Deformable Wire Packs for Cage Rotor Conductivity
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Solution Overview
Problem
Existing squirrel cage rotors for asynchronous machines face inefficiencies due to the material-specific conductance of aluminum and the technical challenges and costs associated with copper die casting, as well as the impracticality of inserting V-shaped prefabricated rods into stamped grooves.
Innovation Solution
A method involving the use of deformable wire packs constructed from multiple wires, which are twisted and connected to short circuit rings, allowing for adjustable material selection and improved electrical conductivity, noise, and vibration performance, without the need for casting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If short circuit rods are cast from aluminum, then the manufacturing process is simple and cost-effective, but the electrical conductivity and motor efficiency are insufficient
Solution Approach 1:
The patent uses composite construction by combining copper wire packs (for conductivity) with aluminum short circuit rings (for cost-effective manufacturing). The copper wires are embedded in the aluminum rings, creating a composite structure that leverages the high conductivity of copper while maintaining the manufacturing advantages of aluminum casting.
Solution Approach 2:
The patent changes the material parameter from pure aluminum to a copper-aluminum composite structure. By introducing copper wires into the aluminum casting, the electrical conductivity parameter is significantly improved while the manufacturing process remains relatively simple.
2Reliability
If short circuit rods are cast from copper, then the electrical conductivity and motor efficiency are improved, but the manufacturing process becomes more difficult and expensive
Solution Approach 1:
Instead of casting pure copper rods which is difficult and expensive, the patent creates a composite structure where copper wires are embedded in an aluminum matrix. This allows the system to benefit from copper's high conductivity while avoiding the manufacturing difficulties of copper casting.
Solution Approach 2:
The aluminum short circuit ring acts as an intermediary material that facilitates the integration of copper wires. The aluminum provides a cost-effective, easily manufacturable base structure that can accommodate and electrically connect the copper wire packs.
3Object-affected harmful factors
If V-shaped prefabricated rods are used, then the noise and vibration behavior is improved, but the rods cannot be pushed into the stamped grooves
Solution Approach 1:
The patent introduces flexibility by using deformable wire packs instead of rigid prefabricated rods. The wire packs can be deformed during the twisting process to achieve the desired V-shape configuration, making them adaptable to the groove geometry while maintaining the noise and vibration benefits of the V-arrangement.
Solution Approach 2:
The patent changes the structural parameter from rigid to flexible by using wire packs that can be deformed. This flexibility allows the short circuit rods to be formed into V-shapes after insertion, enabling both easy assembly and improved acoustic performance.
4Object-affected harmful factors
If the individual rotor cores are twisted to create offset short circuit rods, then the noise and vibration behavior is improved, but the wire packs must be deformable
Solution Approach 1:
The patent uses flexible wire packs that can be deformed during the twisting process. These flexible wire structures allow the rotor cores to be twisted relative to each other, creating the offset V-arrangement that improves noise and vibration characteristics.
Solution Approach 2:
The wire packs transition from a straight configuration to a deformed V-shape during the twisting process. This dynamic deformation capability allows the system to achieve the desired geometric arrangement for improved acoustic performance while maintaining structural integrity.
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 approach enhances electrical conductivity, reduces noise and vibration, and allows for cost-effective material selection by using wire packs as flexible short circuit rods, combining the benefits of copper conductivity with the simplicity and cost-effectiveness of aluminum casting.
Implementation Method 1
twisting the individual rotor cores relative to one another, the wire packs being deformed
Implementation Method 2
the wire packs, which act as short circuit rods, have a satisfactory electrical conductivity
Data Source
AI summary
A method for producing a cage rotor for an asynchronous machine has the following steps: providing a laminated rotor core made of a plurality of stacked rotor laminations which each have a plurality of rotor lamination grooves distributed in the circumferential direction; placing rod-shaped wire bundles, which are each made up of a plurality of wires, into the rotor lamination grooves; rotating the individual rotor laminations relative to each other, thereby deforming the wire bundles; placing short-circuit rings on both end faces of the laminated rotor core, and connecting the wire bundles to the short-circuit rings.