US20120104879A1 - Noise reduction structures for electrical machines - Google Patents
Noise reduction structures for electrical machines Download PDFInfo
- Publication number
- US20120104879A1 US20120104879A1 US13/285,150 US201113285150A US2012104879A1 US 20120104879 A1 US20120104879 A1 US 20120104879A1 US 201113285150 A US201113285150 A US 201113285150A US 2012104879 A1 US2012104879 A1 US 2012104879A1
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- United States
- Prior art keywords
- rotor
- poles
- laminations
- component
- rotationally
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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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
- H02K1/22—Rotating parts of the magnetic circuit
- H02K1/32—Rotating parts of the magnetic circuit with channels or ducts for flow of cooling medium
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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
- H02K1/22—Rotating parts of the magnetic circuit
- H02K1/24—Rotor cores with salient poles ; Variable reluctance rotors
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/26—Measuring arrangements characterised by the use of optical techniques for measuring angles or tapers; for testing the alignment of axes
-
- 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
- H02K1/14—Stator cores with salient poles
-
- 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
- H02K1/20—Stationary parts of the magnetic circuit with channels or ducts for flow of cooling medium
-
- 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
- H02K1/14—Stator cores with salient poles
- H02K1/146—Stator cores with salient poles consisting of a generally annular yoke with salient poles
-
- 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
- H02K1/14—Stator cores with salient poles
- H02K1/146—Stator cores with salient poles consisting of a generally annular yoke with salient poles
- H02K1/148—Sectional cores
-
- 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
- H02K15/12—Impregnating, heating or drying of windings, stators, rotors or machines
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- 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/64—Electric machine technologies in electromobility
Definitions
- Switched reluctance machines have made limited entry into commercial applications.
- a major problem limiting the desirability of using SRMs in commercial applications is the acoustic noise they generate. This acoustic noise is attributed to: (1) high normal forces caused by various imbalances in the non-uniform air gap between an SRM's rotor and stator, (2) discontinuous currents in the SRM's machine windings causing discontinuous torque that produces very high torque pulsations, and (3) the rotor functioning like an impeller.
- Many emerging applications, such as commercial refrigeration motor drives require quiet operation with less noise than that of a very good single-speed induction motor. In the case of variable-speed motor drives, the noise of an SRM drive should be comparable to that of a permanent magnet brushless de motor drive. SRMs have not satisfactorily met the noise requirement to satisfy commercial applications.
- the invention disclosed herein provides solutions to the high-noise generation of a switched reluctance machine (SRM) that can be implemented for high-volume applications.
- SRM switched reluctance machine
- High-volume applications require inexpensive machine designs that are simple to implement.
- An invention is described in this application with three preferred embodiments for mitigating the acoustic noise of an SRM. Normal forces, imbalance in the air gap, saturation in laminations, and torque ripple all contribute to acoustic noise. The acoustic noise is further exacerbated by electronic switching of current in the SRM's winding.
- An object of the invention is to reduce the fluid flow and air gap imbalance by: (1) encapsulating a machine's rotor/stator slots, (2) rotating a machine's stacked rotor laminations, and (3) providing discs on both ends of a machine's rotor/stator stack.
- an electrical machine component having: (1) a plurality of salient poles, projecting along a radial axis of the component, that each conveys an applied electromagnetic flux; and (2) an electrically and magnetically inert solid material within a space between a rotationally-adjacent pair of salient poles.
- a machine rotor having: (1) a plurality of salient poles, projecting along a radial axis of the rotor, that each conveys an applied electromagnetic flux; (2) a space between a rotationally-adjacent pair of salient poles that inhibits conveyance of an applied electromagnetic flux; and (3) first and second opposing structures that each extends at least partially across the rotationally-adjacent pair of poles and has an outward salient projection along the radial axis of the rotor.
- an electrical machine having: (1) an electrical component having a plurality of salient poles, projecting along a radial axis of the component, that each conveys an applied electromagnetic flux; and (2) an annulus disposed outside a first axial surface of the electrical component.
