Manufacturing method of out-of-alignment short-circuited rotors and out-of-alignment short-circuited rotor

FIELD: electricity.

SUBSTANCE: invention relates to electric engineering and can be used at manufacture of a short-circuited rotor of an asynchronous machine. The invention proposes a manufacturing method of short-circuited rotor (1) for asynchronous machine (2), which includes core (5) with bevelled slots (4), end rings (6) from the first material and short-circuited bars (3; 11; 12) from the second material with higher specific electric conductivity in comparison to the first material, which are moulded-on from faces to core (5) of the rotor, and which are laid into bevelled slots (4) of short-circuited rotor (1) and almost fully fill internal zone (7) of the slots if to look in radial direction of core (5) of the rotor.

EFFECT: increasing efficiency of an asynchronous machine.

24 cl, 10 dwg

 

The invention relates to a method of manufacturing a squirrel-cage rotor with beveled grooves for asynchronous machines and manufactured in such a way squirrel-cage rotor.

New regulations on the efficiency of induction machines, such as ΙΕ1, ΙΕ2, ΙΕ3, require a higher degree of application of the material, because to comply with these rules structure length these machines have more and more to increase. Repeatedly proven ways die-casting aluminum in the future will become increasingly difficult to meet the increasing requirements to the efficiency of the machine.

However, the desired efficiency is achieved through the short-circuited rotor of copper. Due to the higher electrical conductivity of copper compared to aluminum, even with a shorter structural length can be achieved with higher efficiency.

For the manufacture of squirrel cage rotors of copper known method of molding. However, it is very complex and, in particular, in the case of large axial height of technologically infeasible. Requirements for molding the shape and process parameters in the application of liquid copper with a temperature over 1100°C can be performed only with very high costs.

From DE 4308683 A1 is known a method of manufacturing a squirrel-cage rotor, wherein the first grooves of the package of iron of the rotor stacked with�standing copper squirrel-cage bars. These copper rods are connected to the ends of the short-circuiting rings. To manufacture these short-circuiting rings is used a method of injection molding of aluminum. Simultaneously with the casting and short-circuiting rings remaining in the grooves compared to the stacked copper rods section is filled with aluminum, resulting in short-circuiting rings are connected also formed in the remaining section, injection-molded rod parts. In addition, from this publication it is known that after laying cage bars, this package of iron of the rotor are twisted to the desired twisting angle, which improves the driving performance of the car.

So made asynchronous machine has the advantage that laid in the grooves of the copper rods, the efficiency is in the range of efficiency in induction motors with cast copper rotor, however, production costs are markedly lower. This is because the process of die-casting aluminum having a significantly lower melting point than copper.

The basis of the invention lies in the task of improving the efficiency of such an asynchronous machine.

This problem is solved by the method of manufacturing a squirrel-cage rotor for an asynchronous machine with signs claim 1 of the formula. The method includes the following steps:

- implementation of Pak�the iron rotor with beveled grooves;

- laying the short-circuited terminals of the second material in the beveled grooves of a package of iron of the rotor;

- burst from the ends to the package of iron of the rotor short-circuiting rings of the first material with a lower specific electrical conductivity than the second material,

and before placement in the slots of the cage rods are twisted with the possibility of introducing them before applying the cast of the first material substantially without preload in package iron rotor with beveled grooves, almost completely filling the interior, when viewed in the radial direction, the area of the grooves, whereby the first material in the casting process can not penetrate into the internal area of the grooves.

In addition, this task is solved by a squirrel-cage rotor for an asynchronous machine with signs of paragraph 9 of the formula. It contains:

package iron with grooves;

- prelite ends to the package of iron of the rotor short-circuiting ring of the first material and

- located in the grooves of the short-circuited terminals of the second material with a higher specific electrical conductivity than the first material, and the

package of iron of the rotor has a beveled grooves, and

- squirrel cage rods almost completely fill the interior, when viewed in the radial direction of the package of iron of the rotor, the area �Azov.

Preferred embodiments of the invention are characterized in the dependent claims.

