Rotor Wire Guide Elastic Tabs for Thermal Stress
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Solution Overview
Problem
Existing guide devices for winding electrically conductive wires around high-speed generator rotors face issues with mechanical stress and thermal expansion, leading to weakened connecting means and potential breakage due to transmitted movements during assembly and operation.
Innovation Solution
A guide device with radially extending branches connected independently to a receiving ring via elastic connections with tabs forming non-zero angles, allowing axial and angular deformation, and featuring guide grooves for wire placement, enabling reliable and cost-effective fixation and movement adaptation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If branches are connected rigidly to maintain structural strength, then mechanical strength is improved, but the device cannot adapt to thermal expansion and radial movements
Solution Approach 1:
The connecting means changes its physical state from rigid to elastic by utilizing the elastic properties of the tab material. The tab is designed with specific dimensional parameters (thickness less than branch thickness) to enable elastic deformation, allowing the connection to adapt to thermal expansion and radial movements while maintaining structural integrity.
2Adaptability or versatility
If elastic connection means are used to allow movement adaptation, then adaptability is improved, but the connecting means are weakened and subject to breakage
Solution Approach 1:
The elastic properties are localized specifically to the tab portion of the connecting means, while the rest of the branch structure maintains its full thickness and structural strength. This localized elasticity allows movement adaptation without compromising the overall strength of the connecting means or the branch structure.
Solution Approach 2:
The connecting means combines regions of different structural properties: a thin elastic tab for flexibility and adaptation, connected to thicker rigid branch portions for strength. This composite structure integrates both elastic and rigid characteristics within a single component, allowing the device to simultaneously adapt to movements and resist breakage.
3Strength
If thick tabs are used in connecting means to increase strength, then strength is improved, but axial deformation and angular movement capability are reduced
Solution Approach 1:
The thickness parameter of the tab is specifically controlled to be less than the thickness of the branch it connects. This parameter change enables the tab to undergo axial deformation and angular movement while the branch itself maintains its full thickness and structural strength. The differential thickness creates the necessary flexibility-gr strength balance.
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 and adaptable guide device that decouples branch movements, allowing for reliable wire winding and maintenance under high mechanical and thermal stresses while ensuring efficient implementation on the rotor.
Implementation Method 1
each branch being connected independently of one another to the ring by means of elastic connection comprising at least one tab, the thickness of a tab in the radial plane of the rotor being less than the thickness of the branch to which the connecting means comprising said tab is connected so that the device allows axial deformation and angle of the branches
Data Source
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AI summary
Guiding device (12) for winding electrically conductive wires (8, 9) around an electrically conductive block (3) of an electric motor rotor (1) comprising a shaft (2) extending axially in the rotor (1), the device (12) comprising at least two branches (13, 14) extending radially from the shaft (2). In addition, the guiding device includes a receiving ring (18) configured to extend around the shaft (2) and around which the branches (13, 14) are arranged, each branch (13, 14) being independently connected to the ring (18) by an elastic connecting means (19, 20) comprising at least one lug (23, 24, 25, 26), the thickness of a lug (23, 24) in the radial plane of the rotor being less than the thickness of the branch (13) to which the connecting means (19) comprising said lug (23, 24) is connected.