KR101240591B1 - An armature coil unit and manufaturing method and afpm generator having it - Google Patents

Abstract

PURPOSE: An armature coil unit, a manufacturing method thereof, and an axial field permanent magnet generator including the same are provided to improve generating efficiency by reducing core loss through applying a structure, in which a steel plate including silicon is overlapped in a shape of a roll, to a yoke. CONSTITUTION: A case(31) includes an upper case and a lower case. An armature coil unit is embedded inside a fixing plate(32a) which is composed of resin. A yoke(35a) is fixed in a shaft part(32) which rotatably supports the case. A magnet supporting part(35b) is arranged in an upper part of the lower surface and a lower part of the upper surface of the case. A plurality of coils(36) is arranged to be faced with a plurality of permanent magnets(34).

Description

An armature coil unit and manufaturing method and AFPM generator having it

The present invention relates to an armature coil unit and a method for manufacturing the same, and an AFPM generator having the same, an armature coil unit and a method for manufacturing the same, which can increase the power generation efficiency by reducing the iron loss by applying a superposition of silicon steel plate in a ring shape instead of an iron plate And it is for an AFPM generator having it.

In general wind power generation, the rotational motion of the propeller is transmitted to the fixed shaft of the generator to convert the rotational energy into electrical energy. The output from the generator is connected to the power system, or collected in a battery and used as power when needed.

There are various types of generators, and two types of generators, which have different structural aspects, are used in order to use permanent magnets for field magnets.

In the radial gap type generator in which a stator is arranged around the outer side of the cylindrical rotor, a plurality of permanent magnets are arranged in a direction surrounding the circumference of the rotor. Headed radially, the stators are arranged to face the permanent magnets. The stator has a structure in which coils are wound around iron cores having a plurality of tooth shapes in terms of facing the rotor. By using such an iron core, the magnetic flux generated from the magnetic poles of the rotor can be passed through the coil to generate a large torque in the case of a motor and a large voltage in the case of a generator.

However, there is a problem that the use of the iron core generates a loss torque based on cogging torque or hysteresis loss of the iron core, thereby increasing the initial torque. The removal of the iron core can eliminate such problems, but the magnetic gap is lowered, so the radial gap type generator does not have a large output.

In addition, in a wind power generator using a radial gap type, as the nacelle (Nacelle) for accommodating the generator becomes large, the area where the propeller receives the wind decreases, thereby reducing the rotational force of the propeller. That is, the larger the generator, the lower the efficiency in wind power generation.

Another type is an axial gap type generator in which the stator is arranged axially opposed to the rectangular rotor.

The axial gap type generator is attached to the case so as to integrate the yoke formed of the iron plate, a plurality of permanent magnets are arranged on the surface of the yoke, and is arranged up and down in the fixed axis direction through the spacer. Permanent magnets may be arranged on either of the yokes, but the magnetic efficiency is increased by arranging the permanent magnets on the surfaces of both yokes. An armature is disposed between the yokes, and the armature is fixed to a base on which a plurality of coils are accommodated to form a stator and fixed to a fixed shaft. The fixed shaft is rotatably supported through the bearing by the housing.

This structure can increase the output of the magnetic pole without using the iron core, and neodymium magnet (Nd-Fe), a metal compound of neodymium, iron (Fe), and boron (B), one of rare earth metals. If -B) is used, there is no problem of self-saturation by iron core, and it can be used as a high-power rotary machine by fully utilizing its performance.

However, the stator of the generator as described above is composed mainly of the core and the armature coil, and by arranging the magnets in the rotor and the yoke and by using the mutual electromagnetic force of the magnetic flux and current generated by the magnet as a whole, the weight of the permanent magnet generator increases and length There is a limit to shortening the width.

Coreless or slotless type generator for solving the above problems has a structure in which the epoxy resin compound for molding and the coil acting as an armature are integrally formed so that the slot and the core are omitted.

However, the coreless or slotless type generator has a disadvantage in that the yoke in which the armature coils are arranged is formed of an iron plate, thereby reducing the efficiency of the generator due to iron loss.

The present invention is to solve the above problems by applying a structure in which the steel plate containing silicon in the form of a roll instead of overlapping the iron plate yoke is installed permanent magnets or coils can reduce the iron loss and increase the power generation efficiency An object of the present invention is to provide an armature coil unit and an AFPM generator having the same.

