CA1213302A - Magnetic rotor and method of assembly - Google Patents

Magnetic rotor and method of assembly

Info

Publication number
CA1213302A
CA1213302A CA000457037A CA457037A CA1213302A CA 1213302 A CA1213302 A CA 1213302A CA 000457037 A CA000457037 A CA 000457037A CA 457037 A CA457037 A CA 457037A CA 1213302 A CA1213302 A CA 1213302A
Authority
CA
Canada
Prior art keywords
core
turn supports
rotor
shaft
shaft fittings
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA000457037A
Other languages
French (fr)
Inventor
Philip C. Mosher
Mohd A. Aleem
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sundstrand Corp
Original Assignee
Sundstrand Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sundstrand Corp filed Critical Sundstrand Corp
Application granted granted Critical
Publication of CA1213302A publication Critical patent/CA1213302A/en
Expired legal-status Critical Current

Links

Classifications

    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K1/00Details of the magnetic circuit
    • H02K1/06Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22Rotating parts of the magnetic circuit
    • H02K1/24Rotor cores with salient poles ; Variable reluctance rotors
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K1/00Details of the magnetic circuit
    • H02K1/06Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22Rotating parts of the magnetic circuit
    • H02K1/28Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49002Electrical device making
    • Y10T29/49009Dynamoelectric machine
    • Y10T29/49012Rotor

Abstract

MAGNETIC ROTOR AND METHOD OF ASSEMBLY
Abstract A high speed shaftless rotor construction is disclosed including a method of sequentially building up the rotor to facilitate disassembly for reworking and maintaining precise alignment of the reassembled ele-ments. End turn supports are matched and preliminarily assembled with bolts to the core and the parts machined to achieve desired tolerances. After machining, the end turn supports are separated from the core, matched with end shaft fittings and additional machining carried out, after which the turn supports are separated from the end shaft fittings and reattached with the core, The shaft fittings are realigned with the assembled end support fittings and bolted into position after which final machining can be completed. All elements are then disassembled and the parts deburred and cleaned to eliminate any contamination prior to winding the field coil. After reassembly, winding of the field core and completion of the electrical connections, a cylindrical sleeve is disposed over the main core assembly and conventionally joined to effect a rigid structural rotor member capable of withstanding high speeds.

Description

~2~33~ ~01683 MAG~FTIC ROTOR AND METHOD OF ASSEMBLY

Descri~ion Technical Yield This invention relates to rotors for use in electrical generators and more particularly to a sequen-tially built rotor and a method of assembly.

Background Ar~
High speed, high performance generator rotors are generally built without center shafts to provide maximum magnetic material. To maintain the structural integrity of this type rotor, one possible course is to complete the rotor and associated shafts as a unit, as taught in U.S. Patent 4,024,628, to Crites. However, because the rotor assembly is an integral unit, any defect or failure in any portion of the rotor renders the entire structure useless.
As an alternative to a single piece con-struction, rotors may be sequentially built up and the parts permanently joined as by welding. The welding operation is intricate and demands a great amount of care and precision. This necessarily results in a time-consuming process and the performance of a great number of ~teps. Further reworking of the rotor is precluded by the welded joints.
A rotor assembled with bolts or rivets gener-ally has one main drawback. To withstand the large stresses encountered, large bolts or rivets must be used requiring lar~e b~res thrsugh the assembled elements.
The possibility of air gaps about the fastener raises the problem of disruption of the magnetic path which, in turn, lowers generator efficiency.

