Electric machine rotor-body assembly
An apparatus for forming a rotor for an electric machine includes serially adding layers of material to form a rotor body having a radially-extending post configured to receive a set of electrically-conductive windings, and also having a radially-extending winding end turn support formed contiguously from the rotor body.
1 . A rotor assembly, comprising:
a rotor body that comprises:
a plurality of posts extending in a radial direction and configured to receive a set of electrically-conductive windings about at least one of the plurality of posts; and
a winding end turn support axially spaced from the at least one of the plurality of posts by a radially-extending recess; and
at least one conduit within the rotor body defining a fluid passage, the at least one conduit further comprises a first portion, a second portion, and a third portion, the first portion of the at least one conduit having a first U-shaped bend located within the winding end turn support and at least partially radially underlying the radially-extending recess, wherein the first portion of the at least one conduit extending radially through the rotor body, the second portion of the at least one conduit extending axially and fluidly coupled to the first portion of the at least one conduit, wherein the first U-shaped bend further comprises a first leg extending radially, a second leg extending radially, and a third leg connecting the first leg and the second leg, wherein the third portion of the at least one conduit comprises a second U-shaped bend fluidly coupled to the second portion of the at least one conduit.
2 . The rotor assembly of claim 1 , further comprising an end cap coupled to an axial end of the at least one of the plurality of posts.
3 . The rotor assembly of claim 2 wherein the winding end turn support is axially spaced from the end cap.
4 . The rotor assembly of claim 1 , further comprising a second conduit on an opposite side to the at least one conduit, the second conduit and the at least one conduit being positioned in axially-extending positions on opposite sides of the at least one of the plurality of posts.
5 . The rotor assembly of claim 1 , wherein the at least one of the plurality of posts defines serial layers of material, wherein the serial layers of material are arranged in a radial direction.
6 . The rotor assembly of claim 5 , wherein the at least one of the plurality of posts defines serial layers of material, wherein the serial layers of material are layered in a radial direction.
7 . The rotor assembly of claim 1 , wherein the at least one of the plurality of posts defines a polished exposed surface having a surface roughness average between 0.4 and 3.0 micrometers.
8 . The rotor assembly of claim 1 , further comprising a set of windings wound about the at least one of the plurality of posts.
9 . The rotor assembly of claim 1 , wherein the winding end turn support comprises a radial segment, the U-shaped bend being located within the radial segment.
10 . A main machine rotor, comprising:
a rotor body;
a plurality of winding posts extending in a radial direction from a center portion of the rotor body;
a winding end turn support axially spaced from at least one of the plurality of winding posts;
a shaft; and
at least one conduit within the rotor body defining a fluid passage, the at least one conduit further comprises a first portion and a second portion, the first portion of the at least one conduit having a U-shaped bend located within the winding end turn support, wherein the first portion extending radially through the rotor body, the second portion of the at least one conduit extending axially and fluidly coupled to the first portion of the at least one conduit, wherein the U-shaped bend further comprises a first leg extending radially from a center portion of the shaft, a second leg extending radially, and a third leg connecting the first leg and the second leg.
11 . The main machine rotor of claim 10 , wherein the least one conduit comprising a third portion that includes a second U-shaped bend.