In-Line strategies and methods to reduce balancing efforts within rotor production for electric drives

Hofmann B, Masuch M, Frey P, Franke J, Merklein M (2016)

Publication Language: English

Publication Type: Conference contribution

Publication year: 2016

Event location: Nürnberg

DOI: 10.1109/EDPC.2016.7851310

Abstract

Within a research project focussing the optimization of the entire process chain of rotor production, balancing is identified as one of the processes with a high potential for innovation. As most research efforts concentrate on the additive or subtractive process itself, the presented paper follows a different approach concentrating on the impact of process steps prior to rotor assembly and the actual balancing operation.
Within current production processes, weighing is almost exclusively performed as an end-of–line process to take the entire rotor assembly into account. However, concerning the production of drives with permanent magnets, particularly those with magnets integrated into the lamination stack (IPM-Drives), production steps leading to the rotor assembly already deliver prefabricated lamination modules that can be evaluated regarding their imbalance. By determining the imbalance of those modules and a varying rotational combination of a number of modules being needed to form a complete rotor assembly, balancing efforts are considered to be reduced significantly; resulting in a lighter rotor assembly due to thinner end caps on the rotor.

The presented Paper describes methods and strategies to evaluate the imbalance of single lamination stacks and their preferred orientation prior to their assembly onto the rotor shaft. Depending on the rotor topology (pole number, magnet count), restrictions regarding free rotation have to be considered. Additionally, known methods for balancing in single and double layers have to be practically analysed and compared for the balancing operation in focus.

Using pre-stacked laminations, the balancing operation is validated in practice to determine actual effects on the imbalance of a complete lamination stack. Using different combinations for aggregating single packages, the imbalance can be reduced by up to 30%.

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How to cite

APA:

Hofmann, B., Masuch, M., Frey, P., Franke, J., & Merklein, M. (2016). In-Line strategies and methods to reduce balancing efforts within rotor production for electric drives. In Proceedings of the 6th International Electric Drives Production Conference (EDPC). Nürnberg, DE.

MLA:

Hofmann, Benjamin, et al. "In-Line strategies and methods to reduce balancing efforts within rotor production for electric drives." Proceedings of the 6th International Electric Drives Production Conference (EDPC), Nürnberg 2016.

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