~33~ ~01~83 A further drawback with sequentially built rotors is that contaminants ar,e likely to find their way between mated partsf which may be permanently engaged.
Rotor operation may be impaired. Because the parts are not re~dily separable, the entire rotor may be unusable.
The present invention is directed to overcoming the problems enumerated above~

Disclosure_of the Invention The present invention comprises a sequentially built rotor and a method of assembling the rotor elements which basically are a rotor core, longitudinally spaced end turn supports, and end shaft fittings.
According to the present invention, the end turn supports are aligned at the axial ends of an unwound core to complete a core subassembly and the subassembly bored ~o close tolerances for reception of lengthwise clamping bolts. With the subassembly intact, machining as desired is carried out. The end turn supports are then removed from the core and ma$ched to the end shaft fittings and additional machining performed as required.
The end supports are separated from the shaft fittings and rebolted to the core. The shaft fittings are in turn connected to the core subassembly by boring additional axial holes to close tolerances for bolting. Final machining of the rotor, main field winding and completion of electrical connections then occurs. A sleeve is placed over the completed assembly to provide a rigid . ~tructural member.
The present invention has as one of its princi-pal objectives the provision of a rigid rotor that iscapable of high rotational speeds and which can be ~ 2 ~ 3 3 0 æ B01683 disassembled for reworking without loss of precise ~lignment between elements.
~ pon removal of he ~leeve housing, the ele-ments can be ~uccessively separated by releasing the bolts joining the end shaft fittings and in turn those mounting the end turn supp~rts with the core. This feature is particularly advantageous in that it permits precise machining in various stages of assembly after whic~ the entire assembly can be disassembled, deburred and cleaned to remove c~ntaminants as machining chips, grinding dust, etc. prior to winding the field coil.
While the process facilitates assembly and disassembly, the end product of the process is a high quality structure. The bores for the bolts are machined lS to close tolerances. The bolts employed are precision ground, high strength, high permeability bolts which become part of the final assembly and positively retain the elements. Further, the bolts, which are selected for high magnetic permeability, account for low magne~ic loss.

Brief Description of the Drawings Fig. l is a perspective view of a completed ro~or assembly according to the present invention;
~ig. 2 is a perspective view of the rotor core;
25Fig. 3 is an exploded view of the core assembly with mated end turn supp~rt~;
Fig. 4 is an end shaft fitting for ~he core matched with an end turn suppor~;
Fig. 5 is the opposite end ~haft fitting from that in Fig. 4 matched with an end turn support; and Fig. 6 is an exploded view of the end shaft fittings and field ~und core subassembly.

~2~3~0æ B~1683 ~est Mode for Carrying Out the Invention Fig. 1 depicts a completed rotor assembly 10 made according to the invention and comprising generally a main core assembly 12 surrounded by a cylindrical sleeve 14 and oppositely directed and axially aligned end shaft fittings 16, 18.
The main core assembly 12 is detailed in Figs.
2 and 3 and comprises an I-shaped core 20 made from bonded lamination layers 22. At each end of the core 20 is an end turn support 24 configured to nominally match the cross ~ection of the core 20. The end turn supports 24 have axially oppositely opening rectangular recesses 26 which, with oppositely opening rectangular recesses 28 in the core 20 and end turn supports 24, provide a continuous undercut about the main core assembly 12, for the inclusion of the field windings 30 (Fig. 6).
A ff~rre~tr~ bore 32 is axially machined to close tolerances through each of the end turn supports 24 and the core 20 and threadably receives a bolt 34. A
single bolt 34 is inserted axially through each end ~urn support at substantially diametrically opposing regions of the core assembly 12 and is of sufficient length to extend into the opposite end tuxn support 24 so as to prohibit relative rotation between the core 20 and end turn Supports 24.
N-shaped wedges 34 are closely mated in the core xecesses 28, and have lengthwise, rectangular pathways 36 for the field windings 30 defined by spaced ;. axial flanges 38 of a length equal to the distance between opposed faces of the end turn ~upports 24.
Machining of the core 20 and assembled ~nd turn supports 24 constituting the core ~ubassembly 12, can take place before the addition of the wedges 34. The 12~330,~ B01688 wedges 34 are assembled to the core 20 by suitable fasteners ~not shown) before completion of the final machinin~ of the outside diame$er thereof.
~he end turn supports 24 are then rem~ved from the core and matched with the end shaft fittings 16, 18 illustrated in Figs. 4 and 5. Because ~he matching of the end turn supports 24 is the same for both end shaft fittings 16, 18, like reference numerals are used to designate parts at each end of the core. Each of the end shaft fittings 16, 18 has a circular cast base 46 with an integrally formed, axially directed collar 48.
The collars are concentric with the rotational axis of shafts 17,19 which are integral with and extend oppo-sitely from the bases 46.
Alignment between the end turn supports 24 and shaft fittings 16, lB is maintained by a pair of dowels 50 extending within diametrically opposed axial bores 52 and 53 in the end turn supports 24 and in the bases 46, respectively. When properly matched, the end turn ~o supports 24 and end shaft fittings 16, 1~ are machined to desired tolerances.
The end shaft fittings 16, 18 and end turn supports 24 are then separated and the and supports 24 rebolted with the core 20~ The shaft fittings 16, 18 and core assem~ly 12 are mated as illustrated in Fig. 6.
Bores 54 are machined to close tolerances through the bases 46, the end turn supports 24 and into the core 20.
A second set of precision grou~d bolts S6 are threadably ,. received in the bores 54 and are tightened to secure the end shaft fittings 16,18, to the core subassembly.
Additional machining of the collars 48 and the end turn supports 24 proceeds if re~uired.

