METHOD FOR MANUFACTURING A ROTOR FOR A SLIP RING MOTOR, ROTOR FOR A SLIP RING MOTOR AND SLIP RING MOTOR

Abstract

A method for manufacturing a rotor for a slip ring motor, including the steps of: a) arranging a plurality of electric cables inside a hollow shaft, wherein the electric cables are distributed over an inner circumference of the hollow shaft, b) filling a resin into an empty space defined between the hollow shaft and the electric cables, c) arranging a rod inside the hollow shaft thereby displacing the resin into an annular gap between the rod and the hollow shaft, wherein the electric cables are arranged in the annular gap, and d) curing of the resin to form the rotor.

Claims

1. A method for manufacturing a rotor for a slip ring motor, the method comprising the steps of: a) arranging a plurality of electric cables inside a hollow shaft, wherein the electric cables are distributed over an inner circumference of the hollow shaft, b) filling a resin into an empty space defined between the hollow shaft and the electric cables, c) arranging a rod inside the hollow shaft thereby displacing the resin into an annular gap between the rod and the hollow shaft, wherein the electric cables are arranged in the annular gap, and d) curing of the resin to form the rotor.

2. The method of claim 1, wherein, prior to step b), spacers are arranged inside the hollow shaft, the spacers holding the cables to the inner circumference of the hollow shaft.

3. The method of claim 2, wherein the spacers each have an opening, the rod being pushed therethrough in step c).

4. The method of claim 2, wherein the spacers have recesses on their outer circumference, each recess guiding one of the electric cables.

5. The method of claim 4, wherein the spacers each comprise at least three support portions and a recess portion between two of the support portions, respectively, wherein each of the support portions lies directly against the inner circumference of the hollow shaft and each of the recess portions has one or more of the recesses.

6. The method of claim 1, wherein the rod is made of plastic material.

7. The method of claim 1, wherein the rod is made of a glass fiber composite.

8. The method of claim 2, wherein the rod is configured to engage the spacers so as to prevent movement of the spacers due to the filling of the resin in step b).

9. The method of claim 8, wherein the rod comprises a plurality of shoulders, each configured to engage an associated spacer, a diameter of the rod decreasing in a stepwise fashion at each shoulder.

10. The method of claim 9, wherein diameters of the openings in the associated spacers correspond to the rod diameter at a respective shoulder.

11. The method of claim 1, wherein the hollow shaft is, prior to step b), arranged such that its central axis is oriented parallel to the direction of gravity, and the resin is filled into the hollow shaft from above.

12. The method of claim 1, wherein, if it is determined after step c) that the annular gap is not completely filled with resin, additional resin is filled into the annular gap to completely fill the annular gap.

13. The method of claim 4, wherein the recesses in the spacers are formed as axial grooves and the openings in the spacers are formed as central holes.

14. The method of claim 1, wherein the resin is an epoxy resin.

15. A rotor for a slip ring motor, comprising a hollow shaft, a plurality of electric cables distributed over an inner circumference of the hollow shaft, a rod arranged inside the hollow shaft to form an annular gap between the rod and the hollow shaft, wherein the electric cables are arranged in the annular gap, and a cured resin provided in the annular gap between the electric cables.

16. A slip ring motor with a power output of >1 MW, comprising a rotor having a hollow shaft, a plurality of electric cables distributed over an inner circumference of the hollow shaft, a rod arranged inside the hollow shaft to form an annular gap between the rod and the hollow shaft, wherein the electric cables are arranged in the annular gap, and a cured resin provided in the annular gap between the electric cables.

Description

[0050] In the Figures, like reference numerals designate like or functionally equivalent elements, unless otherwise indicated.

[0051] FIG. 1 shows, in a partial section view, a slip ring motor 1 in accordance with an embodiment of the present invention.

[0052] The slip ring motor 1 drives a compressor (not shown) used in an air separation plant, for example. The slip ring motor 1 comprises a rotor 2 arranged inside a stator (not shown). The rotor 2 is of the wound type. The rotor 2 comprises multiple windings 3a, 3b. The windings 3a, 3b are connected by a first and a second electric cable 4, 5 to a first and a second slip ring 6, 7. In order to simplify representation, only two cables 4, 5 and two slip rings 6, 7 are shown in FIG. 1. Typically, six or more cables and corresponding slip rings are provided.

