Rotor Winding Support Structure Without Potting Compound
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Solution Overview
Problem
Existing methods for mechanically supporting rotor windings in electric machines, such as potting with compound, are complex, costly, and prone to rejection, while alternative solutions like winding supports with flat springs increase production complexity.
Innovation Solution
A rotor design featuring wedge-shaped winding supports and support devices with conical connections that secure rotor windings without potting, using axial and radial forces to stabilize the windings against centrifugal forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If potting compound is used to mechanically support rotor windings, then the windings are stabilized against centrifugal forces, but the production process becomes complex and costly with high rejection risk
Solution Approach 1:
The invention extracts and eliminates the potting compound from the rotor structure, replacing it with a mechanical support system consisting of support devices and support rings that provide stabilization without requiring complex production processes or sealing operations
Solution Approach 2:
The support devices and support rings act as intermediary mechanical elements between the rotor windings and the rotor body, providing the necessary stabilization against centrifugal forces without requiring potting compound and associated complex production steps
2Stability of the object's composition
If winding supports with flat springs are used to push winding portions against salient poles, then mechanical support is provided, but production complexity increases
Solution Approach 1:
The invention employs simple, easily manufacturable support devices and support rings that can be quickly installed and provide effective mechanical support, replacing complex flat spring systems with simpler structural elements
3Force
If support devices are fastened via axial force with wedge-shaped conical connections, then winding supports are pushed into grooves via radial force, but the connection complexity increases
Solution Approach 1:
The invention employs conical (wedge-shaped) connections between support devices and support rings, where the inclined surfaces transform axial fastening forces into radial forces that push winding supports into grooves, providing an elegant mechanical force transformation without complex mechanisms
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 design stabilizes rotor windings effectively against centrifugal forces, eliminating the need for potting compound and reducing production complexity and costs.
Implementation Method 1
A support ring, radially surrounding the winding head, of the respective support device has a wedge-shaped cross section at least in some regions, and end portions, projecting axially on both sides from the grooves, of the winding supports have in each case at least in some regions a wedge-shaped cross section which forms, with the wedge-shaped cross section of the respective support ring, a positive conical connection, pushing the winding supports into the grooves via a radial force
Implementation Method 2
end portions, projecting axially on both sides from the grooves, of the winding supports have in each case at least in some regions a wedge-shaped cross section which forms, with the wedge-shaped cross section of the respective support ring, a positive conical connection, pushing the winding supports into the grooves via a radial force
Data Source
AI summary
The invention relates to a rotor for an externally excited electric machine of a motor vehicle, having: a rotor body with a large number of salient poles, wherein in each case one groove extending axially between two end sides of the rotor body is formed between two adjacent salient poles; rotor windings including winding conductors that are wound about the salient poles forming axial and end-side winding portions, wherein the axial winding portions of two adjacent rotor windings are arranged in each groove and the end-side winding portions form protruding winding heads at the end sides of the rotor body; per groove, one winding support is arranged between the axial winding portions of the two adjacent rotor windings; and two support devices, arranged at the end sides of the rotor body for covering the winding heads.