing coolant ingress, while using conductive materials like copper and copper alloys for the slip rings and busbars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the slip ring device is plugged from the outside onto the rotor shaft, then the installation is simple, but the bearing arrangement cannot provide a fluid-tight seal between the rotor and rubbing contacts
Solution Approach 1:
Instead of plugging the slip ring device from the outside onto the rotor shaft, the invention inverts the arrangement by integrating the slip ring device within the shaft section. The shaft section is designed with a hollow interior that accommodates the slip ring device, allowing the rubbing contacts to approach from the outside while the slip rings remain protected inside, thereby achieving both simple installation and fluid-tight sealing.
Solution Approach 2:
The slip ring device is nested within the hollow shaft section, with the slip rings positioned inside the shaft section's interior space. This nesting arrangement allows the bearing device to be arranged on the outer surface of the shaft section, creating a nested configuration where the slip ring device is contained within the shaft section, enabling fluid-tight sealing while maintaining structural integrity.
2Reliability
If the slip ring device is integrated within the shaft section with a continuous outer shell surface, then a fluid-tight seal is achieved, but the device complexity increases
Solution Approach 1:
The shaft section is designed to serve multiple functions: it provides structural support for the rotor, contains the hollow interior for housing the slip ring device, maintains a continuous outer shell surface for fluid-tight sealing, and accommodates the bearing device on its outer surface. This multi-functionality reduces the need for separate components, thereby limiting the increase in device complexity while achieving reliable fluid-tight sealing.
3Reliability
If the slip ring device is arranged within the shaft section, then coolant ingress is prevented, but the manufacturing cost increases
Solution Approach 1:
The invention merges the shaft section and slip ring device into an integrated assembly where the hollow shaft section serves as both a structural component and a protective housing for the slip ring device. This merging eliminates the need for separate protective housings or complex sealing mechanisms, thereby limiting the increase in manufacturing cost while effectively preventing coolant ingress to the slip rings.
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 design provides a simple and cost-effective solution that maintains a fluid-tight seal, reducing manufacturing costs and preventing coolant contact with the slip rings, thus enhancing the rotor's operational integrity.
Implementation Method 1
a first busbar (ESS) connected to the first slip ring (ESR) and running through the shaft section (WA), wherein one end (ESSE) of the first busbar (ESS) is guided through a first busbar opening (ESO) formed in the flange section (FA) and is thus led out of an interior of the hollow shaft body (HWK)
Data Source
AI summary
A rotor for a separately excited electric machine, including an assembled rotor shaft having a cylindrical hollow shaft body, at the respective axial end of which a shaft stub is arranged, wherein the respective shaft stub has a flange section and a shaft section including an outer shell surface, a slip ring device running through the shaft section, including at least one annular first slip ring which protrudes beyond a distal end of the shaft section in the axial direction of the rotor, and a first busbar connected to the first slip ring and running through the shaft section, wherein one end of the first busbar is guided through a first busbar opening formed in the flange section, and is thus led out of an interior of the hollow shaft body.