Abstract A high speed shaftless rotor construction is disclosed including a method of sequentially building up the rotor to facilitate disassembly for reworking and maintaining precise alignment of the reassembled elements. End turn supports are matched and preliminarily assembled with bolts to the core and the parts machined to achieve desired tolerances. After machining, the end turn supports are separated from the core, matched with end shaft fittings and additional machining carried out, after which the turn supports are separated from the end shaft fittings and reattached with the core. The shaft fittings are realigned with the assembled end support fittings and bolted into position after which final machining can be completed. All elements are then disassembled and the parts deburred and cleaned to eliminate any contamination prior to winding the field coil. After reassembly, winding of the field core and completion of the electrical connections, a cylindrical sleeve is disposed over the main core assembly and conventionally joined to effect a rigid structural rotor member capable of withstanding high speeds.
A method for sequentially building up a rotor for an electric machine comprising the steps of: providing a magnetic core having opposed ends and a rotational axis; removably attaching a turn support at each end of the core to define a core subassembly; machining the core subassembly to match the core and turn supports; removing the turn supports from the core; providing an axial shaft fitting for each of the ends of the core subassembly; aligning each of the turn supports with one of the shaft fittings; machining the aligned turn supports and shaft fittings to effect matching; disassembling the shaft fittings and turn supports; reattaching the turn supports at the ends of the core; and removably attaching a shaft fitting at each end of the core subassembly; whereby said rotor can be readily disassembled for reworking and reassembled with the alignment of the core, turn supports and shaft fittings precisely maintained.
Claim 2
Independent Claim
152 words
A method for sequentially building up a rotor for an electric machine comprising the steps of: providing a magnetic core having opposed ends and a rotational axis; removably attaching a turn support at each end of the core to define a core subassembly; machining the core subassembly to match the core and turn supports; removing the turn supports from the core; providing an axial shaft fitting for each of the ends of the core subassembly; aligning each of the turn supports with one of the shaft fittings; machining the aligned turn supports and shaft fittings to effect matching; disassembling the shaft fittings and turn supports; reattaching the turn supports at the ends of the core; and removably attaching a shaft fitting at each end of the core subassembly; whereby said rotor can be readily disassembled for reworking and reassembled with the alignment of the core, turn supports and shaft fittings precisely maintained.
Claim 3
Dependent Claim
32 words
The method of claim 1 wherein a subsequent machining operation is performed after the shaft fittings are attached at the ends of the core subassembly to make the rotor a finished size.
Claim 4
Dependent Claim
30 words
The method of claim 1 wherein each turn support is removably attached to the core by at least one bolt extending axially through the turn support and into the core.
Claim 5
Dependent Claim
34 words
The method of claim 1 wherein each shaft fitting is attached to the core subassembly by at least one bolt extending axially through the shaft fitting, an end turn support and into the core.
Claim 6
Dependent Claim
30 words
The method of claim 1 including the step of providing a cylindrical sleeve over the core subassembly after the shaft fittings are attached at the ends of the core subassembly.
Claim 7
Dependent Claim
22 words
The method of claim 3 wherein the bolts are made from a material having a high magnetic permeability for low magnetic loss.