- the annulus is a barrier between a space outside the axial surface of the electrical component and a space between a rotationally-adjacent pair of poles.
- FIGS. 1( a ) and 1 ( b ) illustrate a rotor stack assembly having a plurality of laminations
- FIGS. 2( a ) and 2 ( b ) illustrate a rotor having its slots filled with a material
- FIG. 3 illustrates a stator having its slots filled with a material
- FIGS. 4( a ) and 4 ( b ) illustrate a rotor lamination stack in which a lamination at each end of the stack is phase-rotated with respect to the laminations sandwiched between the two end laminations;
- FIG. 5( a ) illustrates a rotor lamination stack having phase-shifted end laminations that do not entirely cover the longitudinal sides of rotor slots;
- FIG. 5( b ) illustrates a rotor lamination stack in which multiple phase-shifted end laminations cover the longitudinal sides of rotor slots
- FIGS. 6( a ) and 6 ( b ) illustrate an annulus that blocks the air flow along the axial path of a rotor lamination stack
- FIG. 7( b ) illustrates an annulus that is disposed at one axial end of a stator so as to cover the open space between each rotationally-adjacent pair of poles.
- FIGS. 1( a ) and 1 ( b ) illustrate a rotor lamination stack 1 having a plurality of laminations.
- Individual rotor laminations 2 ( 1 )- 2 ( x ) are stacked together such that their pole faces 11 and slots 12 line up along an axial direction of rotor lamination stack 1 .
- Rotor laminations 2 ( 1 )- 2 ( x ) are stacked one on top of the other to a length known as a stack length, which determines the torque and power output of a machine comprising rotor lamination stack 1 and a stator (not shown).
- the stator may be any type of switched reluctance machine (SRM), such as those described by Ramu, Krishnan, “Switched reluctance motor drives”, CRC Press, 2001, which is incorporated herein in its entirety by reference.
- SRM switched reluctance machine
- the vortex noise component has a very low frequency compared to the tonal-component frequency and is not a major cause for concern in an SRM.
- the tonal-frequency noise component has exactly the same value as the combined phase frequencies in the SRM.
- the fan-blade noise component directly adds to the noise component due to normal forces, created by the alignment of the stator and rotor poles, since their frequencies are the same.
- the noise at this common frequency (i.e., the phase frequency) and its higher-order harmonics, which are integral multiples of this frequency, are the most troubling noise components in the SRM.
- An SRM rotor because of its sizeable slot dimensions compared to the pole face dimensions (e.g., as much as 100 to 125% of the pole face area), provides a large flow surface and area for air circulation as the rotor rotates, creating an aerodynamic effect on the SRM.
- the aerodynamic effect will be reduced by blocking the airflow path.
- Such airflow blocking may be achieved by covering the slot volume with a material.
- the covering material is magnetically and electrically inert so that: (1) the flux distribution of the rotor and stator structures is not distorted from the intended design and (2) the material does not create magnetic or electric losses.
- the material (1) is sufficiently adhesive to hold on to rotor laminations 2 ( 1 )- 2 ( x ), (2) has sufficient thermal tolerance to withstand the peak temperature of the rotor, and (3) is inexpensive for high-volume product applications.
- Such material may be an encapsulation epoxy, resin, or powder.
- rotor lamination stack 1 is placed in a cup having an inner nonstick surface and a height that is flush with rotor lamination stack 1 .
- the cup has a circular surface and its bottom is a disc that can be secured tightly and subsequently removed.
- the cylindrical periphery of the cup has flexible parts that can be tightened around rotor lamination stack 1 with a latch-like mechanism.
- material 22 is cured within rotor lamination stack the stack can be removed by removing the bottom disc from the filling assembly fixture and unlatching the cylindrical part of the cup body.
- the rotor shaft hole within rotor lamination stack 1 may be masked to prevent poured material 22 from entering.