The invention provides cost-effective production of highly efficient squirrel-cage rotor for an asynchronous machine with excellent performance properties. The proposed hybrid design squirrel-cage rotor meets the above mentioned standards on efficiency ΙΕ1, ΙΕ2, ΙΕ3 significantly more cost effective manner compared with rotor manufactured by pressure casting of copper. Squirrel-cage rotor bars are made of a material with a higher specific electrical conductivity than the material short-circuiting rings.

In a preferred embodiment of the invention as a first material for short-circuiting rings can be applied, for example, aluminum and the second material for the short-circuited terminals - copper. Short-circuiting rings of cast aluminum from the melt with a temperature of about 600°C, whereby this process can be very well managed. Due to the very high electrical conductivity of the short-circuited terminals, the efficiency of squirrel-cage rotor is very high. In the case of the preferred use of aluminum as the first material further significantly decreases the moment of inertia short�closed rotor for example, compared to solid copper rotor, resulting in improved machine dynamics and further increase the efficiency, in particular, in the case of highly dynamic applications.

The basis of the invention lies in the fact that the squirrel-cage rotor of such a hybrid design can be further improved with respect to its performance, if the package is made of iron with beveled grooves. At the expense of such compliance is prevented higher harmonics in the rotating magnetic field, reduced noise and significantly reduced ripple torque.

Beveled grooves can be created due to the fact that it is already equipped with squirrel-cage terminals package of iron of the rotor is twisted. However, when using straight bars decreases the fill factor of the slots, since the twisting is equipped with short-circuited terminals of the package of iron of the rotor is possible only when after laying cage rods into grooves in them still remains a certain amount of free space.

Therefore, according to the invention the filling of the grooves squirrel cage rods of a second material having a higher electrical conductivity increases due to the fact that even before packing in a package of iron of the rotor cage bars are twisted in such a way that they are applied before�eat first cast material is introduced substantially without preload in package iron rotor with beveled grooves so they almost completely fill the interior, when viewed in the radial direction, the area of the grooves, whereby the first material in the casting process can not penetrate into the internal area of the grooves. Consequently, in the radially inner area of the package of iron of the rotor are almost exclusively short-circuited terminals from a relatively electrically conductive second material, whereas the remaining cross-section of the grooves can be filled with the first material. Because the first material has a lower electrical conductivity than the second material, it is possible, therefore, very easy to create a launcher cores for induction machines. The starting point of these rods is that during start-up of asynchronous machine to cause a higher electrical resistance. Since during start-up due to the skin effect the displacement current in the squirrel-cage rotor from the inner zone to the outer zone, the current flows at this point in the first place, in a radially external area of the grooves in which the first material.

If a trigger rods is desired, the cross-section of short-circuited terminals can be preferable to choose so that the twisted cores are completely filled grooves. The result is the maximum possible fill factor of the slots.

Fill the rest after laying the short-circuited terminals of the cross-section of the grooves is achieved in a highly preferred embodiment, due to the fact that filled their slots filled by way of injection molding the first material through which produced short-circuiting rings. To do this, launch rods short rods are placed in the grooves so that the external, when viewed in the radial direction of the rotor, the area of the grooves by injection molding is filled with the first material. Thus, for example, in another preferred embodiment, made of copper squirrel-cage terminals located in the inner zone of the grooves, forming thus the working terminals of the asynchronous machine, while the die-cast aluminum starting rods are located in the external zone of the grooves. It is also short-circuiting ring can be made preferred by way of aluminum, resulting in relatively easy and thus less inert squirrel-cage rotor.

Especially pronounced decrease in the content of higher harmonics in the rotating field, the torque ripple and noise of the machine is achieved in a preferred embodiment of the �of subramania by the bevel of the beveled grooves corresponds to a grooving step.

Prevention of losses by eddy currents and hysteresis in a short-circuited rotor is achieved by the fact that the method includes the further manufacture of the package of the rotor due to the blending of electrical steel plates in the axial direction, wherein the plates are twisted relative to each other so that they are beveled grooves.

