High Mechanical Strength Electrical Connection System and Method

Abstract

In accordance with one embodiment, the present technique provides a bushing that is configured to electrically and mechanically couple a conductor bar of a rotor assembly to an end ring of the rotor assembly. The exemplary bushing has an interior surface that is configured to abut against the conductor bar and an exterior surface that is configured to abut the perimetric surface of an end slot. Advantageously, the bushing, because of a good fit in the end slot and around the conductor bar, provides a good electrical connection between the conductor bar and the end ring. Moreover, the exemplary bushing also provides interferences fits that at least partially secure the end ring to the rotor core.

1 . A bushing for use with a motor rotor having a rotor core, an end member being disposed on an end of the rotor core and having an end slot, and a conductive member extending through the rotor core and the end member, the bushing comprising:
 a body having an interior section configured to receive a portion of the conductive member and having an exterior section, wherein the interior section is configured to abut the conductive member, and wherein the exterior section is configured to abut the end slot, to at least partially secure the end member to the rotor core and to electrically couple the conductive member to the end member.   
   
   
       2 . The bushing as recited in  claim 1 , wherein the interior section tapers with respect to a longitudinal axis of the body. 
   
   
       3 . The bushing as recited in  claim 1 , wherein the body is configured to establish an interference fit with the end slot and the conductive member upon insertion into the end slot. 
   
   
       4 . he bushing as recited in  claim 1 , wherein the body comprises copper. 
   
   
       5 . The bushing as recited in  claim 1 , wherein the body comprises a material having a lower yield strength than the yield strength of the conductive member material. 
   
   
       6 . The bushing as recited in  claim 1 , wherein the exterior section has an arcuate surface. 
   
   
       7 - 34 . (canceled) 
   
   
       35 . A method of manufacturing a rotor, the method comprising the acts of:
 aligning an end member with a rotor core such that a rotor slot extending through the rotor core cooperates with an end slot in the end member to form a rotor channel that extends through the rotor core and the end member;   disposing a conductive member in the rotor channel; and   disposing a securing member in the end slot and at least partially about conductive member to electrically couple the end member and the conductive member.   
   
   
       36 . The method as recited in  claim 35 , comprising abutting an exterior section of the securing member with the end slot and abutting an interior section of the securing member with the conductive member. 
   
   
       37 . The method as recited in  claim 35 , comprising establishing interference fit via the securing member to at least partially secure the end member to the rotor core. 
   
   
       38 . The method as recited in  claim 35 , comprising mechanically pressing the securing member into the end slot. 
   
   
       39 . A method of manufacturing a rotor having a rotor core and an end member disposed at an end of the rotor core, the method comprising the acts of:
 disposing a securing member in an end slot of the end member and at least partially about a conductive member extending through the rotor core the securing member cooperating with the end slot and the conductive member to at least partially and mechanically secure the end member to the rotor core.