Rotor Winding Support Arrangement for Centrifugal Load Restraint
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Solution Overview
Problem
Conventional support arrangements for rotor windings in electric motors are either excessively material-intensive or fail to adequately secure the windings, leading to potential dislocation under centrifugal forces.
Innovation Solution
A support arrangement featuring an annular star disc with radially extending arms and axially extending fork structures to secure winding overhangs, combined with an end plate that absorbs radial loads, reducing material usage and enhancing winding security.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional means for securing rotor windings are used, then the windings are secured to the rotor core, but an excessive amount of material is utilized which increases the weight of the rotor core
Solution Approach 1:
The support arrangement is segmented into multiple radially extending arms that are evenly distributed around the rotor core. Each arm independently supports winding overhang portions, distributing the securing function across multiple discrete elements rather than using a single massive structure, thereby reducing overall material usage while maintaining securing reliability.
Solution Approach 2:
The support arrangement extends radially outward from the rotor core in a dimensional configuration that efficiently utilizes space. The arms extend in the radial dimension while the fork structures provide support in the axial dimension, creating a three-dimensional support network that secures windings with minimal material.
2Reliability
If conventional means for securing rotor windings are used, then the windings are secured to the rotor core, but the windings are not sufficiently secured and may be dislocated under centrifugal forces
Solution Approach 1:
The support arrangement is divided into multiple discrete arms spaced around the rotor circumference. Each arm provides localized support for specific winding overhang portions, creating multiple securement points that collectively prevent dislocation under centrifugal forces while using less total material than a continuous support structure.
Solution Approach 2:
The fork structures are positioned to engage and support the winding overhang portions before the rotor operates at high speed. This preliminary positioning ensures that windings are properly secured and guided into place before centrifugal forces become significant, preventing dislocation without requiring excessive securing material.
3Power
If permanent magnets are used in the rotor, then the motor performance is improved, but environmental degradation and pollution occur due to mining and refining of rare earth elements
Solution Approach 1:
The invention extracts and removes the permanent magnets from the rotor design, replacing them with an electrically excited rotor using windings around the rotor core. This extraction eliminates the need for rare earth elements and their associated environmental degradation from mining and refining, while maintaining motor functionality through alternative electromagnetic excitation.
4Power
If permanent magnets are used in the rotor, then the motor performance is improved, but challenges in recycling and disposal occur due to hazardous materials
Solution Approach 1:
The permanent magnets are extracted from the rotor design and replaced with an electrically excited winding system. This removal eliminates hazardous materials from the rotor construction, making the rotor easier to manufacture, recycle, and dispose of without the complex handling requirements associated with permanent magnet materials.
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 proposed support arrangement effectively secures rotor windings with reduced material usage, absorbing centrifugal forces and maintaining structural integrity while allowing the use of cheaper, recyclable materials for the star disc.
Implementation Method 1
the windings which will be affected by centrifugal forces, there is a need of securing the windings to the rotor core in order to prevent the windings from being dislocated
Data Source
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AI summary
The present disclosure relates to a support arrangement (1) comprising an annular star disc (10) having a plurality of evenly distributed radially extending arms (11), each arm (11) being arranged to extend along a pole base (103a) of a corresponding pole (103) of said rotor. Each arm (11) comprises, at a distal portion (13) thereof, an axially extending fork structure (15) arranged to support a winding arrangement (104) of said rotor. Further, the support arrangement (1) comprises an end plate (20) arranged to, at an installed state, be connected to said star disc (10) for enclosing said base portion (102a).