- the cup can be made with a protrusion at the center to correspond to the shaft hole of rotor lamination stack 1 , so that the placement of rotor lamination stack 1 on the protrusion closes the shaft hole of rotor lamination stack 1 .
- rotor lamination stack 1 is first press fitted to a rotor shaft, placed in a cup surrounding rotor lamination stack 1 to the height of the stack, and then the encapsulating material is poured into the cup. After material 22 is poured or otherwise applied, rotor lamination stack 1 may be cured in a temperature-controlled oven or naturally, by exposing it to air, so that material 22 bonds with rotor lamination stack 1 . The bonding is intended to provide good adhesion and mechanical strength for withstanding forces normally encountered in the rotor body.
- Curing material 22 in a temperature-controlled oven is quicker and may be accomplished in a few minutes. Curing at ambient temperature may take hours. The appropriate method of curing for a particular application may be chosen based on economic considerations.
- Rotor laminations 2 ( 1 )- 2 ( x ) may be stacked in any manner, such as: (1) symmetrically, with one lamination on top of another so as to provide uniform slots and pole surfaces having no phase shift among them, (2) skewed so as to have a phase shift among laminations, (3) partially skewed, or (4) partial uniform stacking.
- the above-described technique of encapsulating space within the slots of a rotor lamination stack may be applied to the slots of a stator or a stator lamination stack. Applying this technique to the stator slots prevents air flow generated by the rotation of the rotor from entering the interstice space, which would create additional friction and noise.
- FIG. 3 illustrates a stator having its slots filled with a material.
- a stator 30 with a plurality of poles 32 and a winding 34 around each pole has a filling material 22 of epoxy.
- Filling material 22 partially or entirely fills stator slots 36 and is contoured to be flush with the stator lamination stack end-surfaces and pole faces.
- Encapsulation with epoxy or another material creates added cost due to the encapsulation material, process, and curing and the fixtures for creating the encapsulation. Particularly for 100 Watt and higher machines, the cost becomes significant, which is undesirable for high-volume applications that are cost-sensitive. Alternatives to encapsulation are described below.
- FIGS. 4( a ) and 4 ( b ) illustrate a second embodiment of a rotor lamination stack 40 in which a lamination at each end of the stack is phase-rotated with respect to the laminations sandwiched between the two end laminations. More specifically, a rotor lamination 42 ( 1 ) disposed at one longitudinal end of rotor lamination stack 40 is rotated, about a rotational axis of rotor lamination stack 40 , so as to be out of phase with rotor laminations 42 ( 2 )- 42 ( x ⁇ 1).
- a pole 11 of rotor lamination 42 ( 1 ) partially or fully covers a slot 12 of rotor laminations 42 ( 2 )- 42 ( x ⁇ 1). And each slot 12 of rotor laminations 42 ( 2 )- 42 ( x ⁇ 1) is so covered by a pole 11 of rotor lamination 42 ( 1 ).
- a pole 11 of a rotor lamination 42 ( x ) on the opposite side of rotor lamination stack 40 partially or fully covers a slot 12 of rotor laminations 42 ( 2 )- 42 ( x ⁇ 1) such that each slot 12 of rotor laminations 42 ( 2 )- 42 ( x ⁇ 1) is so covered by a pole 11 of rotor lamination 42 ( x ).
- the offset rotor laminations 42 ( 1 ) and 42 ( x ) and stator pole periphery create a barrier inhibiting the flow of air into and out of slots 12 .
- two or three laminations may be phase rotated at each end of rotor lamination stack 40 .
- An advantage of this embodiment is that no special materials or discs have to be made and the use of the rotor laminations to inhibit the flow of air is inexpensive. Additionally, the production process is simple and may be automated to phase shift the end laminations by half a rotor pole pitch from the rest of the lamination stack. Overall, the process for producing this embodiment is easy and inexpensive to implement and the detrimental effects on the performance of the machine are negligible. Experimental results confirm that this embodiment reduces acoustic noise of the machine to an extent equal to that achieved with the first embodiment.