[0053] The cables 4, 5 are guided from the windings 3a, 3b to the slip rings 6, 7 inside a hollow shaft 9 (shown in partial section) of the rotor 2. The slip ring 6, 7 are rotationally fixed to the shaft 9 so as to rotate with the same. The slip ring 6, 7 are contacted by brushes 11, 12, respectively. The brushes 11, 12 are stationary and connected electrically to an external resistance 10.

[0054] The cable 4 is shown to be connected to the slip ring 6, and the cable 5 is connected to the slip ring 7. Further, the cable 4 is connected, preferably by a contact bolt (not shown), to a male contact element 14 of a first rotating unit 15 (see FIG. 3), and the cable 5 is connected, preferably by another contact bolt (not shown), to a male contact element 16 of the first rotating unit 15. Black dots in FIGS. 1 and 3 indicate points of electrical connection of the cables 4, 5 or contact bolts.

[0055] The rotating unit 15 may comprise a ring 17 as seen in the axial view of FIG. 3. The ring 17 is made of a material electrically insulating the male contact elements 14, 16 against each other. For example, the ring 17 is made of glass fiber composite.

[0056] Further, the slip ring motor 1 comprises a second rotating unit 18 shown in an axial view in FIG. 2. The second rotating unit 18 comprises a ring 19. The ring 19 is made up of a base ring element 20 (see FIG. 1) and a conducting ring element 21. The base ring element 20 is configured as an electrical insulator, for example made of glass fiber composite. The conducting ring element 21 on the other hand is made of a conducting material, for example copper. Female contact elements 22, 23 (see FIG. 2) are attached to the conducting ring element 21, wherein electrical connection is made between the female contact elements 22, 23 and the conducting ring element 21.

[0057] Of course, the first rotating unit 15 may comprise more than two, for example six to twelve male contact elements, and the second rotating unit 18 may comprise more than two, for example six to twelve female contact elements, as indicated by the dotted lines in FIGS. 2 and 3. For illustration purposes, only two such elements are shown in FIGS. 2 and 3, respectively.

[0058] Both rotating units 15, 18 are attached to the shaft 9 so as to rotate with the same. Yet, the first rotating unit 15 is also fixed axially to the shaft 9, whereas the second rotating unit 18 is configured to be moved along the axis 24 on the hollow shaft 9.

[0059] FIG. 1 shows a first state in which the first and second rotating unit 15, 18 are spaced apart from each other such that the male and female contact elements 14, 16, 22, 23 are disengaged from one another. Thus, the cables 4, 5 and the corresponding windings 3a, 3b are not switched to short circuit. Consequently, the inrush current induced during startup of the slip ring motor 1 passes from the winding 3a through the cable 4, via the slip ring 6 and the brush 11 into the external resistance 10. The external resistance 10 may comprise an electrolyte or any other high-resistance material. After passing through the external resistance 10, the current returns to the winding 3b via the brush 12, the slip ring 7 and the cable 5. The path of the current through the external resistance 10 is indicated by a dashed arrow.

[0060] When the slip ring motor 1 has started up, i.e. as the rounds per minute of the rotor 2 increase, the current through the cables 4, 5 becomes smaller. Thus, it is desirable to switch off the external resistance 10 when the slip ring motor 1 has reached its nominal speed. To this end, the second rotation unit 18 is moved in a direction 25 along the axis 24 into a second state (not shown), in which the male contact elements 14, 16 engage the female contact elements 22, 23. Consequently, the cables 4, 5 are switched to short circuit since the current goes from the cable 4 through the male contact element 14 into the female contact element 22, through the conducting ring element 21 and via the female contact element 23 and the male contact element 16 into the cable 5.

[0061] Even though presently only explained with respect to a single phase and/or a single pair of windings 3a, 3b, the same principle holds for the other phases and/or other pairs of windings.

[0062] FIG. shows, in a partial section view, a method step in the manufacture of the rotor 2 of FIG. 1 in accordance with an embodiment.

[0063] Prior to the method step shown in FIG. 4, the cables 4, 5 are arranged inside the hollow shaft 9. This may be done in a horizontal orientation of the rotor 2, i.e. when the axis of rotation 24 of the rotor 2 is oriented horizontally.

