CN102292897A - 用于轴向场装置的扇块式定子 - Google Patents
用于轴向场装置的扇块式定子 Download PDFInfo
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
- H02K3/26—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/12—Stationary parts of the magnetic circuit
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K21/00—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets
- H02K21/12—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets
- H02K21/24—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/46—Fastening of windings on the stator or rotor structure
- H02K3/47—Air-gap windings, i.e. iron-free windings
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- H—ELECTRICITY
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- H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
- H02K2203/03—Machines characterised by the wiring boards, i.e. printed circuit boards or similar structures for connecting the winding terminations
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
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Abstract
一种包括扇块式定子组件的轴向旋转能量装置,该扇块式定子组件具有布置成环形阵列的多个扇块。每个定子扇块通过堆叠多个PCB功率导体层和多个PCB串联层而构造。每个层具有从内部通孔延伸到外部通孔的径向导体。所述通孔电连接功率导体层和串联导体层的选定的径向导体。对于连接到选定的外部通孔的电流的一个相,每个功率导体层包括一对正极和负极端子通孔。通过将第一部分电连接到位于一个扇块中的负极端子通孔、并且将第二部分电连接到位于相邻扇块中的正极端子通孔,子PCB层将两个相邻的扇块电连接,并且电流导体将这两个端子通孔电连接在一起。
Description
技术领域
本发明涉及一种改进的定子,该定子用于作为马达或发电机的轴向场旋转能量装置,如Jore等人的美国专利No.7,109,625所描述的。
背景技术
利用单片印刷电路板(PCB)定子制造的机器的尺寸会受到PCB制造设施中采用的处理设备的性能的限制。大容量设施具有最大尺寸的PCB面板,该面板能够在自动设备上进行处理。某些较低容量的设施常规地处理比大容量制造设施(manufacture)更大的PCB面板尺寸,但是成本会更高,因为需要更多的劳力和更高的材料成本。为了成本高效地制造结合PCB定子的大型轴向场旋转机器,示出并描述了一种扇块式PCB定子。这些扇块允许比采用单片PCB定子设计所可能的直径大得多的机器。而且,这些扇块可以在大容量制造设施中制造,从而提供最佳的成本。
发明内容
本发明提供一种轴向旋转能量装置,该装置布置在多相电流配置中。该装置包括转子,该转子具有多个固定到其上的永磁极,还包括扇块式定子组件,该定子组件具有多个布置成环形阵列的扇块。每个定子扇块通过将多个印刷电路板功率导体层和多个采用单片PCB定子设计所可能的直径大得多的机器堆叠在一起而构造。而且,这些扇块可以在大容量制造设施中制造,从而提供最佳的成本。
发明内容