Asynchronous machine, comprising a stator with stator windings and a squirrel-cage rotor, made in one of the embodiments described above, is made considerably more cost-effective than the rotor, manufactured by pressure casting of copper, however, meets the standards of efficiency that cannot be achieved with a relatively simply manufactured by injection molding from aluminum rotor, and due to the proposed twisting has excellent performance properties. Efficiency is particularly high, because by pre-twisting the short-circuited terminals, the entire internal area of the grooves are completely filled with them.

The invention is explained in more detail below by examples of its implementation, is depicted in the drawings, which represent:

- Fig. 1: front view of the twisted cage stud for installation in a groove of a package of iron of the rotor in one embodiment, the implementation of�of bretania;

- Fig. 2: a perspective view of a short-circuited terminal of Fig. 1;

- Fig. 3: side view of the package of iron of the rotor in one embodiment of the invention;

- Fig. 4: end view of the package of iron of the rotor of Fig. 3;

- Fig. 5: sectional view of the package of iron of the rotor of Fig. 4 short-circuited with straight rods;

- Fig. 6: sectional view of the package of iron of the rotor of Fig. 4 pre-twisted cage bars;

- Fig. 7: perspective view of the direct short-circuited terminals;

- Fig. 8: a perspective view of a pre-twisted cage bars;

- Fig. 9: sectional view of the package of the rotor with beveled grooves containing an axially laminated electrical steel plate;

- Fig. 10: asynchronous machine with squirrel-cage rotor in one embodiment of the invention.

Fig. 1 and 2 show a twisted cage terminal 3 for installation in a groove of a package of iron of the rotor. The twist indicated by the angle 13, which characterizes caused by torsional displacement of both ends of the rod 3 in the direction of the periphery of the machine. The rod 3 is formed, for example, in the form of a copper rod that can be stacked with almost no preload in the beveled groove of the package.

Fig. 3 the side view depicts a package 5 iron rotor 1. Dashed lines are caused by twisting the location of grooves PA�ETA 5 iron. After laying the rods 3 to the package 5 iron with the ends perelivayutsya short-circuiting ring 6. In the casting process the remaining section of the grooves are not filled by rods 3, is filled with casting material.

Fig. 4 shows an end view of the package of iron 5 from Fig. 3. We are talking about a partial sectional view, which shows that by twisting the first end 14 of the groove is the circumferential direction of the offset from the second end of the end 15 of the same groove exactly one slot step 9.

Fig. 5 shows a section through the package of iron 5 from Fig. 4 short-circuited with straight rods 11. The grooves 4 are filled due to the fact that the rods 11 are stacked in the twisted package 5 iron is equipped with a package of 5 iron is twisted. The rods 11 are provided respectively in an oblique position. However, in a radially inner area of the groove 7 occurs the free space 16, whereby in the area 7 of the groove decreases the fill factor. A similar effect causes the manufacturing method, in which the rods 11 are placed in the already twisted iron package 5.

Further, in Fig. 5 shows that the radially outer zone 8 of the groove filled with the first material. Because this material, which is mostly die-cast aluminum, has a lower compared to the rods 11 electrical conductivity, actual�Vanir, thus, the starter cores for induction machines.

The use of straight rods 11 has the advantage of reducing the fill factor of the groove in a radially inner zone 7.

Fig. 6 shows a section through the package of iron 5 from Fig. 4 with twisted cage bars 12. It is clearly seen that all the inner zone of the groove 7 is filled with a rod 12, which represents, in particular, twisted copper rod. This is a high filling of the grooves causes the maximum possible efficiency. In a radially external area 8 is also implemented starting rod from die-cast aluminium. Thanks to almost 100% completely filling the groove in a radially inner zone 7 copper rod die-cast aluminum is almost exclusively in the outer zone 8, forming there own at the time of starting the high ohmic resistance of the squirrel-cage rotor.

Fig. 7 shows a direct short-circuited rod 11 arranged in a package of iron 5 from Fig. 5. In contrast, in Fig. 8 shows already twisted cage rod 12, which in Fig. 6 can be achieved the maximum possible filling of the groove.