The armature coil unit according to the present invention for achieving the above object comprises a plurality of coils disposed to face the plurality of permanent magnets to generate electricity by the permanent magnet, and the yoke to which the coil is coupled The yoke has a hollow portion in the center thereof, and the plurality of coils are disposed adjacent to each other along the circumferential direction of the yoke, and are formed to surround the outer circumferential surface of the yoke from the inner circumferential surface of the hollow portion toward the radial direction of the yoke. It is done.

The yoke is characterized in that the impregnated with the impregnation agent by winding a thin metal strip.

The yoke is characterized in that the iron and silicon are composed in a predetermined weight ratio.

The yoke is divided into a plurality of unit yokes by one or more dividing lines extending radially from the center of the hollow portion.

Method of manufacturing an armature coil unit according to the present invention for achieving the above object is a steel sheet manufacturing step of manufacturing a silicon steel sheet by mixing iron, silicon and impurities, and processing the silicon steel sheet to have a set width and thickness silicon A strip manufacturing step of manufacturing a thin strip, a winding step of winding up the silicon thin strip to form a silicon thin roll, an impregnation step of vacuum impregnating the silicon thin roll with an impregnation liquid, and an impregnation liquid in the impregnation step A dividing step of cutting the thin silicon thin roll fixed by the dividing into a plurality of dividing yokes, an inserting step of inserting the dividing yokes into a coil provided with an insertion hole to insert the dividing yokes, and the dividing yokes It characterized in that it comprises a bonding step of bonding the respective divided yoke by applying an adhesive on the cut surface of the.

AFPM generator according to the present invention for achieving the above object is a case provided with a receiving space, the shaft portion is installed in the receiving space relative to the case, the permanent magnets disposed in the case or shaft and And an armature coil unit disposed to face the permanent magnets and including a yoke to which coils for generating electricity by the permanent magnets are coupled, wherein the yoke has a hollow portion formed at a center thereof, and the plurality of coils are disposed on the yoke. It is arranged to be adjacent to each other along the circumferential direction of the yoke, characterized in that formed to surround the outer peripheral surface of the yoke from the inner peripheral surface of the hollow portion toward the radial direction of the yoke.

According to the armature coil unit and the AFPM generator having the same according to the present invention, the cogging torque is reduced by omitting the core and the slot of the generator, and the iron loss is applied by applying a structure in which the yoke in which the coil is installed is overlapped with a roll type containing silicon. There is an advantage to increase the power generation efficiency of the generator by reducing.

1 is a cross-sectional view showing an embodiment of an AFPM generator having an armature coil unit according to the present invention,
2 is a perspective view illustrating a method of manufacturing the armature coil unit shown in FIG. 1,
3 is a perspective view of the armature coil unit shown in FIG.
4 is an exploded perspective view of the armature coil unit shown in FIGS. 1 and 3.

Hereinafter, an AFPM generator having an armature coil unit according to a preferred embodiment of the present invention with reference to the accompanying drawings will be described in more detail.

 1 to 4 illustrate an AFPM generator according to a first embodiment of the present invention. 1 to 4, the AFPM generator having the armature coil unit according to the present invention induces electricity by the case 31, the shaft portion 32, the field permanent magnets 34, and the permanent magnets. And an armature coil unit comprising a yoke 35a to which the coils 36 are coupled.

The case 31 includes an upper case and a lower case having flanges that are mutually engageable. An insertion hole through which the upper end of the shaft portion can be inserted is formed in the center portion of the upper case, and a bearing member for rotatably supporting the shaft portion inserted into the insertion hole is provided.

An armature coil unit is fixed to the shaft portion 32. The armature coil unit is embedded in a fixed plate 32a made of a resin chemical.

The yoke 35a is made of a ferromagnetic material, and the thin strip is rolled up so that a hollow strip having a size of a thin strip shape larger than the radius of the shaft portion 32 and smaller than the radius of the case 31 is formed. It is fixed by impregnation with an impregnation agent to maintain the disc shape.

2, the yoke 35a is formed by cutting a thin sheet of metal sheet cast to a predetermined thickness as shown in FIG. 2 to form a thin strip, and winding the manufactured thin strip in a roll form to be superimposed and fixed with an impregnating agent. It is formed through a process.