本发明提供一种轴向旋转能量装置,该装置布置在多相电流配置中。该装置包括转子,该转子具有多个固定到其上的永磁极,还包括扇块式定子组件,该定子组件具有多个布置成环形阵列的扇块。每个定子扇块通过将多个印刷电路板功率导体层和多个印刷电路板串联层堆叠在一起而构造。每个定子扇块具有用于电流的每个相的至少一个工作功率导体层和与一个功率导体层相关联的至少一个串联导体层。每个功率导体层和串联导体层具有从内径通孔延伸到外径通孔的径向导体。所述通孔提供用于将串联导体层的选定径向导体电连接到功率导体层的选定径向导体。对于连接到功率导体层的选定外部通孔的电流的一相,每个功率导体层包括一对正极和负极端子通孔。采用子印刷电路板将两个相邻扇块电连接在一起。每个子印刷电路板具有第一部分和第二部分,其中第一部分电连接到位于一个扇块中的负极端子通孔,第二部分电连接到位于相邻扇块中的正极端子通孔。在子印刷电路板上提供电流导体,用于将负极端子通孔和正极端子通孔电连接在一起。
附图说明
为了清楚理解本发明并容易实现本发明,下面将参照附图仅以示例方式来描述本发明的优选实施例,其中:
图1是利用本发明的部件脱离的轴向场装置的分解组件视图;
图2是沿图1中的线2-2得到的横截面视图,其示出了本发明的第一实施例;
图3是通过选定的定子扇块和子印刷电路板示出了轴向场装置的一相的电路的示意图;
图4是根据本发明的第一实施例用于相A的定子板的功率层的一个扇块的详细视图;
图5是根据本发明的第一实施例用于相A的定子板的串联层的一个扇块的详细视图;
图6是根据本发明的第一实施例用于相B的定子板的功率层的一个扇块的详细视图;
图7是根据本发明的第一实施例用于相B的定子板的串联层的一个扇块的详细视图;
图8是根据本发明的第一实施例用于相C的定子板的功率层的一个扇块的详细视图;
图9是根据本发明的第一实施例用于相C的定子板的串联层的一个扇块的详细视图;
图10是示出用于相A、B和C的串联层和功率层的堆叠布置的示意图;
图11是示出用于相A、B和C的串联层和功率层的另一种堆叠布置的示意图;
图12是根据本发明的第二实施例的定子板的功率层的一个扇块的详细视图;
图13是根据本发明的第三实施例的定子板的功率层的一个扇块的详细视图;
图14是定子板的平面视图,其示出了根据本发明的第一实施例的定子扇块和子印刷电路板的布置;
图15示出了用于A相的子印刷电路板;
图16示出了用于B相的子印刷电路板;
图17示出了用于C相的子印刷电路板;
图18示出了用于电绝缘的A、B和C相的子印刷电路板;
图19是沿图1中的线2-2得到的横截面视图,其示出了本发明的第四实施例;以及
图20是沿图14中的线20-20得到的透视截面图。
具体实施方式
在图1中示出了根据本发明的轴向间隙装置10,该装置具有:具有多个端子盖14的壳体12A、一对轴承16、驱动轴18、一对转子20A和20B、另一个壳体12B和扇块式定子组件24,其中所述一对转子20A和20B中的每个均具有环形阵列的永磁体22并且这些永磁体的围绕着该阵列交替极性。扇块式定子组件24包括一对夹紧环26A和26B、多个紧固件28诸如螺栓、多个端子接线片30以及多个定子扇块32。定子扇块32包括多层印刷电路板,所述印刷电路板的形状设计成配合在一起,以形成定子扇块32的环形阵列。每个定子扇块32中的多层传导材料为轴向间隙装置10的每个电相提供多个匝。
图2示出了夹紧环26A和26B和螺栓28如何紧固在定子扇块32的向内边缘的任一侧上。定子扇块32的外部边缘通过壳体12A和12B的夹紧力保持就位。夹紧环26A、26B和壳体12A、12B将定子组件24悬置在转子20A和20B上安装的永磁体22之间的空气间隙中。如图1所示,每个定子扇块32具有多个端子接线片30。端子接线片30由导电材料诸如铜制成。每个扇块上的接线片的数量取决于机器中电相的数量。每相都具有正极和负极端子接线片30。所示的装置具有三个电相,因此每个定子扇块32具有六个端子接线片30。图2示出了每个端子接线片30如何穿过壳体12A中的接线片开口34,从而将定子扇块32电连接到子印刷电路板36。绝缘材料可以放置在接线片30周围,在此处它穿过接线片开口34以防止接线片30与壳体12A电接触。通过焊接或利用其它装置紧固的方式,诸如通过端子接线片30的螺纹部分上的带螺纹的螺母,将端子接线片30附接到定子扇块32以及子印刷电路板36。多层子印刷电路板36将一个定子扇块32中的每个相电连接到相邻定子扇块32中的每个对应相。
图3通过选定的定子扇块32和子印刷电路板36示意性地示出了轴向间隙装置10的一个相的电路。电流通过特定相的正极端子接线片30进入定子扇块32。电流流过第一工作匝38(工作匝是轴向场装置10的磁性间隙内电路的转矩发生部分),然后进入内部匝40、然后进入第二工作匝42、然后进入外部端匝44、然后进入第三工作匝46,依此类推,直到电流流过定子扇块32的特定相的所有匝。第一和第三工作匝38和46与一个磁极相关联,因此所示的轴向场装置10具有两个匝。图3所示的电路图具有两个工作匝,然而,工作匝的数量可以是取决于轴向场装置10的性能需求的任意数量,只受限于定子扇块32中工作匝可用的物理空间。在图3中还示出了轴向场装置10中定子扇块32的数量和磁体22的磁极的数量之间的关系。在优选实施例中,每个定子扇块32将有两个磁极。
