Serpentine Short-Circuiting Ring for Electric Machine Rotor
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Solution Overview
Problem
The existing manufacturing methods for short-circuiting rings in electric machines are costly and subject to tight tolerances, leading to high production expenses and inefficiencies.
Innovation Solution
A short-circuiting ring manufactured from a single-piece strip material using a bending method, featuring a serpentine annular body with double-wall regions and meanders, allowing for cost-effective and flexible production with larger tolerances, and enhanced cooling through air circulation vanes and tapered receptacle sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If casting or plugging methods are used to manufacture short-circuiting rings, then structural integrity is achieved, but manufacturing cost increases and production efficiency decreases
Solution Approach 1:
The short-circuiting ring is divided into multiple individual bars that are inserted into slots of the rotor core, rather than manufacturing the entire ring as a single piece. This segmentation allows for simpler, more cost-effective manufacturing of individual components while maintaining the functional integrity of the short-circuiting structure.
Solution Approach 2:
Multiple separate manufacturing steps (casting or plugging individual bars) are combined into a single integrated process where pre-fabricated bars are inserted into the rotor core slots and electrically connected. This merging of operations simplifies the overall manufacturing process and reduces production time.
2Manufacturing precision
If metal-cutting methods are used to manufacture receptacles for rods, then precise tolerances are achieved, but manufacturing cost increases
Solution Approach 1:
Instead of cutting receptacles into a solid rotor core structure, the approach is inverted: receptacles are formed as integral parts of the laminated rotor core structure during stacking, and bars are inserted into these pre-formed slots. This eliminates the need for costly metal-cutting operations while maintaining precise tolerances through controlled stacking processes.
3Strength
If conventional manufacturing methods are used for short-circuiting rings, then structural strength is maintained, but material wastage increases
Solution Approach 1:
The short-circuiting ring structure is segmented into individual bars that can be manufactured from standard stock materials with minimal wastage. Each bar is optimized for its specific function and inserted into the rotor core, eliminating the material wastage associated with casting or cutting from large blocks.
Solution Approach 2:
The manufacturing approach changes from bulk material processing (casting or cutting) to precision fabrication of individual bars from optimized cross-sections. This parameter change in the manufacturing process allows for near-net-shape fabrication of each bar, minimizing material wastage while maintaining the required structural strength.
Data Source
AI summary
The invention relates to a short-circuiting ring for an electric machine, comprising a single-piece serpentine ring member (7) made of a single-piece strip material. The invention also relates to a rotor for an electric machine.