Fig. 9 shows a section through the package of iron with beveled grooves containing an axially laminated plate 10 electrical steel. The plates 10 are twisted relative to each other so that there is a need�th bevel grooves, for example, exactly one slot pitch. By blending the iron package 5 may be made from the imaged plate 10. Alternatively, a package of iron can be manufactured by blending of the plates 10 at the filling mandrel with a tapered filling the groove.

Fig. 10 shows an asynchronous machine 2 with squirrel-cage rotor. Due to its hybrid structure that contains a squirrel-cage rotor of copper rods connected to the ends of the rings, die-cast aluminium, high efficiency is achieved. Since squirrel-cage rotor is provided with oblique grooves, the asynchronous machine has an extremely low content of higher harmonics, it is very low noise and low torque ripple.

1. A method of manufacturing a squirrel-cage rotor (1) for the asynchronous machine (2) comprising the following steps:
- a package of iron (5) of the rotor with beveled grooves (4);
- laying cage rods (3; 11; 12) of the second material in the beveled grooves (4) pack of iron (5) of the rotor;
- burst from the ends to the package of iron (5) of the rotor short-circuiting rings (6) from a first material with a lower specific electrical conductivity than the second material,
characterized in that before packing in the grooves (4) squirrel cage rods (3; 11; 12) are twisted with providing the opportunity�spine introducing them before applying the cast of the first material substantially without preload in package iron (5) of the rotor with beveled grooves so they almost completely fill the interior, when viewed in the radial direction, the area (7) of the grooves, whereby the first material in the casting process can not penetrate into the inner zone (7) of the grooves.

2. A method according to claim 1, wherein the grooves (4) with stacked them in the cage rods (3; 11; 12) is filled by way of injection molding the first material, and the short-circuiting rings (6) are also produced by molding under pressure.

3. A method according to claim 1, wherein the squirrel cage rods (3; 11; 12) are placed in the grooves (4) with possibility of external fill, when viewed in the radial direction of the rotor (1), area (8) of the groove by injection molding the first material.

4. A method according to claim 2, wherein the short-circuited terminals (3; 11; 12) are placed in the grooves (4) with possibility of external fill, when viewed in the radial direction of the rotor (1), area (8) of the groove by injection molding the first material.

5. A method according to claim 1, wherein the first material used the aluminum and the second material is copper.

6. Method according to one of claims. 2-4, wherein the first material used the aluminum and the second material is copper.

7. Method according to one of claims. 1-5, in which the bevel beveled interlocking grooves corresponds to step (9).

8. Method one those conducted through. 1-5, in which the package of iron (5) of the rotor is made by blending plates (10) electrical steel in the axial direction, wherein the plates (10) are twisted relative to each other so that they are beveled grooves.

9. Squirrel-cage rotor (1) for the asynchronous machine (2), and it contains:
package of iron (5) with grooves (4);
- prelite ends to the package of iron (5) of the rotor short-circuiting ring (6) from a first material and
- located in the grooves (4) squirrel cage rods (3; 11; 12) of a second material with a higher specific electrical conductivity than the first material, and a package of iron (5) of the rotor is beveled grooves
characterized in that squirrel-cage rods (3; 11; 12) is almost completely fill the interior, when viewed in the radial direction of the package of iron (5) of the rotor zone (7) of the grooves due to the fact that in the manufacture of squirrel-cage rotor (1) squirrel cage rods (3; 11; 12) before packing in the grooves (4) are twisted in such a way that they are before the application of first cast material is introduced substantially without preload in package iron (5) of the rotor with beveled grooves, almost completely filling the interior, when viewed in the radial direction, the area (7) of the grooves, whereby the first material in the casting process can not penetrate into the inner zone (7) of the groove�V.

10. Rotor according to claim 9, in which the grooves (4) with stacked them in the cage rods (3; 11; 12) is filled by way of injection molding the first material, and the short-circuiting ring (6) is made by molding under pressure.

11. Rotor according to claim 9, which is filled with the first material area of the grooves (4) is located outside, when viewed in the radial direction of the rotor (1).