~213~C~Z B01683 Bolts 56 and end turn bolts 34 are then with-drawn so that all the aggrega~:e elements can be separ-a~ed, debl~rred and cleaned to remove any machininy chips or grinding dust or any other cvntamination that may have accumulated.
The end turn supports 24 are then reassembled to the core 20, the field coil 30 wound and the wedges 39 replaced. The shaft fittings 16,1B are then reassembled to the end turn supports 24 after such reassembly. The cylindrical sleeve 14 is interference fit with the peripheral surfaces of the commonly machined core, end turn supports and end shaft fittings and secured in a conventional manner to complete the rotor 10~
From the foregoing it can be seen that the bolts 34~ 56 simply and positively maintain the core 20, end turn supports 24 and end shaft fittings 16, 18 in assembled relationship. By simpiy releasing in ~urn bolts 56 and 34, the core 20 end turn supports 24 and end shaft fittings 16, lB can be freed to accomplish cleaning reworking or replacement of parts.
Precise alignment of the core end turn supports and end shaft fittings during reassembly is assured by the bolts 34, 56.
Because bolts 34, 56 and the receiving bores 32, 54 are machined to close tolerances, air gaps are minimized so that little disruption of the magnetic path occurs. Generator efficiency is further enhanced by the use of bolts with high magnetic permeability which . accounts for reduced magnetic loss in the rotor.

Claims (17)

Claims
1. A method for sequentially building up a rotor for an electric machine comprising the steps of:
providing a magnetic core having opposed ends and a rotational axis;
removably attaching a turn support at each end of the core to define a core subassembly;
removably attaching a shaft fitting to each end turn support; and providing a sleeve housing about the core subassembly;
whereby said rotor can be readily disassembled for reworking and reassembled with the alignment of the core, turn supports and shaft fittings precisely main-tained.
2. The method of claim 1 including the step of performing a machining operation on the core subassembly to match the turn supports with the core prior to attach-ing the shaft fittings to the core subassembly.
3. The method of claim 1 including the steps of aligning each of the turn supports with one of the shaft fittings prior to attaching the turn supports to the ends of the core and performing a machining operation to match the turn supports with the shaft fittings.
4. The method of claim 1 including the step of machining the assembled core assembly and shaft fittings to a desired tolerance prior to providing the sleeve housing about the core subassembly.
5. The method of claim 4 including the steps of disassembling the core, turn supports and shaft fittings after the machining step removing contaminant or foreign matter accumulated on at least one of the cores, turn supports and shaft fittings and thereafter reassembling the core, turn supports and shaft fittings.
6. The method of claim 5 including the step of winding a field coil about the core subassembly before reassembling the shaft fittings.
7. A method for sequentially building up a rotor for an electric machine comprising the steps of:
providing a magnetic core having opposed ends and a rotational axis;
removably attaching a turn support at each end of the core to define a core subassembly;
machining the core subassembly to match the core and turn supports;
removing the turn supports from the core;
providing an axial shaft fitting for each of the ends of the core subassembly;
aligning each of the turn supports with one of the shaft fittings;
machining the aligned turn supports and shaft fittings to effect matching;
disassembling the shaft fittings and turn supports;
reattaching the turn supports at the ends of the core; and removably attaching a shaft fitting at each end of the core subassembly;

