DE102017117017A1 - Transverse flux machine with U-profile - Google Patents

Abstract

U-profile, for a transverse flux machine, wherein the U-profile is extruded in the production with an iron powder or a cobalt alloy and bonded at room temperature with a liquid silicon ceramic and a transverse flux machine, are arranged in the U-profiles with different polarity alternately, wherein the Side edges facing the magnet.

Description

The present invention relates to a further development of the soft magnetic material of the U-profiles associated with an optimized arrangement of the U-profiles for a transverse flux machine.

State of the art

With transversal flux machines, it is possible to achieve a much higher torque density compared to conventional machines of the same construction volume. This is due to the fact that, in contrast to asynchronous machines in transverse flux machines, an increase of the torque can be achieved by increasing the number of poles. In the case of transversal flux machines, in contrast to conventional electric machines, the magnetic flux is not directed longitudinally, but transversely.

A unilateral transverse flux machine is used for example in the EP 1005136 A1 described where were reduced by a special configuration of the U-shaped and I-shaped yokes, the scattering paths, so that the rotational thrust is higher.

Another embodiment of a transverse flux machine, which is easier to produce in terms of production and at the same time has the highest possible efficiency and the highest possible torque, is also known from US Pat DE 102006038576 known.

The higher torque is bought in transversal flux machines by a construction, which consists of very many individual parts. Due to the easily manufacturable ring windings and the possible automatable assembly of many items but outweigh the benefits.

The object of the present invention is to further increase the torque of the transversal flux machine over known constructions, while at the same time the construction should not be as complicated and expensive as possible.

The object of the invention is achieved by a U-profile, for a transverse flux machine. The U-profile is extruded during production with an iron powder or a cobalt alloy and bonded at room temperature with a liquid silicon ceramic.

For iron powder, the magnetic saturation is reached only at 2.15 Tesla. For a cobalt alloy, the magnetic saturation occurs only at 2.4 Tesla. By improving the materials of the U-profile, the field strength in the flux-conducting materials can be increased by magnetic concentrators up to 2.15 Tesla and with cobalt up to 2.4 Tesla.

In one embodiment of the U-profile, the grain size of the powder or powder alloy is 5 μm. In this case, a tolerance of z. Eg ± 1%, ± 5%, ± 10% or ± 20%.

Powder with z. B. 5 microns grain size brings a significant reduction in eddy current losses with it.

Advantage of the powder with z. B. 5 .mu.m grain size is the application in high-frequency controllers, since the eddy current losses are low due to the high-resistance silicon ceramic.

Advantage of the powder version is that the production costs are very low, since the production technology is very simple. The new material being extruded simplifies production and significantly reduces costs.

The object according to the invention is furthermore achieved by a transverse flux machine in which U-profiles with different polarity are arranged alternately, the side edges facing the magnet.

In transverse flux machines, permanent magnets are arranged on the rotor along the circumference in a number corresponding to the number of poles of the machine. At the stator of the machine are so-called U-yokes made of magnetically good conductive material, for example, from sheets or as here of soft magnetic powder with a silicon-ceramic bond.

New is the increase in usable magnetic surface associated with a high performance and lower losses. The optimized transverse flux motor with a U-profile construction optimally utilizes the existing magnetic surface.

One possible manufacturing variant is described below:

The motor / generator consists of rotor and stator, the external rotor builds a bell motor. The possibility for the construction of an indoor and outdoor runner is also available.

The rotor can be mounted by placing magnets on a support, then placing a bell-shaped over it and extruding the bell. The stator can be mounted by winding the coil, overmolding with a support for the soft-magnetic parts, and with cavities soft magnetic material are filled by extrusion.

There are several preferred applications of the invention listed below:

The U-profile and / or the transverse flux machine can be used in a high-frequency control.

By reducing the eddy current losses due to the material, the use in high-frequency control systems, since the eddy current losses are low due to the high-resistance silicon ceramic.