The thin strip constituting the yoke 35a contains 6% by weight to 6.5% by weight of silicon (Si) and aluminum and the rest of the other elements in order to increase the specific resistance of the steel to improve the iron loss characteristics.

Silicon thin strip having a silicon (Si) concentration of 6% to 6.5% by weight as described above is typically rolled thin in an alloy state of low silicon concentration to form a thin plate and then silicon using chemical vapor deposition (CVD) technique When (Si) is added, it can be produced using a method of making silicon steel containing 6 to 6.5% by weight of silicon (Si).

An example of an electrical steel sheet containing 6.5% by weight of silicon (Si) may include the brand name 'JNEX' of Japan's 'JFE' company. Although not attached, iron loss according to the content of silicon (Si) in the 'JFE' company, maximum As a result of experiments on permeability and DC magnetostriction, the iron loss was the lowest at 6.5% by weight, the maximum permeability was the maximum, and the DC magnetostriction was nearly zero.

As described above, the electrical steel sheet containing 6.5 wt% of silicon (Si) has a small iron loss and generates little heat, and a small amount of distortion when magnetized by magnetic force can reduce noise when applied to a generator or a motor. There is this.

The yoke 35a is fixed to the shaft portion 32 rotatably supporting the case 31, and the magnet support portion 35b on the inner circumferential surface of the case 31 so that the permanent magnet 34 can be disposed in the vertical direction of the yoke. ) Is combined.

The magnet support part 35b is disposed on the upper and lower surfaces of the case 31 in the direction in which the permanent magnet faces the yoke 35a so that magnetic flux can pass through the coil 36 coupled to the yoke 35a. do.

The magnet support part 35b is preferably made of a ferromagnetic material to improve the magnetic force characteristics of the magnet, and has a structure in which the thin silicon thin strip is rolled in the form of a roll in the same manner as the yoke 35a.

In the present embodiment, the yoke 35a is fixed to the shaft 32, and the magnet support 35b for supporting the permanent magnet 34 is fixed to the case 31 to face the yoke 35a to rotate the case. Although an outer rotor structure is applied, an inner rotor structure in which the yoke 35a is fixed to the case 31 and the magnet support 35b is fixed to the shaft portion 32 to rotate the shaft portion may be applied. It may be.

The coils 36 are disposed adjacent to each other along the circumferential direction of the yoke 35a and are formed to surround the outer circumferential surface in the radial direction of the yoke 35a from the inner circumferential surface of the hollow portion provided in the yoke 35a. That is, the wire constituting the coil 36 has a structure wound around the inner circumferential surface of the hollow portion, the upper surface of the yoke 35a, the edge circumferential surface and the bottom surface of the yoke 35a.

The yoke 35a includes a plurality of unit yokes 35a 'divided by dividing lines passing through the center of the hollow part. Each of the unit yokes 35a` may restore each cut surface formed by the dividing line to a disk shape through joining such as welding.

The yoke 35a has a structure separated into two unit yokes to minimize the portions to be joined to each other, but alternatively, the yoke 35a may be divided into two or more.

The coil 36 coupled to the yoke 35a may be coupled by dividing the yoke 35a onto a dividing line and then fitting one end of the divided unit yoke 35a to the coil 36 to form a coil 36. After the) is inserted, join and fix the cut surface.

In the yoke described in this embodiment, a structure in which a steel sheet containing silicon (Si) is wound in a roll shape has been described as an embodiment. However, unlike the illustrated example, the yoke uses an existing iron plate having a hollow portion in the center thereof. It is, of course, applicable to those laminated up and down or formed into a disk shape having a predetermined thickness.

Meanwhile, FIG. 5 shows an AFPM generator according to the second embodiment of the present invention.

 Referring to FIG. 5, the AFPM generator according to the present invention includes a case 31, a shaft portion 32, a permanent magnet 134, and an armature coil unit 135a. The generator applied in this embodiment applies an inner rotor structure in which the housing 31 is fixed and the shaft portion 132 rotates with respect to the housing 31.