whereby said rotor can be readily disassembled for reworking and reassembled with the alignment of the core, turn supports and shaft fittings precisely main-tained.
8. The method of claim 7 wherein a subsequent machining operation is performed after the shaft fittings are attached at the ends of the core subassembly to make the rotor a finished size.
9. The method of claim 7 wherein each turn support is removably attached to the core by at least one bolt extending axially through the turn support and into the core.
10. The method of claim 7 wherein each shaft fitting is attached to the core subassembly by at least one bolt extending axially through the shaft fitting, an end turn support and into the core.
11. The method of claim 7 including the step of providing a cylindrical sleeve over the core sub-assembly after the shaft fittings are attached at the ends of the core subassembly.
12. The method of claim 9 wherein the bolts are made from a material having a high magnetic permea-* bility for low magnetic loss.
13. A built-up rotor for an electric machine comprising:
a main rotatable core having a lengthwise rotational axis;
two end turn supports;
means removably securing an end turn support at each axial end of the core to form a core subassembly;
two end shaft fittings;
means removably securing an end shaft fitting to each of the end turn supports; and a sleeve positionable over the core sub-assembly;
said core, end shaft fittings and end turn supports being readily disassembled for reworking of the rotor and reassembled with the alignment of the core, turn supports and shaft fittings precisely maintained.
14. The built-up rotor of claim 13 wherein the means removably securing each end shaft fitting with an end turn support comprises at least one bolt extending axially through each end shaft fitting, an end support and into the core.
15. The built-up rotor of claim 13 wherein said core and end turn supports each have a peripheral surface and said core and end turn supports are commonly machined so that the peripheral surfaces define common cylinders over which the sleeve is positioned.
16. The built-up rotor of claim 13 wherein said core and end shaft fittings each have a peripheral surface and said core and end shaft fittings are commonly machined so that the peripheral surfaces define common cylinders over which the sleeve is positioned.
17. The built-up rotor of claim 15 wherein the sleeve is interference fit with the peripheral surfaces of the core and end turn support.
CA000457037A 1983-08-17 1984-06-20 Magnetic rotor and method of assembly Expired CA1213302A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US06/523,924 US4562641A (en) 1983-08-17 1983-08-17 Method of assembling a magnetic rotor
US523,924 1983-08-17

Publications (1)

Publication Number Publication Date
CA1213302A true CA1213302A (en) 1986-10-28

Family

ID=24086990

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000457037A Expired CA1213302A (en) 1983-08-17 1984-06-20 Magnetic rotor and method of assembly

Country Status (10)

Country Link
US (1) US4562641A (en)
EP (1) EP0153324B1 (en)
JP (1) JPS60502035A (en)
CA (1) CA1213302A (en)
DE (1) DE3490366T1 (en)
GB (1) GB2154913B (en)
IL (1) IL72327A (en)
IT (1) IT1178404B (en)
SG (1) SG51787G (en)
WO (1) WO1985000937A1 (en)

