CN104641433B - 制造层合绕组的方法和层合绕组 - Google Patents
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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
- H02K3/24—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors with channels or ducts for cooling medium between the conductors
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/2847—Sheets; Strips
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/061—Winding flat conductive wires or sheets
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
- H02K15/0407—Windings manufactured by etching, printing or stamping the complete coil
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
- H02K15/0435—Wound windings
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
- H02K15/0435—Wound windings
- H02K15/0478—Wave windings, undulated windings
-
- 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
- H02K3/12—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
-
- 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
- H02K3/18—Windings for salient poles
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/4902—Electromagnet, transformer or inductor
- Y10T29/49071—Electromagnet, transformer or inductor by winding or coiling
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Windings For Motors And Generators (AREA)
- Manufacture Of Motors, Generators (AREA)
Abstract
本发明涉及一种制造具有径向凹槽的用于电机的层合绕组的方法,该方法包括:在条带中切出切口,其中,这些切口形成该层合绕组的径向凹槽;以及,缠绕该条带以形成所述层合绕组。本发明还涉及一种根据该方法制造的用于电机的层合绕组。
Description
技术领域
本公开涉及一种制造具有径向凹槽的用于电机的层合绕组的方法,以及根据该方法制造的用于电机的层合绕组。
背景技术
如今,存在着对如下电机的需求:该电机能够在延长的时段内转化比其连续的指定功率(也称为额定功率)大若干倍的功率。与冷却方法相结合的额定功率通常决定了机器的重量和空间。通过加热该电机的热质量来处理在高于额定功率的功率水平下的较短工作时段。这对于电动汽车和混合动力车而言不是最不相关的,其中,在有限时段内对于比额定功率高若干倍的功率的需要例如发生在延长的加速或较长时间的上坡行驶中。在这种情况下,即使电机从电磁角度能够提供该功率,对电机的热质量的加热在非常高的功率下可能也不足以处理延长的一段工作时间,因此,必须使用其他替代的冷却构思。
层合绕组可用在电机中。从i.a.专利US 4,398,112中可以获知这种层合绕组,其中描述了四分之三绕组(three quarter winding),在通过切割或铣削形成多个凹槽之前,它们将条带卷绕并胶粘到筒上。这种制造方法阻碍了通过该绕组供给冷却介质(例如气体或液体)的可能性。
已知的是,在专利US 4,398,112的制造方法中,在铣削或切割出所述凹槽之后,该四分之三绕组在每个凹槽中在各个绕组匝之间具有增加的短路风险,因而,该凹槽侧需要被抛光。
在专利US 4,398,112中,所述四分之三绕组没有考虑由于每个绕组凹槽的末端处的尖角引起的电介质弱点(dielectric weakness),它可能降低绕组和磁芯之间的击穿电压。
已知的是,通过使用气体介质(穿过绕组内的间隙的空气流)来冷却绕组,US 5,331,244A中描述了这一点。该文献中的绕组设计是空气磁芯电机。
一种已知的制造电机铁芯的方法是首先对条带进行冲切、然后缠绕该条带的制造方法,文献EP 10685A1和US 3,019,998A中描述了该制造方法。DE 4427323中公开了另一种方法,其中,材料条带在其被缠绕成层合绕组之前被预先切割。
存在着改进这种层合绕组制造方法以及改进该层合绕组的需求。
发明内容
从以下描述中,本公开的这些和其它目的将变得明显。根据一个方面,公开了一种制造具有径向凹槽的用于电机的层合绕组的方法,该方法包括:在条带上切出切口,其中,这些切口形成该层合绕组的径向凹槽;以及,缠绕该条带以形成所述层合绕组。
可分别计算切口之间的间距,以便实现各个绕组匝之间的期望间隔。
可分别计算切口之间的间距,以便能够实现各个凹槽之间的期望角度。
绕组的轴向长度可由导电材料的所述条带的宽度限定。
可在绕组的不同截面处使用导体的不同横截面积。
可进行上述切出切口的步骤,使得这些切口交替地位于该条带的每个纵向侧,其中,当该层合绕组的绕组直径增加时,对于该层合绕组的每一匝,相邻切口之间的间距增加,从而实现了该层合绕组的各个绕组匝之间的期望的径向间隔。
当用在电机中时,相邻的绕组匝之间的径向间隔能够提供对该层合绕组的冷却。所述冷却主要通过该层合绕组的表面与冷却介质之间的对流而发生。
根据本公开的另一方面,公开了一种用于电机的层合绕组,该层合绕组是根据上述方法而制造的,其中,气态或液态的冷却介质被输送通过绕组匝之间的间隙。
该层合绕组可以是用于一种带有冷却介质的轴向流的径向磁通电动机。
附图说明
下面,将通过附图出本公开,在这些附图中,
图1是在缠绕期间的层合绕组的透视图;
图2是图1的层合绕组的细节的局部放大图;