- rotor laminations 42 ( 1 ) and 42 ( x ) can be phase rotated to cover an entire slot, as seen from the perspective of a plan view (i.e., as seen along the axis of rotation).
- a partial covering of slots 12 may be achieved.
- FIG. 5( a ) illustrates phase-shifted end laminations that do not entirely cover the longitudinal sides of slots 12 . More specifically, end laminations 51 and 52 are phase shifted in opposite directions with respect to intermediary laminations 50 . As illustrated, no unhindered path exists through a slot 12 along an axis parallel to the axis of rotation. However, end laminations 51 and 52 could be phase rotated in a single direction or opposite directions so as to provide an unhindered path through a slot 12 along an axis parallel to the axis of rotation.
- FIG. 5( b ) illustrates the use of multiple phase-shifted end laminations for covering the longitudinal sides of slots 12 at one longitudinal end of a rotor lamination stack 54 .
- a first rotor lamination 55 is phase shifted with respect to intermediary rotor laminations 50 and a second rotor lamination 56 is phase shifted with respect to both first rotor lamination 55 and intermediary rotor laminations 50 .
- first and second rotor laminations 55 and 56 cover all of slots 12 along a longitudinal side of rotor lamination stack 54 .
- a pair of laminations 57 and 58 are phase rotated with respect to one another and intermediary rotor laminations 50 so as to cover all of slots 12 along the opposite longitudinal side of rotor lamination stack 54 .
- FIG. 5( b ) illustrates that two laminations are phase shifted at each end of rotor lamination stack 54
- more than two laminations may be offset with respect to one another and intermediary rotor laminations 50 so as to cover slots 12 along each longitudinal side of rotor lamination stack 54 . Covering the entire portion of slots 12 along each longitudinal side provides greater acoustic noise reduction than covering only a portion of slots 12 along each longitudinal side.
- Rotor laminations 50 may be stacked in any manner, such as: (1) symmetrically, with one lamination on top of another so as to provide uniform slots and pole surfaces having no phase shift among them, (2) skewed so as to have a phase shift among laminations, (3) partially skewed, or (4) partial uniform stacking.
- Rotor laminations 51 , 52 , 55 - 58 may be identical to intermediary laminations 50 , to reduce manufacturing cost, or may have different pole and slot arcs that one another and intermediary laminations 50 .
- the first and second embodiments may be combined so that slots 12 of intermediary laminations 50 are partially or entirely filled with an encapsulating material and bounded by laminations on all sides except an outer radial periphery.
- FIGS. 6( a ) and 6 ( b ) illustrate the use of an annuluses to block air flow along the axial path of a rotor lamination stack 61 .
- Each annulus 62 may be as thick as a rotor lamination but made of lighter and stronger material.
- An annulus 62 may be placed on each end of rotor lamination stack 61 .
- the annulus material is preferably both electrically and magnetically inert, capable of withstanding the thermal environment of the rotor without any deterioration, and strong enough to withstand the forces surrounding the rotor lamination block.
- each annulus 62 has the same outer diameter as rotor lamination stack 61 or is equal to the minimum diameter of a contoured rotor tooth, so as to have a higher dimensional tolerance.
- annulus 62 Thin plastic rings and fiber board used in a printed circuit board base are suitable materials for annulus 62 .
- An advantage of using annulus 62 is that it is easier, in a production environment, to add the annulus than to employ phase-shifted laminations. Also, annuluses are less expensive, lighter in weight, and provide a uniform surface, similar to encapsulation, that is flush with the axial ends of the lamination stack; with phase-shifted laminations, an unevenness of the axial-end surface exists between the slots and poles of the end laminations.
- FIGS. 7( a ) and 7 ( b ) illustrate the use of an annulus to block the air flow path along the axial path of a stator lamination stack.
- FIG. 7( a ) illustrates a stator 70 with a plurality of poles 72 and a winding 74 around each pole.
