Multi-pole generator rotor and method of making the same

• US 6,465,928 B1
• Filed: 12/23/1998
• Issued: 10/15/2002
• Est. Priority Date: 12/23/1998
• Status: Expired due to Fees

• Current Assignee: Sundstrand Corporation (Raytheon Technologies Corporation d/b/a RTX)
• Original Assignee: Hamilton Sundstrand Corporation (Raytheon Technologies Corporation d/b/a RTX)
• Inventors: Shervington, Roger Malcolm, Magnuson, Roger Carl
• Primary Examiner(s): Ramirez, Nestor
• Assistant Examiner(s): Perez, Guillermo
• Application Number:
  US09/220,250
• Time in Patent Office: 1,392 Days
• Field of Search: 310/214, 310/260, 310/270, 310/262, 310/170, 310/169, 310/168, 310/42, 310/179, 310/180, 310/184, 310/194, 310/195, 310/198, 310/208, 310/218, 310/261, 310/185, 310/129, 310/269
• US Class Current: 310/270
• CPC Class Codes: H02K 1/24 Rotor cores with salient poles ; Variable reluctance rotors
• CPC Class Codes: H02K 1/28 Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures
• CPC Class Codes: H02K 3/46 Fastening of windings on the stator or rotor structure
• CPC Class Codes: H02K 3/487 Slot-closing devices

Abstract

A multi-pole generator rotor and a method of making the same are disclosed. A multi-pole generator rotor includes a rotor body having a central portion with a generally cylindrical outer surface. The outer surface includes three pairs of diametrically opposed slots extending along a length of the central portion, with each of the slots being sized to receive therein a plurality of wires. Each of the slots further includes a pair of opposed retaining flanges. A plurality of retaining members are sized for insertion into a corresponding one of the slots. Each retaining member engages a pair of the retaining flanges from its corresponding slot. The retaining members thereby retaining the wires disposed in each slot against radially outward displacement. A method of forming a multi-pole generator rotor includes the steps of providing the above rotor body, winding first, second and third wire coils by repeatedly winding a wire through a first, second, and third set of opposing slot pairs, and inserting a retaining member longitudinally into each of the slots.

Claims

1. A multi-pole generator rotor, comprising:

a rotor body, the rotor body having a pair of ends, the rotor body including a central portion having a generally cylindrical outer surface, the outer surface having at least one pair of diametrically opposed slots extending along a length of the central portion, each of the slots being sized to receive therein a plurality of wires, each of the slots further including a pair of opposed retaining flanges;

a plurality of retaining members, each of the retaining members being sized for insertion into a corresponding one of the slots and to engage the retaining flanges of its corresponding slot, the retaining members thereby retaining the wires disposed in each slot against radially outward displacement;

an end support mounted to each of the ends, each end support having a plurality of prongs, each of the prongs being spaced to receive therebetween a portion of the wire winding; and

an end cap mounted to each of the ends of the rotor body over an adjacent one of the end supports, each of the end caps including a plurality of diametrically oriented slots sized to receive therein another portion of the wire winding.

2. The generator rotor of claim 1, wherein the outer surface includes an odd number of pairs of diametrically opposed slots.

3. A multi-pole generator rotor, comprising:

a rotor body, the rotor body having a pair of ends connected by a central axis, the rotor body further including a central portion having a generally cylindrical outer surface, the outer surface having three pairs of diametrically opposed slots extending along a length of the central portion, each of the slots including a pair of opposed retaining flanges;

a plurality of retaining members, each of the retaining members being sized for insertion into a corresponding one of the slots and to engage the retaining flanges of its corresponding slot, the retaining members thereby retaining the wires disposed in each slot against radially outward displacement;

a continuous wire winding, the wire winding including a plurality of wire sections disposed in each of the slots, the wire winding further including a plurality of end portions adjacent each of the rotor body ends, each of the wire winding end portions crossing the central axis;

an end support mounted to each of the rotor body ends, each end support supporting the adjacent wire end portions; and

a cap member mounted to each of the rotor body ends, each of the cap members engaging an adjacent end support, each of the cap members further including three intersecting grooves, each of the grooves being sized to overlie an adjacent wire end portion.

4. A multi-pole generator rotor comprising:

a rotor body, the rotor body including a pair of ends connected by a central axis, the rotor body further including a generally cylindrical central portion, the central portion including a plurality of slots extending along the length thereof, each of the slots further having a pair of longitudinally extending edge portions, each of the edge portions defining a retaining flange; and

a plurality of retaining members, each of the retaining members having a pair of ends and being sized for insertion in a corresponding one of the slots, each of the retaining members including a pair of edges sized to engage its corresponding slot edge portions;

a continuous wire winding, the wire winding having a plurality of wire sections disposed in each of the slots, the wire winding including three coils, each of the coils engaging a pair of diametrically opposed slots, each of the coils further including a pair of end portions adjacent each of the rotor body ends, each of the coil end portions crossing the central axis;

a coil support mounted to each of the rotor body ends, each coil support supporting the adjacent coil ends; and

a cap mounted to each of the rotor body ends, each cap engaging the adjacent retaining member ends, each cap further including a plurality of grooves sized to receive the adjacent coil ends;

whereby the wire winding portion disposed in each slot is held in a fixed position by the corresponding retaining member.

5. A multi-pole generator rotor comprising:

a rotor body including a pair of ends and an interconnecting central axis, the rotor body having a generally cylindrical central portion, the central portion including a plurality of slots extending along the length thereof, each of the slots being sized to receive a portion of the wire winding, each of the slots further having a pair of longitudinally extending edge portions, each of the edge portions defining a retaining flange; and

a plurality of retaining members, each of the retaining members being sized for insertion in a corresponding one of the slots, each of the retaining members including a pair of edges sized to engage its corresponding slot edge portions;

a wire winding forming three coils, each of the coils being disposed in a pair of diametrically opposed slots, each of the coils including a pair of end portions, a first one of the end portions of each coil being disposed adjacent a first one of the ends of the rotor body, a second one of the end portions of each coil being disposed adjacent a second one of the ends of the rotor body;

a cap mounted to each of the ends of the rotor body, each cap having three intersecting grooves, each of the grooves being sized to overlie one of the end portions of the coil;

an end support mounted to each rotor body end, the end support at each rotor body end being mounted between the adjacent rotor body end and the adjacent cap, each end support including six aligning prongs;

whereby the wire winding portion disposed in each slot is held in a fixed position by the corresponding retaining member.