继续参照图3,电流从最后一个工作匝流入负极端子接线片30以及子印刷电路板36,子印刷电路板36将电流从第一定子扇块32的负极端子接线片30传导到第二定子扇块32的正极端子接线片30。然后电流流过第二定子扇块32中特定相的所有匝,然后通过第二定子扇块的负极端子接线片30流出至第二子印刷电路板36。电流以相同方式被引导到整个扇块阵列。
图4示出了蚀刻在一个定子功率扇块32A中的一层传导材料的图案(pattern)。该图案具有与轴向场装置10的三个电相相关的各种传导路径。该图案具有A+、B+、C+、A-、B-和C-端子接线片30。每个端子接线片30终止于焊盘48。每个焊盘48具有电连接到相应焊盘48的多个端子通孔50。端子导体52将焊盘48电连接到外部通孔焊盘(pad)54,所述外部通孔焊盘具有多个外部通孔56。图4所示的图案被称为电相A的功率层,因为是在这一层上构建到A相的定子扇块32的电连接。该功率层的端子导体52接续有焊盘A+和A-。用于B+、C+、B-和C-的焊盘48与对应的端子接线片30接触,但是这些焊盘不连接到这一层上的端子导体52。
在图4中,箭头示出了电流方向,以示意相A的功率层的导体的关系。这些箭头仅供参考,因为轴向场装置可以用作无刷DC或同步AC马达或发电机。该电流示出为开始于焊盘48A+,流过端子导体52至外部通孔焊盘54。外部通孔焊盘54接续有相A功率层上的第一工作导体38。第一工作导体38将电流连接到内部通孔焊盘58。如图4所示,第一工作导体38基本上位于永磁体22的通量内部。流过第一工作导体38的电流将产生洛仑兹力,该洛仑兹力作用于流过的电流和磁通量之间。外部通孔焊盘54具有多个外部通孔56,这些外部通孔是电镀的,其将相A功率层上的外部通孔焊盘54电连接到定子扇块32的所有其它传导层上的对应外部通孔焊盘54。内部通孔焊盘58也具有多个内部通孔60,所述内部通孔将相A功率层上的内部通孔焊盘58电连接到定子扇块32的所有其它传导层上的对应内部通孔焊盘58。
如图4至图9所示,外部通孔焊盘54由每个传导层上的第一工作导体38接续。因此,外部通孔56和内部通孔60将所有工作导体连接在一起,从而使得流过相A功率层上的第一工作导体38的电流与定子扇块所有层上的对应工作导体38并联。这对于定子扇块的所有相的所有工作导体都是相同的。
继续参照图4,电流从内部通孔焊盘58流到第一内部端匝40。电流从第一内部端匝40流到内部通孔焊盘58,所述内部通孔焊盘连接到第二工作导体42。第二工作导体42将电流载入外部通孔焊盘54。该电路看上去在外部通孔焊盘54处终止,但是如上所述,内部和外部通孔60和56将所有传导材料层上的所有第二工作导体42并联连接。下面将要描述的图案示出了相A的电路是如何接续的。
图5示出了蚀刻在定子串联扇块32B的另一传导层中的图案。图5所示的图案被称为用于电相A的串联层,因为它包含将相A的工作匝串联电连接的外部端匝。电流从第二工作导体42的端部的外部通孔焊盘54流入第一外部端匝44。然后电流流到具有外部通孔56的外部通孔焊盘54,然后流入第三工作导体62。电流从第三工作导体62流入具有内部通孔60的内部通孔焊盘58。定子扇块的所有传导材料层上的第三工作导体62都通过外部通孔56和内部通孔60并联地电连接。电流从内部通孔焊盘58继续流到第二内部端匝64,然后流到内部通孔焊盘58和然后到第四工作导体66。电流继续流过图5所示的工作导体、外部通孔焊盘、外部端匝、内部通孔焊盘和内部端匝,直到到达第十工作导体68。电流从第十工作导体68流到具有外部通孔56的外部通孔焊盘54。该电路看上去终止于外部通孔焊盘54处,但是如上所述,内部和外部通孔60和56将所有传导材料层上的所有第十工作导体68并联连接。再次参照图4,电流从与第十工作导体相关联的外部通孔焊盘54流到端子导体52,然后流到A-焊盘48。
对于相B和相C的功率层和串联层而言,这些图案和电流流向是类似的。图6示出了蚀刻在定子功率扇块32A的另一传导材料层中的图案,其中该传导材料层是相B的功率层。图7示出了用于相B的定子串联扇块32B的另一层上的图案。图8示出了用于相C的定子功率扇块32A上的图案。以及图9示出了定子串联扇块32B上的图案。
通过将用于A、B和C相的单个定子功率扇块32A和定子串联扇块32B彼此堆叠,其中在每层之间提供替代的介电层33,从而构造包括整个定子的环形阵列的多层定子扇块32。相A、B和C的定子功率扇块32A和定子串联扇块32B的堆叠顺序是可以选择的。定子扇块的每层类型可以重复。定子扇块中的串联层的数量可以比功率层的数量多。优选选定各层的顺序,以便提供定子扇块的所有不同层中电流均匀分布,尤其使得流过内部和外部通孔的轴向长度的电流均匀分布。电流均匀分布的主要优点是优化定子扇块32的热耗散。通过减小热应力来增强每个定子扇块32的耐用性,其中热应力会引起层的层离和通孔壁破裂。