An armature coil unit having a plurality of coils 136 coupled to the yoke 135a is fixed to the lower inner circumferential surface of the case 31. The shaft support 132 is provided with a magnet support 135b, and the bottom of the magnet support 135b is fixed with permanent magnets 134 to face the armature coil unit.

The magnet supporting portion 135b is fixed to the edge of the fixing plate made of resinized material on the shaft portion 132.

In FIG. 5, the armature coil unit is described as being disposed only on the lower inner circumferential surface of the case 31. Alternatively, the armature coil unit may be disposed only on the upper inner circumferential surface of the case 31, and as shown in FIG. It may be arranged up and down respectively on the lower inner peripheral surface. In this case, it is preferable to arrange the permanent magnet 134 on the upper surface of the magnet support 135b so as to face the armature coil unit.

On the other hand, the AFPM generator according to the invention may apply a structure in which the armature coil unit and the permanent magnets 134 are alternately arranged in the vertical direction along the extending direction of the shaft portion 132 in the vertical direction.

Referring to FIG. 7, inside the case 31, a plurality of armature coil units are fixed to be spaced apart from each other in a vertical direction. The armature coil unit may be fixed to the inner circumferential surface of the case 31 using an adhesive.

The shaft portion 132 is provided with a magnet support 135b fixed to the edge of the fixed plate coupled along the radial direction to support the permanent magnet 134. A plurality of permanent magnets 134 are disposed on the upper and lower surfaces of the magnet support part 135b so as to provide magnetic force to the armature coil unit located relatively upward and the armature coil unit located downward.

Hereinafter, a process of manufacturing the armature coil unit according to the present invention will be described in detail.

The armature coil unit according to the present invention is a steel sheet manufacturing step of manufacturing a silicon steel sheet by mixing iron, silicon (Si) and impurities, and a strip manufacturing step of manufacturing a silicon thin strip by processing the silicon steel sheet to have a set width and thickness; A winding step of forming a silicon thin roll by winding the silicon thin strip overlapping, an impregnation step of vacuum impregnating the silicon thin roll with an impregnation liquid, and passing through the center of the silicon thin roll fixed by the impregnation liquid in the impregnation step. The silicon thin roll is cut along the extension line, divided into a plurality of split yokes, a split yoke is inserted into a coil provided with an insertion hole for inserting the split yokes, and an adhesive is applied to the cut surfaces of the split yokes so that the respective split yokes are separated from each other. And a bonding step for bonding.

Steel sheet manufacturing step is to cast and roll iron containing silicon (Si).

In general, the silicon (Si) manufactured in the steel sheet manufacturing step may be a mixture of 2.95 to 3.5% by weight of iron and other impurities, or alternatively, containing 6 to 6.5% by weight of silicon (Si). You may.

In the above-described silicon steel sheet containing 6.5 wt% of silicon (Si), a steel sheet containing 4 wt% or less of silicon (Si) is usually made of 6 wt% or more of silicon (Si) by chemical vapor deposition (CVD). The method of manufacture to contain can be applied.

In the strip manufacturing step, a silicon steel sheet manufactured to a predetermined specification is rolled into a thin long silicon thin strip to have a thickness of 0.1 mm to 0.3 mm.

The winding step is a step of forming the silicon thin strips produced in the strip manufacturing step in the form of a roll overlapping to form a silicon thin roll through the process of winding to a predetermined inner diameter and outer diameter. The winding step determines the radius of the hollow and the radius of the yoke.

After the winding step further includes a heat treatment step and shape correction step.

In the heat treatment step, it is kept at 850 ° C. for about 240 minutes, changes in temperature by ± 100 ° C. per hour, and is subjected to air cooling at 400 ° C., followed by nitrogen.

In the shape correction step, the shape is corrected so that the top and bottom of the silicon thin roll roll wound in a roll shape are flat.

In the impregnation step, the silicon thin roll, which has undergone the shape calibration step, is precipitated in the impregnated solution impregnated solution for about 1 hour and vacuum impregnated to infiltrate the impregnated solution between the overlapped silicon thin strips. The impregnation agent used in the impregnation step is preferably to use a strong adhesive force so that the silicon thin strips are not separated from each other by their elastic force in the process of cutting in the division step described later. For example, the impregnating agent may use '2278B' of '3M'.

After the impregnation step, the method further includes a drying step of drying the roll-shaped silicon thin strip precipitated in the impregnation solution at 170 ° C. for about 12 hours.