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US4667123A (en) * 1985-11-20 1987-05-19 The Garrett Corporation Two pole permanent magnet rotor construction for toothless stator electrical machine
IL80995A0 (en) * 1985-12-23 1987-03-31 Sundstrand Corp Salient pole rotor
US5345669A (en) * 1988-06-08 1994-09-13 General Electric Company Method of making a permanent magnet rotor
US5563463A (en) * 1988-06-08 1996-10-08 General Electric Company Permanent magnet rotor
US5040286A (en) * 1988-06-08 1991-08-20 General Electric Company Method for making permanent magnet rotor
US5144735A (en) * 1988-06-08 1992-09-08 General Electric Company Apparatus for assembling a permanent magnet rotor
US5237737A (en) * 1988-06-08 1993-08-24 General Electric Company Method of making a permanent magnet rotor
US5298823A (en) * 1992-09-04 1994-03-29 Sundstrand Corporation Main field winding and connections for a dynamoelectric machine
US5325009A (en) * 1993-05-07 1994-06-28 Sundstrand Corporation Rotor shaft with integral wedge retainers for core of a two-pole generator
US5323080A (en) * 1993-05-07 1994-06-21 Sundstrand Corporation One-piece rotor shaft for two-pole rotor
US5848461A (en) * 1996-05-28 1998-12-15 Ford Motor Company Electrical machine having a rotor with an improved rotor stop
FR2759506B1 (en) * 1997-02-07 2003-08-15 Jeumont Ind ROTOR SHAFT OF AN ELECTRIC MACHINE
US6465928B1 (en) * 1998-12-23 2002-10-15 Hamilton Sundstrand Corporation Multi-pole generator rotor and method of making the same
US6417596B1 (en) * 2000-05-19 2002-07-09 A. O. Smith Corporation Apparatus and method for attaching a shaft to an electric motor rotor
US6859019B2 (en) 2001-08-30 2005-02-22 Honeywell International, Inc. System and method for coupling rectifiers of an exciter to the rotor of a main generator
US6727634B2 (en) 2001-08-30 2004-04-27 Honeywell International, Inc. System and method for end turn retention on a high speed generator rotor
US6791230B2 (en) 2001-09-07 2004-09-14 Honeywell International, Inc. System and method for retaining wedges in a rotor
US6753637B2 (en) 2001-09-07 2004-06-22 Honeywell International, Inc. Exciter rotor assembly
US6734585B2 (en) 2001-11-16 2004-05-11 Honeywell International, Inc. Rotor end caps and a method of cooling a high speed generator
US6794792B2 (en) * 2002-11-13 2004-09-21 General Electric Company Cold structural enclosure for multi-pole rotor having super-conducting field coil windings.
US7015617B2 (en) * 2003-07-29 2006-03-21 Honeywell International, Inc. High speed generator with rotor coil support assemblies secured to interlamination disks
US7546674B2 (en) * 2005-10-31 2009-06-16 Gm Global Technology Operations, Inc. Method of rotor assembly without the hub
US8339011B2 (en) * 2009-12-07 2012-12-25 Hamilton Sundstrand Corporation Rotor assembly wire support
CN102280960B (en) * 2011-08-09 2012-12-12 西安东风仪表厂 Fixing method for motor rotor magnetic steel
DE102014206356A1 (en) * 2014-04-03 2015-10-08 Bayerische Motoren Werke Aktiengesellschaft Improved star wheel for an electric machine
US9893584B2 (en) * 2015-06-24 2018-02-13 Hamilton Sundstrand Corporation End winding support for an electric generator

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Also Published As

Publication number Publication date
GB2154913B (en) 1987-04-23
JPS60502035A (en) 1985-11-21
GB8508484D0 (en) 1985-05-09
IT8448717A0 (en) 1984-08-10
DE3490366T1 (en) 1985-09-19
GB2154913A (en) 1985-09-18
EP0153324B1 (en) 1989-09-27
WO1985000937A1 (en) 1985-02-28
EP0153324A4 (en) 1985-12-30
IL72327A0 (en) 1984-11-30
SG51787G (en) 1988-02-19
IT8448717A1 (en) 1986-02-10
EP0153324A1 (en) 1985-09-04
IT1178404B (en) 1987-09-09
US4562641A (en) 1986-01-07
IL72327A (en) 1988-07-31

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