作为非限制性示例,具有十八层的定子扇块可以具有两个相A的功率层、四个相A的串联层、两个相B的功率层、四个相B的串联层、两个相C的功率层和四个相C的串联层。图10示出了提供电流均匀分布的一种可能的层的堆叠布置。图11示出了提供电流均匀分布以及用于中压和高压的附加绝缘相的另一种可能的层的堆叠布置。
图12示出定子扇块32的另一实施例。在该实施例中,蚀刻到定子功率扇块32A′的传导层中的图案包括用于相A、B和C的端子导体52。在该实施例中,如上所述的用于相A、B和C的功率层可以是相同的。该实施例的主要优点是每相可以并联更多的端子导体52。然而,在图4、图6和图8中所示的功率层32A上设置的内部端匝在该实施例中并没有出现。利用该定子功率扇块32A′,就需要使用图5、图7和图9中所示的用于相A、B和C的三个定子串联扇块32B。
图13示出了定子扇块的另一实施例,其中内部端匝设置在定子功率扇块32A″上,该定子功率扇块包含用于相A、B和C的端子导体52。该图案则可以是相A的功率层,并且该实施例中的功率层可因此不相同。相B的功率层可以包含相B的内部端匝,并且相C的功率层可以包含相C的内部端匝。利用定子能量扇块32A″,仍然需要使用图5、图7和图9中所示的用于相A、B和C的三个定子串联扇块32B。
图14示出了定子组件的一个实施例中的定子扇块32和子印刷电路板36的布置。该定子组件具有用于相A、B和C的相导线70;内部夹紧环26A;螺栓28;以及附接到定子扇块32阵列的多个子印刷电路板36。定子组件24包括六个端子接线片30,所述端子接线片连接到如图所示的六个相导线70。相导线70可以如图所示布置,或者可以配置成与定子组件24呈Y字型或△型连接,这是本领域的公知的。
子印刷电路板36用于将相邻定子扇块32电连接在一起。如图20所示,子板36被布置成使得子印刷电路板36的三个端子接线片30(A-、B-和C-)定位在一个定子扇块32的对应端子接线片30的上方,并且同一子印刷电路板36的三个端子接线片30(A+、B+和C+)定位在相邻定子扇块32的对应端子接线片30的上方。
图15至图17示出了子印刷电路板36中每个传导材料层上的电流路径。图15示出了蚀刻在子印刷电路板36中的图案,其中子印刷电路板具有用于A-和A+的端子通孔50,并且电流路径位于其间。用于B-、C-、B+和C+的端子通孔50与用于A-和A+的端子通孔50绝缘。端子接线片30具有带有通孔50的焊盘48,该通孔将焊盘48电连接到子印刷电路板36的所有其它传导材料层上的对应焊盘48。在图15中,相A的电流从A-焊盘48流动通过子印刷电路板36至A+焊盘48。在图16中,相B的电流从B-焊盘48通过子印刷电路板36至B+焊盘48。在图17中,相C的电流从C-焊盘48流动通过子印刷电路板36至C+焊盘48。图18示出子印刷电路板36,该子印刷电路板具有相互绝缘的用于A-、B-、C-、A+、B+和C+的所有焊盘48。在优选实施例中,图15-17所示的子印刷电路板36彼此堆叠,其中在它们之间具有介电基层。图18所示的子印刷电路板36优选地位于子印刷电路板堆叠的第一层和最后一层上,以便电绝缘子印刷电路板36外表面上的相。
图19示出了本发明的另一实施例,其中定子组件24具有两个阵列的定子扇块32。这些定子扇块通过端子接线片30并联地电连接。外部间隔器74和内部间隔器76保持定子扇块分离,以允许电绝缘和热耗散。图19中还示出了并联地跨过每组端子接线片30安装的两个堆叠的子印刷电路板36的布置。如通过该示例可以理解的,定子组件24内部可以存在多于两个阵列的定子扇块32。还可以理解的是,可以有并联地跨过每组端子接线片30安装的多于两个堆叠的子印刷电路板36。具有并联安装的定子扇块32的阵列和子印刷电路板36的堆叠的好处是减小电路的电阻。
尽管已经示出和描述了本发明的基本新颖特征,但是可以理解的是,在不偏离本发明精神或范围的前提下,本领域那些技术人员还可以进行多种替代、变型和变化。因此,所有这些变型或变化形式都包含在由权利要求所限定的本发明范围内。
Claims (7)
1.一种具有正负极性、多相电流端子的轴向场旋转能量装置,包括:
具有多个永磁极的转子;以及
具有布置成环形阵列的多个定子扇块的扇块式定子组件,其中每个定子扇块具有:
多个印刷电路板功率导体层,所述印刷电路板功率导体层具有用于电流的每个相的至少一个功率导体层,每个所述功率导体层具有在内部通孔和外部通孔之间延伸的多个径向导体的图案,所述内部通孔位于所述功率导体层的内径上,并且所述外部通孔位于所述功率导体层的外径上;