The super synchronous motors are particularly suitable for installation in small diameter pipes, similar to pneumatic cylinders or as spindle motors, the length of the motors has less importance. The most important goal is possible a low speed with a high torque and no gear is needed.

Another application is in wind turbines, with a focus on slow speeds without gears and lighter weight. Other versions are external rotor motors and small motors, which can be operated directly with mains voltage.

Supersynchronous motors as external rotor motor for driving electric vehicles with high torque already at start and good efficiency in traffic jam.

An application in the automotive field is particularly suitable, since the engine is very low in production and the torque is higher, which saves gear stages. Examples are window regulators with spindle, ventilation flaps and actuators.

The machine can be further improved by the following measures:

A low speed is achieved by a high number of poles with small paths per step.

A high torque and a high power per unit weight is achieved by a high number of poles with small magnets or by a better utilization of the magnetic surface or by a high air gap induction.

High efficiency during slow running is achieved by a high number of poles.

A high efficiency with little Stromwärme- and little iron losses is achieved by a large rotor diameter in relation to the outer diameter. Such can be achieved by the double-sided magnet series, as in 1 shown. If the machine is designed as both internal and external rotor, the torque can be almost doubled.

The object of the invention is additionally or alternatively solved in other words by a multi-phase high-performance synchronous machine, characterized by transverse flux guide by alternately arranged U-profiles with the side edges facing the magnet. The U-profiles are filled with an iron powder with z. B: extruded 5 μm grain size, bound at room temperature with a liquid silicon ceramic, while the magnetic saturation is reached only at 2.15 Tesla. Furthermore, the powder alloy can be connected to cobalt so that, the magnetic saturation takes place only at 2.4 Tesla. The motor / generators can be created in a segmented design, with the segments repeating as often as desired.

list of figures

The invention will be more fully understood from the following description and the accompanying drawings, which are given by way of example only, and thus are not intended to limit the disclosure.

• 1 ein Grundprinzip,
• 2 einen einfachen Aufbau mit zwei U-Profilen,
• 3 einen Aufbau mit vereinigten U-Profilen (Schale),
• 4 zwei verbundene Schalen ohne Wicklung,
• 5 einen Aufbau als Segment,
• 6 einen Aufbau als Radnabenmotor.

Show it:

• 1 a basic principle
• 2 a simple structure with two U-profiles,
• 3 a structure with united U-profiles (shell),
• 4 two connected shells without winding,
• 5 a structure as a segment,
• 6 a structure as a hub motor.

1 shows the basic principle of the technology, it consists of two U-profiles, which are arranged against each other (double-row) and form the basic unit of the stator. Here are the inference 1 , the magnets 2 , the soft magnetic U-profiles 3 and the winding 4 shown. The arrangement is such that the open sides of the U-profiles face each other. The windings of the coil pass through the profiles between the legs.

2 shows an example of the structure of a simple engine technology consisting of two soft magnetic U-profiles 5 and 6 and a coil 7 , The two U-profiles comprise the coil (non-contact, or isolated) with their legs. These lie in the axial direction of the coil. The base support of the U-profiles and thus the U-profiles themselves are arranged at right angles to each other. Each basic carrier is arranged on another of the two end faces of the coil.

3 shows an example of the structure of a complex U-profile structure, namely a first shell 8th in which a coil can be inserted. This structure can be overmoulded and a second shell 9 as in 4 shown to be placed on this structure. Alternatively, both shells can be encapsulated after their assembly, z. B. with plastic to ensure strength and insulation.

4 shows such assembled two shells (without encapsulation) 8 and 9. The structure is analogous to the simple structure of 2 with 2 times 2 thighs here now with 2 times 8 thighs. The basic carrier of a shell connects the eight legs magnetically and can therefore z. B. be made of metal. One shell makes the magnetic north pole another the magnetic south pole. The legs of the two shells are alternately spaced into each other. This creates a change between two poles or pole pairs in circulation. In this way, any number of pole pairs for the electric motor with only two workpieces (the shells) can be produced.

