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Author:Bernas, Madeleine
Title:Productization of a high-speed solid rotor induction motor prototype
Suurnopeusmoottorin prototyypin tuotteistaminen sarjatuotantoon
Publication type:Master's thesis
Publication year:2014
Pages:(13) + 82      Language:   eng
Department/School:Koneenrakennustekniikan laitos
Main subject:Koneensuunnittelu   (K3001)
Supervisor:Ekman, Kalevi
Instructor:Ikäheimo, Jouni
Electronic version URL: http://urn.fi/URN:NBN:fi:aalto-201410062748
OEVS:
Electronic archive copy is available via Aalto Thesis Database.
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Location:P1 Ark Aalto  4850   | Archive
Keywords:high-speed technology
electric motors
productization
concurrent engineering
DFMA
dimensional and geometrical tolerancing
suurnopeustekniikka
sähkömoottori
tuotteistaminen
rinnakkaissuunnittelu
mitta- ja geometrinen tolerointi
Abstract (eng):Productization is the art of developing a customized product, service or prototype into a standardized marketable and commercialized product.
In this thesis a high-speed induction motor prototype is designed for manufacturing.
The motor has an output power of 86 kW, rotational speed of 21 000 rpm and IEC frame size 160.
The motor has a copper coated solid rotor concept, hybrid bearings and a totally enclosed air cooling system.

High-speed motor systems provide advantages as improvement of over-all efficiency and reliability in comparison to conventional systems by eliminating the gear box normally used for applications requiring high-speed.
In the literature study mechanical restrictions and design considerations due to high rotational speed and centrifugal forces on machine elements are reviewed.
Different machine elements are presented as alternatives for high-speed motor components.

To construct a profitable product from manufacturing point of view a concurrent engineering philosophy and DFMA method is adopted.
The system of hybrid bearings was retained and the bearing support parts design was reconstructed by reconsidering necessity of the tolerances and altering unnecessarily tight tolerances.
It was decided that the bearing end shields and the motor frame foot should be incorporated into one part and produced by casting iron in serial production.
Prototype evaluation concludes that a standard stator frame can be used and several rotor concepts were evaluated.

The potential for reducing the manufacturing costs of the prototype motor are substantial.
However, regarding the rotor concepts more development needs to be done to ensure a functional rotor concept.
Abstract (fin):Työn tavoitteena oli tuotteistaa suurnopeussähkömoottorin prototyyppi sarjatuotantoa varten.
Lähtökohteena oli 86kW:n suurnopeusmoottori, jonka pyörimisnopeus on 21 000 r/min ja IEC runkokoko 160.
Moottorilla on kuparipinnoitettu massiiviroottori roottorikonseptina, hybridilaakereita ja ilmajäähdytys.

Suurnopeusteknologia mahdollistaa paremman kokonaishyötysuhteen ja kestävämmän järjestelmän poistamalla perinteisesti käytetty vaihteisto suurta pyörimisnopeutta vaativissa sovelluksissa.
Suuri pyörimisnopeus ja keskipakovoimien vaikutus suurnopeusmoottorissa aiheuttaa mekaanisia rajoituksia sekä erilliskomponenttien tarvetta.
Kirjallisuustutkimuksessa esitellään eri komponenttivaihtoehtoja suurnopeusmoottorin kone-elimistöön.

Tuotteistamisprojektissa käytetään rinnakkaissuunnittelun ja DFMA:n periaatteita.
Laakerointiosien toleranssien tarkkuus sekä roottorikonsepti on arvioitu uudestaan ja laakerikilvet ovat yhdistetty staattorirungon jalkaan.
Standardistaattorirunko sekä alunperäiset hybridilaakerit soveltuvat käytettäväksi sarjatuotantomoottorissa prototyyppimoottorin evaluoinnin mukaan.

Moottorin sarjatuotannon kustannukset ovat merkittävästi pienempiä verrattuna prototyyppimoottoriin tuotantokustannuksiin, mutta tarvitaan kuitenkin lisätuotekehitystä saavuttaakseen kannattavan hintalaatusuhteen.
ED:2014-10-05
INSSI record number: 49808
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