每个功率导体层还具有电流的一个相的一对正极和负极端子通孔并且定位成相邻于每个功率导体层的外部边缘,并且还具有用于将正极和负极端子通孔电连接到选定外部通孔的一对端子导体;
多个印刷电路板串联层,其至少一个与每个功率导体层相关联,并且每个包括在内部通孔和外部通孔之间延伸的多个径向导体的图案,所述内部通孔位于所述串联导体层的内径上,并且所述外部通孔位于所述连接串联导体层的外径上;
每个串联导体层还具有多个外部导体和多个内部导体,所述外部导体用于将选定的外部通孔电连接在一起,所述内部导体用于将选定的内部通孔电连接在一起;
功率导体层和串联导体层的内部和外部通孔布置成将串联导体层的选定的径向导体电连接到功率导体层的选定的径向导体;
用于将两个相邻的扇块电连接在一起的子印刷电路板;
每个子印刷电路板具有第一部分和第二部分,其中第一部分电连接到位于一个扇块中的负极端子通孔,并且第二部分电连接到位于相邻扇块中的正极端子通孔,同时电流导体在所述负极端子通孔和所述正极端子通孔之间电连接;以及
该扇块式定子组件还包括一对相导体,用于将电流的一个相的正极和负极电流端子电连接到该扇块式定子组件的选定的正极和负极端子通孔。
2.根据权利要求1所述的轴向场旋转装置,其中每个功率导体层包括用于将选定的内部通孔电连接在一起的多个内部导体。
3.根据权利要求1所述的轴向场旋转能量装置,其中每个印刷电路板功率层具有平面配置,并且每个电路板串联导体层具有平面配置,并且每个定子扇块通过将功率导体层和连接导体层彼此堆叠并且在每层之间具有基层而形成。
4.根据权利要求1所述的轴向场旋转能量装置,其中该定子组件具有中心孔,该中心孔沿垂直于所述层的平面配置的方向通过,还包括延伸通过该中心孔的能够旋转的驱动轴以及还包括第一转子和第二转子,其中第一转子在定子一侧不动地固定到该驱动轴,以及第二转子在定子组件的相对侧不动地固定到驱动轴。
5.根据权利要求4所述的轴向场旋转能量装置,其中第一转子的永磁极相对于该第二转子的永磁极定位,使得磁通线在垂直于功率导体层的平面配置的方向穿过定子组件。
6.根据权利要求1所述的轴向场旋转能量装置,其中每个功率导体层和每个串联导体层分成扇区,其中每个扇区与电流的每个相的正极或负极以及穿过每个扇区的径向导体相关联。
7.根据权利要求1所述的轴向场旋转能量装置,其配置为用于至少一个三相电流。
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CN112425034B (zh) * | 2018-07-10 | 2024-10-01 | 无限电气股份有限公司 | 用于轴向场旋转能量装置的系统和设备 |
CN114915128A (zh) * | 2019-11-11 | 2022-08-16 | 英菲尼顿电气有限公司 | 交替定子 |
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Also Published As
Publication number | Publication date |
---|---|
CN103997137A (zh) | 2014-08-20 |
EP2382701A1 (en) | 2011-11-02 |
CN103997137B (zh) | 2017-04-12 |
CN102292897B (zh) | 2014-04-02 |
US8823241B2 (en) | 2014-09-02 |
US20110273048A1 (en) | 2011-11-10 |
US20140049130A9 (en) | 2014-02-20 |
WO2010083054A1 (en) | 2010-07-22 |
AU2010204925A1 (en) | 2011-07-21 |
US20140175922A1 (en) | 2014-06-26 |
US20180219445A1 (en) | 2018-08-02 |
EP2382701B1 (en) | 2016-11-30 |
CA2748095A1 (en) | 2010-07-22 |
TW201034343A (en) | 2010-09-16 |
EP2382701A4 (en) | 2015-09-16 |
US9762099B2 (en) | 2017-09-12 |
BRPI1005151A2 (pt) | 2016-03-22 |
EP3128646A1 (en) | 2017-02-08 |
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