图3是图1的层合绕组的一部分的局部顶视图;并且
图4是示出了对于图1的层合绕组、不同的电流密度和空气速度下的冷却效果与时间关系的曲线图。
具体实施方式
现在,将参考附图描述所述层合绕组的非限制性示例。
在图1和2中,示出了一种根据本公开的层合绕组的示例。该层合绕组由导电材料的条带制成。图1中示出了制造该层合绕组的通用方法。图2中可以更详细地看到其结构。通过以下方式来制造该层合绕组:在所述条带中形成切口,然后在其平坦侧将该条带缠绕成大致圆柱形卷,使得各个切口以重叠方式布置在最终形成的层合绕组中。因此,该条带在缠绕步骤之前被预先切割。执行缠绕该层合绕组的方法步骤,以便在每个绕组匝之间实现在所述圆柱形卷的径向方向上的间距。换句话说,每个绕组匝由条带制成并与相邻的绕组匝以所述径向间距分隔开。图2中可以更详细地看到这一点。这些重叠的切口限定了最终形成的层合绕组中的凹槽。因此,所述切口被设置成使得它们在该层合绕组中结束于彼此的顶部上,从而所述径向凹槽形成该层合绕组的径向方向上的连续通道。
如图所示,这些切口从所述条带的两侧、以与条带的延伸方向呈横向的方式交替地形成。这些切口之间具有各自的间距,即,在条带的纵向方向上或换句话说在相邻的切口之间具有各自的间距。这样做的原因是:当条带被缠绕成最终的层合绕组时,这给出了控制绕组匝之间的间距的可能性,即,它给出了控制绕组匝之间的径向间距的可能性。当绕组直径增加时,对于该绕组的每一匝,切口之间的间距增加了,从而在该绕组被缠绕时能够形成绕组凹槽。与US 4,398,112中公开的方案相比,如果其切口构成凹槽的所述导电条带在其缠绕之前被冲切,则存在如下可能性:即,在每个绕组匝之间包含该径向间距。其代价将是铜填充因子,即导电材料填充因子。其收益是具有如下能力:即,挤压冷却介质通过所述最终形成的绕组以及在绕组凹槽内的出现损失的地方获得更有效的冷却。由于该层合绕组具有自然较高的填充因子,所以,上述导电填充因子的代价并不是问题。通过该制造方法,也有可能设计在该绕组中的何处将通过控制切口之间的间距来施加冷却,以产生分布在该绕组中的一个或多个较大的间隙,其中,冷却介质流过该间隙以冷却所述绕组。
在层合绕组中直接获得有效冷却的可能性使得能够通过减小绕组端匝来增加电机的有效长度。这不可能用由连续的圆形导体制成的普通绕组来完成。在本公开中,通过选择绕组的导电横截面的不同面积(例如,在该绕组的施加冷却的位置处是一个尺寸,在绕组端部(end turns)中是另一个尺寸,实现了不同的导体横截面积。
从图3可以看到,该层合绕组的每个位置处的横截面积由条带的厚度和该波状条带的宽度表示,该宽度例如是冷却宽度或绕组端部宽度。该绕组的轴向长度由条带的宽度限定,因而,该条带的宽度由层合绕组的有效长度和绕组端部宽度的总和限定。该绕组端部宽度小于冷却宽度。绕组端部中的热应力增加了,但由于向冷却区域的热传递很快,这并不成问题。
图4中公开的冷却曲线图示出了铝和铜绕组材料、0-1.5m/s的空气速度以及10-14.4A/mm2的电流密度。
在所述条带被缠绕成层合绕组之前,可以通过擦拭或磨搓来去除在冲切期间产生的毛刺,从而避免如上所述的使绕组匝短路的风险。这也节省了时间并使该层合绕组的制造成本最小。
在冲切该条带期间,可通过在绕组凹槽的末端处增加一定的半径来解决如上所述的由于每个绕组凹槽的末端处的尖角引起的电介质弱点。当切割或铣削如专利US 4,398,112中的已缠绕好的筒时,由于使绕组端部剥落(flaking up)而损坏该绕组的风险,这并不那么容易做到。
与US 5,331,244A相比,本公开涉及一种具有密集层合铁芯的电机。铁芯通常会妨碍冷却,其中,径向气流经过该绕组的除了绕组端部以外的部分。此外,将风扇径向地放置在电机外侧通常会严重地增大该电机的尺寸,而具有本文公开的层合绕组的电机则不需要这样。
Claims (7)
1.一种制造具有径向凹槽的用于电机的层合绕组的方法,所述层合绕组包括多个单独的绕组匝,所述径向凹槽形成最终的层合绕组的径向方向上的连续通道,所述方法包括:
-在条带中切出切口,其中,所述切口形成所述层合绕组的所述径向凹槽;以及
-以如下方式缠绕所述条带以形成所述层合绕组:使各个切口以重叠的方式布置,以便形成所述最终的层合绕组中的所述径向凹槽,并且在每个绕组匝之间实现所述层合绕组的径向方向上的间隔,
其中,鉴于各个绕组匝之间的期望的径向间隔来分别计算所述切口之间的间距。
2.根据权利要求1所述的方法,其中,鉴于各个凹槽之间的期望角度来分别计算所述切口之间的间距。
3.根据权利要求1或2所述的方法,其中,所述层合绕组的轴向长度由导电材料的所述条带的宽度限定。
4.根据权利要求1或2所述的方法,其中,在所述层合绕组的不同截面处使用所述条带的不同横截面积。
5.根据权利要求1所述的方法,其中,进行所述切出切口的步骤,使得所述切口交替地位于所述条带的每个纵向侧,其中,当所述层合绕组的绕组直径增加时,对于所述层合绕组的每一匝,相邻切口之间的间距增加,从而实现了所述层合绕组的各个绕组匝之间的期望的径向间隔。
6.一种电机,所述电机包括根据权利要求1、2、3、4或5中的任一项所制造的层合绕组,其中,气态或液态的冷却介质被输送通过各个绕组匝之间的径向间隔。
7.根据权利要求6所述的电机,该电机是带有所述冷却介质的轴向流的径向磁通电动机。
Applications Claiming Priority (3)
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SE1200375-2 | 2012-06-21 | ||
SE1200375 | 2012-06-21 | ||
PCT/EP2013/001819 WO2013189602A1 (en) | 2012-06-21 | 2013-06-20 | A method of manufacturing a laminated winding and a laminated winding |
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CN104641433A CN104641433A (zh) | 2015-05-20 |
CN104641433B true CN104641433B (zh) | 2016-12-21 |
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US (2) | US20150155749A1 (zh) |
EP (1) | EP2864992A1 (zh) |
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WO (1) | WO2013189602A1 (zh) |