In the dividing step, the thin silicon thin roll fixed with the impregnation liquid is cut along the extension line passing through the center of the silicon thin plate to be cut into a plurality of dividing yokes, and each dividing yoke is cut to have the same size and shape.

After the dividing step, the dividing yoke is further inserted into the coils having insertion holes formed to correspond to the cross-sectional area of each dividing yoke.

In the bonding step, the divided yokes divided in the dividing step are connected to restore the silicon thin roll shape before the dividing step, and the cut surfaces of the respective divided yokes are bonded using an adhesive. In the bonding step, it is preferable to use an adhesive that suppresses the generation of voids between the cutting surfaces in the process of bonding the cutting surfaces to reduce noise and poor quality.

The yoke structure of the AFPM generator according to the present invention described above has been described with reference to the embodiment shown in the drawings, but this is only an example, and those skilled in the art have various modifications and equivalents therefrom. It will be appreciated that embodiments are possible.

Accordingly, the true scope of protection of the present invention should be determined only by the appended claims.

31: Case
32: shaft portion
32a: fixed plate
34: permanent magnet
35b: magnet support
35a: York
35b: magnet support
36 coil

Claims (8)

delete A plurality of coils disposed to face the plurality of permanent magnets to generate electricity by the permanent magnets;
And a yoke to which the coils are coupled.
The yoke is formed in the center of the hollow portion, the plurality of coils are disposed adjacent to each other along the circumferential direction of the yoke is formed so as to surround the outer peripheral surface of the yoke from the inner circumferential surface of the hollow portion toward the radial direction of the yoke,
The yoke is an armature coil unit, characterized in that the impregnated with the impregnation agent by winding a thin strip made of a metal material. A plurality of coils disposed to face the plurality of permanent magnets to generate electricity by the permanent magnets;
And a yoke to which the coils are coupled.
The yoke is formed in the center of the hollow portion, the plurality of coils are disposed adjacent to each other along the circumferential direction of the yoke is formed so as to surround the outer peripheral surface of the yoke from the inner circumferential surface of the hollow portion toward the radial direction of the yoke,
The yoke is an armature coil unit, characterized in that the iron and silicon are formed in a predetermined weight ratio. The method of claim 3,
The yoke is armature coil unit, characterized in that containing 6% by weight to 6.5% by weight of silicon. A plurality of coils disposed to face the plurality of permanent magnets to generate electricity by the permanent magnets;
And a yoke to which the coils are coupled.
The yoke is formed in the center of the hollow portion, the plurality of coils are disposed adjacent to each other along the circumferential direction of the yoke is formed so as to surround the outer peripheral surface of the yoke from the inner circumferential surface of the hollow portion toward the radial direction of the yoke,
And the yoke is divided into a plurality of unit yokes by one or more dividing lines extending radially from the center of the hollow part. Steel plate manufacturing step of producing a silicon steel sheet by mixing iron and silicon;
A strip manufacturing step of manufacturing the silicon thin strip by processing the silicon steel sheet to have a predetermined width and thickness;
A winding step of winding the silicon thin strip to overlap to form a silicon thin roll;
An impregnation step of vacuum impregnating the silicon thin roll with an impregnation liquid;
A dividing step of cutting the silicon thin roll fixed by the impregnation liquid in the impregnation step and dividing the plurality of divided yokes into a plurality of divided yokes;
An insertion step of inserting the split yoke into a coil provided with an insertion hole so that the split yoke can be inserted;
And a bonding step of bonding the respective divided yokes by applying an adhesive to the cut surfaces of the divided yokes. A case having a receiving space;
A shaft portion installed in the accommodation space to allow rotation relative to the case;
Permanent magnets disposed in the case or shaft;
And an armature coil unit disposed to face the permanent magnets in a direction parallel to the extending direction of the shaft portion, the armature coil unit including a yoke to which a plurality of coils generating electricity by the permanent magnets are coupled.
The yoke has a hollow portion in the center thereof, and the plurality of coils are disposed adjacent to each other along the circumferential direction of the yoke, and are formed to surround the outer circumferential surface of the yoke from the inner circumferential surface of the hollow portion toward the radial direction of the yoke. AFPM generator. delete

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