12. Rotor according to claim 10, which is filled with the first material area of the grooves (4) is located outside, when viewed in the radial direction of the rotor (1).

13. Rotor according to claim 9, in which the first material is aluminum and the other copper.

14. Rotor according to one of claims. 10-12, in which the first material is aluminum and the other copper.

15. Rotor according to one of claims. 9-13, in which the bevel beveled interlocking grooves corresponds to step (9).

16. Rotor according to one of claims. 9-13, in which the package of iron (5) of the rotor comprises a laminated in the axial direction of the plate (10) electrical steel, wherein the plates (10) are twisted relative to each other so that they are beveled grooves.

17. Asynchronous machine (2) comprising a stator with stator windings and a squirrel-cage rotor (1), and squirrel-cage rotor (1) comprises:
package of iron (5) with grooves (4);
- prelite ends to the package of iron (5) of the rotor short-circuiting ring (6) from the first�about material and
- located in the grooves (4) squirrel cage rods (3; 11; 12) of a second material with a higher specific electrical conductivity than the first material, and a package of iron (5) of the rotor is beveled grooves
characterized in that squirrel-cage rods (3; 11; 12) is almost completely fill the interior, when viewed in the radial direction of the package of iron (5) of the rotor zone (7) of the grooves due to the fact that in the manufacture of squirrel-cage rotor (1) squirrel cage rods (3; 11; 12) before packing in the grooves (4) are twisted in such a way that they are before the application of first cast material is introduced substantially without preload in package iron (5) of the rotor with beveled grooves, almost completely filling the interior, when viewed in the radial direction, the area (7) of the grooves, whereby the first material in the casting process can not penetrate into the inner zone (7) of the grooves.

18. Asynchronous machine (2) according to claim 17, in which the grooves (4) with stacked them in the cage rods (3; 11; 12) is filled by way of injection molding the first material, and the short-circuiting ring (6) is made by molding under pressure.

19. Asynchronous machine (2) according to claim 17, which is filled with the first material area of the grooves (4) is located outside, when viewed in the radial direction of the rotor (1).

20. Asynchronous machine (2) according to claim 18, in which� filled with the first material area of the grooves (4) is located outside when viewed in the radial direction of the rotor (1).

21. Asynchronous machine (2) according to claim 17, in which the first material is aluminum and the other copper.

22. Asynchronous machine (2) according to one of claims. 18-20, in which the first material is aluminum and the other copper.

23. Asynchronous machine (2) according to one of claims. 17-21, in which the bevel beveled interlocking grooves corresponds to step (9).

24. Asynchronous machine (2) according to one of claims. 17-21, in which the package of iron (5) of the rotor comprises a laminated in the axial direction of the plate (10) electrical steel, wherein the plates (10) are twisted relative to each other so that they are beveled grooves.



 

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25 cl, 6 dwg

FIELD: electricity.

SUBSTANCE: transformer part of a unit is made with a primary winding connected to a three-phase circuit, and with a secondary z-phase bar winding, arranged in z slots of a transformer magnetic conductor closed at one side with an end ring. The drive part of the unit comprises an induction motor with a short-circuited rotor and stator with a bar winding, electrically connected with the secondary winding of the transformer, and at the other side closed with the end ring. The bars of the secondary winding of the transformer are connected with Z bars-feedthrough plates arranged in a tight partition. Each bar-feedthrough plate at the other side is electrically connected with n bars of the stator winding via intermediate electric wire arched segments adjoining the stator (where n=1, 2, … - multiple number between the bars of the stator winding and the secondary winding of the transformer).

EFFECT: expanded area of application and increased energy characteristics and reliability of a drive-transformer unit.

2 dwg

FIELD: electrical engineering.

SUBSTANCE: core plates are made in the area of internal diameter with slots concentric in relation to this diameter at least in two rows; at that there are at least two slots in each row and bridges between slots are located in the middle of slots in the next row; at that joining of elements fixing core ends to the shaft is made at radial depth from the first row of concentric slots and joining of axial fixing elements to core ends is spread in radial direction to the shaft not farther then the last row of slots from the shaft.