[0064] The cables 4, 5 may be arranged inside the hollow shaft 9 as illustrated in the section IV-IV shown in FIG. 6. Each of the cables 4, 5 (in order to simplify representation only a few cables have been given reference numerals) comprises a conductor 26, for example made of copper, enclosed by a sheath or insulator 27. The cables 4, 5, in particular the sheath or insulator, each touch the inner circumference 28 of the hollow shaft 9 or lie in close vicinity thereto. Close vicinity presently means a distance between the inner circumference 28 and the closest point on the outer surface of a respective cable 4, 5 being no larger than 5 mm, preferably no larger than 3 mm and more preferably no larger than 1 mm.

[0065] As can be seen from FIG. 6, the cables 4, 5 are distributed over the inner circumference 28 in the circumferential direction 29. “Circumferential” refers to the axis of rotation 24 herein.

[0066] Further, FIG. 6 shows a first spacer 30 holding the cables 4, 5 to the inner circumference 28. Preferably, the spacer 30 is introduced into the hollow shaft 9 along with the cables 4, 5 or after the cables 4, 5 have been arranged inside the hollow shaft 9. The spacer 30 may be introduced into the hollow shaft 9 in its horizontal position (see FIG. 1) or in its vertical position (see FIG. 4). In addition to the first spacer 30, a second spacer 31 shown in FIG. 4 and, as the case may be, additional spacers (not shown) may be arranged inside the hollow shaft 9.

[0067] The design of the first spacer 30 will be explained hereinafter in more detail referring to FIGS. 5 and 6. What is being explained herein with regard to the first spacer 30, equally applies to the second spacer 31 and the additional spacers.

[0068] The spacer 30 has a triangular shape comprising support portions 32 at a respective edge. Bent recess portions 33 are arranged between each pair of support portions 32. Each recess portion 33 corresponds to a third of a circle. On the outside, the recess portions 33 each comprise recesses 34 formed as axial grooves. The recesses 34 thus extend parallel to the axis of rotation 24. Each recess portion 33 may comprise, for example, two to six recesses 34. In the present example, each recess portion 33 has four recesses 34. Thus, the spacer 30 of the present example supports a total of 12 cables 4, 5 as can be seen in FIG. 6. Each recess 34 guides an associated cable 4, 5. A radius 35 describing each recess 34 corresponds to the radius of a respective cable 4, 5. On the inside, the recess portions 33 define a semicircular hole 36 extending through the spacer 30. A central axis of the holes 36 is coaxial with the axis of rotation 24 of the rotor 2.

[0069] Once the cables 4, 5 and, preferably, the spacers 30, 31 have been inserted into the hollow shaft 9, the rotor 2 is turned so as to be oriented vertically. That is, the axis of rotation 24 is oriented parallel to the gravity vector 37 shown in FIG. 4. In this position, an open end 38 of the hollow shaft 9 faces upwards. The turning of the rotor 2 may be done using overhead cranes or the like.

[0070] Now, liquid resin 39, for example, an epoxy resin, is filled into the hollow shaft 9, i.e. into the empty space defined by the hollow shaft 9, the cables 4, 5 and the spacers 30, 31. At this point, the resin 39 may be at a temperature of, for example, 50 to 150° C. The resin 39 is poured from above, for example using a container 40 supported by overhead cranes not shown), into the open end 38 of the hollow shaft 9. Especially the holes 36 in the spacers 30, 31 allow the resin 39 to flow downwards and thus fill the hollow shaft 9 from the bottom upwards with resin 39.

[0071] Once, the hollow shaft 9 has been filled partially with resin 39, a rod 41 (depicted in FIGS. 7 and 8) is inserted into the hollow shaft 9 from above through the open side 38. The rod 41 is comprised of, for example, three portions of constant diameter, hereinafter referred to as a first portion 42, a second portion 43 and a third portion 44. The first portion 42 has a diameter D.sub.1, the second portion 43 a diameter D.sub.2 and the third portion 44 a diameter D.sub.3. The diameter D.sub.1 is larger than the diameter D.sub.2, and the diameter D.sub.2 is larger than the diameter D.sub.3. Thus, shoulders 45, 46 are formed at each point where the diameter changes. The shoulders 45, 46 are configured to engage the spacers 30, 31. To this end, the hole 36 in the spacer 31 has a diameter D.sub.3′ corresponding to the diameter D.sub.3 of the third portion 44 of the rod 41. The hole 36 in the spacer 30 has a diameter D.sub.2′ corresponding to the diameter D.sub.2 of the second portion 43 of the rod 41. Thus, the shoulder 46 engages the spacer 31 in the axial direction, i.e. along the axis of rotation 24. At the same time, the shoulder 45 engages the spacer 30 in the axial direction. This engagement occurs when the rod 41 is pushed or lowered from above through the holes 36 in the spacers 30, 31.

