Sun Gear Axial Securing Assembly for Electric Machine Rotors
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Solution Overview
Problem
Existing bearing assemblies for electrical machines fail to securely fasten the sun gear on a rotor shaft at high speeds due to centrifugal forces, necessitating expensive and difficult-to-install special securing rings.
Innovation Solution
A simple and cost-effective assembly that integrates a securing sleeve into the sun gear, which radially secures a standard securing ring, preventing expansion and loosening under centrifugal forces, allowing for easy installation and removal without damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If standard securing rings are used to secure the sun gear on the rotor shaft, then the assembly is simple and cost-effective, but the securing ring expands and loosens under centrifugal forces at high speeds
Solution Approach 1:
The securing system is divided into two functional parts: a standard securing ring for axial positioning and a separate securing element integrated into the sun gear for radial retention. This segmentation allows each component to perform its specific function optimally - the securing ring provides simple axial support while the securing element prevents centrifugal loosening, resolving the contradiction between manufacturing simplicity and securing reliability.
Solution Approach 2:
The securing element is nested within the sun gear structure, specifically in a recess of the end section, while the securing ring remains on the rotor shaft. This nesting arrangement allows the simple standard securing ring to be combined with the integrated securing element, achieving both ease of manufacture and high securing reliability under centrifugal forces.
2Reliability
If special self-locking securing rings are used to prevent loosening under centrifugal force, then securing reliability is improved, but the assembly becomes expensive and difficult to install
Solution Approach 1:
Instead of using a complex self-locking securing ring, the solution segments the function into a simple standard securing ring for axial support and a separate securing element integrated into the sun gear for radial retention. This segmentation maintains securing reliability while dramatically reducing device complexity and installation difficulty.
Solution Approach 2:
The securing element is self-retaining within the sun gear recess, using the sun gear's own structure to provide the retention function. This eliminates the need for complex self-locking mechanisms on the securing ring itself, reducing device complexity while maintaining reliability.
3Reliability
If special self-locking securing rings are used to prevent centrifugal expansion, then securing reliability is improved, but installation time and effort increase significantly
Solution Approach 1:
The securing function is segmented between a standard securing ring that can be quickly installed on the rotor shaft and a securing element already integrated into the sun gear. This segmentation eliminates the time-consuming installation process of special self-locking rings while maintaining securing reliability.
Solution Approach 2:
The securing element is pre-integrated into the sun gear structure during sun gear manufacturing, so that during assembly, only the simple securing ring needs to be installed. This preliminary action eliminates the need for complex installation procedures and significantly reduces installation time.
4Ease of manufacture
If standard securing rings are used, then manufacturing cost is reduced, but the securing ring cannot be easily removed without destruction
Solution Approach 1:
The securing system is segmented into a standard securing ring that can be easily removed from the rotor shaft and a securing element integrated into the sun gear. This allows the securing ring to be reused for maintenance while the securing element remains as a permanent feature, maintaining manufacturing cost benefits while improving uninstallation ease.
Solution Approach 2:
The design allows the standard securing ring to be removed and recovered for reuse, while the securing element remains integrated in the sun gear. This selective discarding and recovering approach maintains cost benefits through reuse of the inexpensive securing ring while ensuring permanent retention through the integrated element.
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 assembly reliably secures the sun gear on the rotor shaft across various speeds using standard, inexpensive securing rings, eliminating the need for expensive special rings and facilitating easy installation and uninstallation.
Implementation Method 1
to secure against the centrifugal forces acting on the securing ring when the rotor shaft rotates
Data Source
AI summary
An assembly secures the axial position of a sun gear of a planetary gearing stage on a rotor shaft of an electrical machine. The sun gear has an end section that is stepped radially outward on the inner diameter and is axially secured on the rotor shaft by means of at least one securing ring. At least one securing element is provided to secure against the centrifugal forces acting on the securing ring during rotation of the rotor shaft. The securing element is inserted into the end section on the sun gear and is at least partially pushed over the securing ring and radially secures the same.