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EP3084929B1 (en) * | 2013-12-20 | 2021-04-28 | Swedish PowerTrain Techcenter AB | Stator for an electric machine |
US11139707B2 (en) | 2015-08-11 | 2021-10-05 | Genesis Robotics And Motion Technologies Canada, Ulc | Axial gap electric machine with permanent magnets arranged between posts |
AU2016304787B2 (en) | 2015-08-11 | 2021-01-07 | Genesis Robotics And Motion Technologies Canada, Ulc | Electric machine |
US11043885B2 (en) | 2016-07-15 | 2021-06-22 | Genesis Robotics And Motion Technologies Canada, Ulc | Rotary actuator |
US10840785B2 (en) * | 2016-11-08 | 2020-11-17 | Digital Aerolus, Inc. | Method for fabricating brushless motor windings |
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US4398112A (en) * | 1976-07-12 | 1983-08-09 | Gils Adrianus W Van | Aminated winding for electric machines |
DE4427323A1 (de) * | 1994-08-02 | 1996-02-15 | Wolfgang Hill | Elektrische Maschine mit Permanentmagneten und einer Erregerfeldwicklung |
JP3346968B2 (ja) * | 1995-10-06 | 2002-11-18 | 三菱電機株式会社 | 交流回転電機の固定子製造方法 |
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US3019998A (en) | 1958-12-15 | 1962-02-06 | Elektro Motoren A G | Strip punching and winding machine |
AU514253B2 (en) | 1978-10-18 | 1981-01-29 | Card-O-Matic Pty. Limited | Manufacturing punched strip for electromagnetic apparatus |
DE4130016A1 (de) | 1990-12-24 | 1993-03-11 | Erich Rabe | Elektronisch kommutierte gleichstrommaschine |
JP2001145286A (ja) * | 1999-11-12 | 2001-05-25 | Mitsubishi Electric Corp | 回転電機の固定子及びその製造方法 |
EP1271575B1 (en) * | 2001-06-21 | 2003-10-08 | Magnetek S.p.A. | Rectangular-development planar windings and inductive component made with one or more of said windings |
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2013
- 2013-06-20 EP EP13742387.7A patent/EP2864992A1/en not_active Withdrawn
- 2013-06-20 US US14/409,222 patent/US20150155749A1/en not_active Abandoned
- 2013-06-20 CN CN201380032287.XA patent/CN104641433B/zh not_active Expired - Fee Related
- 2013-06-20 US US13/922,292 patent/US20130342048A1/en not_active Abandoned
- 2013-06-20 WO PCT/EP2013/001819 patent/WO2013189602A1/en active Application Filing
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4398112A (en) * | 1976-07-12 | 1983-08-09 | Gils Adrianus W Van | Aminated winding for electric machines |
DE4427323A1 (de) * | 1994-08-02 | 1996-02-15 | Wolfgang Hill | Elektrische Maschine mit Permanentmagneten und einer Erregerfeldwicklung |
JP3346968B2 (ja) * | 1995-10-06 | 2002-11-18 | 三菱電機株式会社 | 交流回転電機の固定子製造方法 |
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Publication number | Publication date |
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US20150155749A1 (en) | 2015-06-04 |
EP2864992A1 (en) | 2015-04-29 |
CN104641433A (zh) | 2015-05-20 |
WO2013189602A1 (en) | 2013-12-27 |
US20130342048A1 (en) | 2013-12-26 |
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