Analogous to the figures with 2 times 8 legs, other constructions with another even number of legs are possible.

5 shows schematically the structure of a segment which can be made in a circular or linear manner. It shows the phase offset of the parallel element. Out 3 Elements can be built a 3 phase motor / generator.

The staggered and alternating U-profiles 10 and 11 are arranged in parallel with their legs here. The windings 12 the coil extend through the tunnels formed by the legs and base beams of the U-profiles 10 and 11.

At the same time, a module or segment can also be in a multiple of the number of phases, z. B. be used 30 times, which also creates a 3-phase machine by parallel circuit of the segments of each phase, with the advantage that simple controls with low power can be used as a driver.

6 schematically shows the structure of a machine, for. B. a wheel hub motor, which can also be operated as a generator (engine brake - recuperation).

In the drawing, the windings are on the left in the radial section 13 represented by the soft magnetic U-profiles 14, wherein the horizontal is the axial direction.

In the drawing below are instead of the round profile windings 13 band windings 13a , z. As metal bands passing through the soft magnetic U-profiles 14, shown. Such tape windings 13a At higher powers, they can provide better cooling and a higher degree of filling.

In the right, large part of the drawing, an axial section is shown, in which the windings 13 are wound in parallel in a circle and are fully encompassed by a plurality of successive spaced soft magnetic U-profiles 14.

There is a relation to the described arrangement of soft magnetic U-profiles 14 and windings 13 (eg stator) movable part (eg rotor), which in turn consists of an inner and outer part (rotor ring). Magnetically spaced from the soft magnetic U-profiles 14 through an air gap are magnets 15 and soft magnetic material 16 arranged as a component of the magnetic concentrator in the circumferential direction alternately.

The outer skin of this machine may consist of a paramagnetic material (eg aluminum). The machine is equipped with turned magnets in the number of U-profiles and the spaces are equipped with an extruded soft magnetic high-resistance material.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• EP 1005136 A1 [0003]
• DE 102006038576 [0004]

Claims (11)

U-profile (3, 14), for a transverse flux machine, characterized in that the U-profile is extruded with an iron powder or a powder of a cobalt alloy and bonded at room temperature with a liquid silicon ceramic. U-profile (3, 14) after Claim 1 , characterized in that the grain size of the powder or powder alloy is 5 μm (± 1%, ± 5%, ± 10% or ± 20%). Transverse flux machine, characterized in that U-profiles (3, 14) are arranged alternately with different polarity, wherein the side edges of the magnet (2, 15) facing each other. Transverse flux machine after Claim 3 , characterized in that the machine is created in multi-phase segmented design, the segments can be repeated as often as desired. Transverse flux machine after Claim 3 or 4 , characterized in that the yokes are not closed, but the magnets (2, 15) are arranged on the much larger side surface. Transverse flux machine according to one of Claims 3 to 5 , characterized in that the drive or output of two or more interconnected rotor rings with magnetic poles, which have a particularly large active and usable magnetic surface by their structure. Transverse flux machine according to one of Claims 3 to 6 , characterized in that the U-profiles (3, 14) are designed by the necessary air gap so that the intermediate space serves at the same time as a flow guide for a coolant (eg., Trafoöl). Transverse flux machine according to one of Claims 3 to 7 , characterized in that the machine is designed as an inner and at the same time as an external rotor. Transverse flux machine according to one of Claims 3 to 8th , characterized in that the outer skin of a paramagnetic material (eg., Aluminum), which is equipped with rotated magnet in the number U-profiles and the interstices are equipped with an extruded soft magnetic high-resistance material. Transverse flux machine according to one of Claims 3 to 9 , characterized in that U-profiles (3, 14) according to Claim 1 or 2 be used. U-profile after Claim 1 or 2 or transverse flux machine according to one of Claims 3 to 10 , characterized in that an application of the U-profile or the transverse flux machine takes place in a high-frequency control.

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