Rotor Assembly with Electron Beam Welded End Caps
First Claim
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1. A method of fabricating a rotor assembly for an electric motor, the method comprising:
- inserting a plurality of rotor bars into a corresponding plurality of slots within a stack of laminated discs, wherein a first portion of each of said plurality of rotor bars protrudes from a first end surface of said stack of laminated discs, and wherein a second portion of each of said plurality of rotor bars protrudes from a second end surface of said stack of laminated discs;
mounting a first end cap to said plurality of rotor bars, wherein said first portion of each of said plurality of rotor bars fits within a corresponding slot of a first plurality of slots in said first end cap;
mounting a second end cap to said plurality of rotor bars, wherein said second portion of each of said plurality of rotor bars fits within a corresponding slot of a second plurality of slots in said second end cap;
directing a first electron beam towards a circumferential side surface of said first end cap and fusing at least a region of said first portion of each of said plurality of rotor bars to said corresponding slot of said first plurality of slots of said first end cap; and
directing a second electron beam towards a circumferential side surface of said second end cap and fusing at least a region of said second portion of each of said plurality of rotor bars to said corresponding slot of said second plurality of slots of said second end cap.
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Abstract
A rotor assembly and a method for fabricating the same are provided in which a pair of end caps, positioned at either end of the stack of laminated discs, are fusion welded to the rotor bars using an electron beam welder, thereby yielding improved electrical and mechanical characteristics in a low weight assembly.
11 Citations
20 Claims
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1. A method of fabricating a rotor assembly for an electric motor, the method comprising:
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inserting a plurality of rotor bars into a corresponding plurality of slots within a stack of laminated discs, wherein a first portion of each of said plurality of rotor bars protrudes from a first end surface of said stack of laminated discs, and wherein a second portion of each of said plurality of rotor bars protrudes from a second end surface of said stack of laminated discs; mounting a first end cap to said plurality of rotor bars, wherein said first portion of each of said plurality of rotor bars fits within a corresponding slot of a first plurality of slots in said first end cap; mounting a second end cap to said plurality of rotor bars, wherein said second portion of each of said plurality of rotor bars fits within a corresponding slot of a second plurality of slots in said second end cap; directing a first electron beam towards a circumferential side surface of said first end cap and fusing at least a region of said first portion of each of said plurality of rotor bars to said corresponding slot of said first plurality of slots of said first end cap; and directing a second electron beam towards a circumferential side surface of said second end cap and fusing at least a region of said second portion of each of said plurality of rotor bars to said corresponding slot of said second plurality of slots of said second end cap. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15)
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16. A rotor assembly for an electric motor, comprising:
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a rotor shaft; a plurality of laminated discs formed into a stack of laminated discs, wherein each of said plurality of laminated discs includes a plurality of slots, wherein said plurality of slots of each of said plurality of laminated discs are co-aligned within said stack of laminated discs, and wherein said stack of laminated discs is mounted to said rotor shaft; a plurality of rotor bars passing through said plurality of slots of said stack of laminated discs, wherein a first portion of each of said plurality of rotor bars extends out and away from a first end surface of said stack of laminated discs, and wherein a second portion of each of said plurality of rotor bars extends out and away from a second end surface of said stack of laminated disc; a first end cap fused to said plurality of rotor bars, wherein said first end cap is comprised of a first plurality of slots, wherein said first portion of each of said plurality of rotor bars fits within a corresponding slot of said first plurality of slots, wherein a first end region corresponding to said first portion of each of said plurality of rotor bars is fusion welded via an electron beam to said corresponding slot of said first plurality of slots of said first end cap, and wherein said first end region extends from an outer rotor bar radius defined by said plurality of rotor bars to an inner rotor bar radius defined by said plurality of rotor bars; and a second end cap fused to said plurality of rotor bars, wherein said second end cap is comprised of a second plurality of slots, wherein said second portion of each of said plurality of rotor bars fits within a corresponding slot of said second plurality of slots, wherein a second end region corresponding to said second portion of each of said plurality of rotor bars is fusion welded via said electron beam to said corresponding slot of said second plurality of slots of said second end cap, and wherein said second end region extends from said outer rotor bar radius defined by said plurality of rotor bars to said inner rotor bar radius defined by said plurality of rotor bars. - View Dependent Claims (17, 18, 19, 20)
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Specification