Segmented Rotor Body for Rotary Electric Machine Coil Winding
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Solution Overview
Problem
Conventional rotary electric machine rotors with integral rotor bodies face complexity in winding field coils due to the need for a winding tool, limiting the filling ratio of copper wires and making the assembly process cumbersome.
Innovation Solution
The rotor is composed of individual parts with a hub and teeth that are assembled together, allowing field coils to be wound before assembly, with hooks and grooves providing mechanical fixation and improved alignment, enabling higher copper filling ratios and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an integral rotor body is used with a winding tool, then the field coils can be wound on the teeth, but the filling ratio of copper wires is limited and the assembly process becomes complex
Solution Approach 1:
The rotor body is divided into multiple individual parts, each comprising a hub portion and a tooth. These separate parts can be manufactured independently and assembled later, eliminating the need for a complex winding tool and allowing for simpler coil winding processes on each individual tooth before assembly.
2Ease of manufacture
If a winding tool is placed in the space between teeth, then field coils can be wound, but the space cannot be fully filled with copper wires
Solution Approach 1:
The field coils are wound on the teeth of individual rotor parts before the parts are assembled together. This preliminary action allows for complete utilization of the available space on each tooth without the interference of a winding tool, maximizing the copper filling ratio while maintaining ease of coil winding.
3Strength
If the rotor body is made integral, then structural strength is maintained, but the assembly process becomes cumbersome and complex
Solution Approach 1:
The rotor body is segmented into multiple individual parts that are assembled together to form the complete rotor. This segmentation simplifies the assembly process and manufacturing complexity while the individual parts maintain sufficient structural strength through proper design and connection mechanisms.
Data Source
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AI summary
The invention concerns a rotor (3) for a rotary electric machine, the rotor (3) having an axis of rotation and comprising: - a rotor body (7) comprising a hub (10) to be mounted on a rotor shaft (5) and a plurality of teeth (11) protruding radially from the hub; - a plurality of field coils (15) each wound around a tooth of the plurality of teeth; characterized in that said rotor body (7) comprises a plurality of individual parts (12) each having a portion (14) of the hub and a tooth (11) of the plurality of teeth, the individual parts being distinct parts and fixed together.