EFFECT: prevention of impact of unevenly compacted rotor core on the rotor shaft of an electrical machine.

4 cl, 5 dwg

FIELD: electrical engineering.

SUBSTANCE: axial electric motor is designed to be stationary and open in a plot of land, the body consisting of the lower tier including a foundation slab with the lower support assembly and the upper tier including a star-shaped spherical framework attached to the foundation, the framework symmetrically composed of prop beams tensioned in the centre with an axial support and balancing assembly. Installed between the lower support assembly and the axial support and balancing assembly is a large diameter runner wheel on the end face whereof the short-circuited rotor proper is installed separated from the magnetic conductor of the stator, erected on the foundation slab on a raised platform, with an air gap. The runner wheel shaft is connected to the load via a clutch.

EFFECT: ensuring large magnitude torques combined with design simplification.

3 dwg

FIELD: electricity.

SUBSTANCE: motor consists of body with stator with low and high speed windings mounted in slots, rotor fixed at motor shaft and box of inputs with through joints connected to outputs of specified windings. According to invention winding changeover device is located at motor body; input terminals of the motor should have facilities for connection of feeder current-carrying leads and output terminals of winding changeover device should be connected electrically with through joints connected to outputs of motor windings. Winding changeover device can be located in box of inputs; for this purpose two outputs of this device should be connected through its break-type contacts to outputs of low speed windings of the motor and two outputs through normally open contacts of device should be connected to through joints, which are connected to high speed windings of the motor. Third outputs of low and high speed windings should be interconnected and then connected to the third through joint in box of motor inputs.

EFFECT: simplification of power supply system structure, improvement of control and protection, enhancement of reliability and operation of asynchronous double-speed motors due to their power supply by one cable and due to motor control and protection by one device instead of two devices.

2 cl, 2 dwg

FIELD: electricity.

SUBSTANCE: rotor of an asynchronous electric machine comprises a shaft, a ferromagnetic core fixed coaxially on the shaft - a magnetic conductor with an external surface in the form of a circular cylinder and an electric winding of "squirrel cage" type. At the same time according to this invention, the ferromagnetic core - magnetic conductor consists of longitudinal elements made of material having at least axial electroconductivity, besides, the longitudinal elements with the help of frontal conductors - links are electrically connected to each other only by their end parts, forming a winding of "squirrel cage" type.

EFFECT: considerable improvement of weight and dimension characteristics of an electric machine, reduced prime cost of its manufacturing, considerable reduction of teeth pulsations of the torque on the shaft of the asynchronous electric machine with a rotor made according to this invention.

10 cl, 2 dwg

FIELD: engines and pumps.

SUBSTANCE: in asynchronous motor the following is used: semi-open (up to 2.2 mm) rotor slots of special design without chamfer with transition at the height of 1 mm to wide part of the slot top; stator slots having upper part of arched design and maximum opening up to 4 mm on condition that number of pairs of poles 2p = 6 - 12 is chosen so that frequency of supply voltage is not lower than 4 Hz, with rigid matching of ratio of numbers of rotor slots of 66-130 and stator slots of 54 - 108 at the number of rotor slots more than number of stator slots by 20%; stator winding with number of slots per pole and phase is at least 2; magnetic system made from steel having high values of induction without connection to value of specific losses.

EFFECT: higher energy data and overload capacity of electric motor, including at its operation in generator mode.

2 dwg, 1 tbl

FIELD: process engineering.

SUBSTANCE: invention relates to winding process, particularly, to making of electric coil. In compliance with this process, winding thread 8 is fed from feeder 7 and wound on coil carcass with out-of-round cross-section at relative displacement of winding material 8 and coil carcass. Winding material 8 is subjected to force applied across its length before application on surface to be wound. Said crosswise force is applied to winding material and varies from elastic to plastic pre-stress. Preliminary forming element is brought in interaction with winding material thread.

EFFECT: minimised barrelling of wound material.

11 cl, 7 dwg

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