MATERIALS
meet the specific requirements of the application while remaining cost effective. This high degree of geometric
freedom comes with a certain amount of complexity, which can only be mastered by drawing on the experience gained from previous projects. In order to meet new requirements in the best possible way, Wieland’s project managers and engineers can access a large pool of successfully implemented geometries. By allowing the use of different
materials in the end ring, this new design is well suited for applications requiring high power densities, high efficiency classes and high circumferential speeds. Primary applications include automotive and railway traction machines, and machine tool spindle drives.
COPPER FOR HIGHER PERFORMANCE The robust design allows for a wide range of possibilities for development and improvement, as simply choosing the right material can make a big difference in thermal and energetic performance. Wieland offers rotor components
as well as complete rotors made of copper. Copper has about 50% higher electrical conductivity and better mechanical properties compared to aluminium, and also improves the efficiency of ASMs. So, rotors made of copper are a key component in high-speed machines, where temperature, power and energy density are critical. In most other manufacturing
processes, the high levels of thermal shock and temperatures during the rotor manufacturing process are critical to the tools and cage
components
that are used. Thermal fatigue of components and tools is usually
unavoidable due to the high
The copper rotorbar
temperatures. The microstructure of the component is typically very soft after production, whereas in the new design the shorting rings are composed of several individual disks. After the forming bars have been inserted into the stack of sheets, the end rings are mounted on top of the stack of sheets over the profiles of the forming bars. This design allows “hybrid” end ring geometries. That is, different copper materials or steel end rings can be combined. The advantage of ASM is that the
cages are fabricated by established industrial methods, making it possible to produce any shape with high mechanical strength. The copper profiles of high-speed ASM rotors can therefore be adapted to the electrical and mechanical requirements, creating fine-grained and highly conductive microstructures.
Different copper materials or steel end rings can be combined
THE RIGHT ROTOR As described in a previous article in International Transport Manufacturer on the Zero Porosity Rotor, this process can ensure 0% porosity. However, casting processes that meet high industrial standards mean that the components of the built ASM can also have the same material properties. Wieland offers both types of rotors
ready for immediate use, but they differ in their area of application. The ZRP rotor is intended to be used primarily in the high-power range. The built rotor, on the other hand, is more suitable for more specific requirements, as the assembly method creates more engineering space, allowing more variations in strength and design to meet customer requirements.
The copper rotor bar with steel discs
Gerhard Thumm is Business Development Engineered Products at Wieland Werke.
www.wieland.com
www.engineerlive.com 13
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