[0072] As the rod 41 is pushed down or lowered in the direction of the gravity vector 37, the resin 39 is displaced sideways and upwards into an annular gap 47 thus formed between the rod 41 and the inner circumference 28 of the hollow shaft 9. At this point, cavities which may have remained, for example, cavities 48 (see FIG. 6 showing the resin 39 in the background) defined between the spacers 30, 31, the inner circumference 28 and the cables 4, 5, are filled. This is because of the pressure build-up inside the hollow shaft 9, when the rod 41 is pushed into the resin 39.

[0073] As the rod 41 is pushed into the resin 39 from above, a pressure develops that as explained above—not only fills the cavities 48, but also tends to raise the spacers 30, 31 upwards. By now engaging the spacers 30, 31 with the shoulders 45, 46, the rod 41 prevents such raising of the spacers 30, 31.

[0074] Preferably, the amount of resin 39 in the hollow shaft 9 is selected such that, when the rod 41 has been inserted completely into the hollow shaft 9, i.e. a top surface 49 of the third portion 42 is flush with the open end 38 of the hollow shaft 9, the resin 39 has risen inside the annular gap 47 to a level 50 flush with the open end 38.

[0075] In cases where the amount of resin 39 cannot be determined up front with the necessary accuracy, less resin 39 can be filled into the hollow shaft 9 initially. In a further step, missing resin in the annular gap 47 is filled into the hollow shaft 9 when the rod 41 has been inserted completely.

[0076] Yet, according to another embodiment, the rod 41 is first inserted into the hollow shaft 9, and thereafter the resin 39 is filled into the annular gap 47.

[0077] The rod 41 may comprise a lug 51 which allows easy handling of the rod 41, for example using an overhead crane. This is especially advantageous since the rod 41 needs to be lifted from the ground to a position above the open end 38 of the hollow shaft 9. The portions 42, 43, 44 of the rod 41 may be made of glass fiber composite, for example.

[0078] Once the hollow shaft 9 is completely filled, the resin 39 is cured. During curing of the resin 39, temperatures for example as high as 180° C. or more may occur. Since the amount of resin 39 in the annular gap 47 is reduced due to the presence of the rod 41, thermal expansion and contraction during heating and cooling of the resin 39 is kept to a minimum. Once the resin 39 has fully cured, the rotor 2 is obtained and may be assembled with further components to form the slip ring motor 1.

[0079] Although the present invention has been described in accordance with preferred embodiments, it is obvious for the skilled person in the art that modifications are possible in all embodiments.

LIST OF REFERENCE NUMERALS

[0080] 1 slip ring motor

[0081] 2 rotor

[0082] 3a, 3b windings

[0083] 4 cable

[0084] 5 cable

[0085] 6 slip ring

[0086] 7 slip ring

[0087] 9 shaft

[0088] 10 external resistance

[0089] 11 brush

[0090] 12 brush

[0091] 14 male contact element

[0092] 15 rotating unit

[0093] 16 male contact element

[0094] 17 ring

[0095] 18 rotating unit

[0096] 19 ring

[0097] 20 base ring element

[0098] 21 conducting ring element

[0099] 22 female contact element

[0100] 23 female contact element

[0101] 24 axis

[0102] 25 direction

[0103] 26 conductor

[0104] 27 sheath

[0105] 28 inner circumference

[0106] 29 circumferential direction

[0107] 30 spacer

[0108] 31 spacer

[0109] 32 support portion

[0110] 33 recess portion

[0111] 34 recess

[0112] 35 radius

[0113] 36 hole

[0114] 37 gravity vector

[0115] 38 open end

[0116] 39 resin

[0117] 40 container

[0118] 41 rod

[0119] 42 portion

[0120] 43 portion

[0121] 44 portion

[0122] 45 shoulder

[0123] 46 shoulder

[0124] 47 annular gap

[0125] 48 cavity

[0126] 49 top surface

[0127] 50 level

[0128] 51 lug