- FIG. 7( b ) illustrates, via a plan view, an annulus 76 that is disposed at one axial end of stator 70 so as to cover the open space between each rotationally-adjacent pair of poles 72 without interfering with the rotation of a rotor (not shown) within stator 70 .
- Another annulus (not shown) may be disposed on the opposite axial end of stator 70 in a similar manner.
- All three of the above-described embodiments are applicable to any type of electrical machine, including induction motors, permanent magnet synchronous motors, brushless dc motors, and switched reluctance motors.
- the above-described embodiments may be applied individually or in combination to an electrical machine and to electrical machines having radial or axial field orientations for rotating or linear types of configurations.
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Synchronous Machinery (AREA)
- Iron Core Of Rotating Electric Machines (AREA)
- Control Of Motors That Do Not Use Commutators (AREA)
- Dc-Dc Converters (AREA)
- Control Of Electric Motors In General (AREA)
- Control Of Ac Motors In General (AREA)
- Electric Propulsion And Braking For Vehicles (AREA)
- Motor Or Generator Frames (AREA)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US13/285,150 US20120104879A1 (en) | 2010-11-03 | 2011-10-31 | Noise reduction structures for electrical machines |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US40963810P | 2010-11-03 | 2010-11-03 | |
US13/285,150 US20120104879A1 (en) | 2010-11-03 | 2011-10-31 | Noise reduction structures for electrical machines |
Publications (1)
Publication Number | Publication Date |
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US20120104879A1 true US20120104879A1 (en) | 2012-05-03 |
Family
ID=45995906
Family Applications (7)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US13/285,176 Expired - Fee Related US8952591B2 (en) | 2010-11-03 | 2011-10-31 | Rotor lamination shaping for minimum core loss in SRMs |
US13/285,196 Active 2033-03-11 US9312733B2 (en) | 2010-11-03 | 2011-10-31 | High power density SRM |
US13/285,150 Abandoned US20120104879A1 (en) | 2010-11-03 | 2011-10-31 | Noise reduction structures for electrical machines |
US13/287,234 Expired - Fee Related US8716961B2 (en) | 2010-11-03 | 2011-11-02 | Switched reluctance and PM brushless DC motor drive control for electric vehicle application |
US13/287,207 Expired - Fee Related US9054567B2 (en) | 2010-11-03 | 2011-11-02 | High power density SRMs |
US13/287,221 Expired - Fee Related US8754605B2 (en) | 2010-11-03 | 2011-11-02 | Power factor correction circuits for switched reluctance machines |
US14/593,775 Abandoned US20150124267A1 (en) | 2010-11-03 | 2015-01-09 | Rotor lamination shaping for minimum core loss in srms |
Family Applications Before (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US13/285,176 Expired - Fee Related US8952591B2 (en) | 2010-11-03 | 2011-10-31 | Rotor lamination shaping for minimum core loss in SRMs |
US13/285,196 Active 2033-03-11 US9312733B2 (en) | 2010-11-03 | 2011-10-31 | High power density SRM |
Family Applications After (4)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US13/287,234 Expired - Fee Related US8716961B2 (en) | 2010-11-03 | 2011-11-02 | Switched reluctance and PM brushless DC motor drive control for electric vehicle application |
US13/287,207 Expired - Fee Related US9054567B2 (en) | 2010-11-03 | 2011-11-02 | High power density SRMs |
US13/287,221 Expired - Fee Related US8754605B2 (en) | 2010-11-03 | 2011-11-02 | Power factor correction circuits for switched reluctance machines |
US14/593,775 Abandoned US20150124267A1 (en) | 2010-11-03 | 2015-01-09 | Rotor lamination shaping for minimum core loss in srms |
Country Status (4)
Country | Link |
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US (7) | US8952591B2 (fr) |
EP (1) | EP2636141A1 (fr) |
CN (1) | CN103190069A (fr) |
WO (5) | WO2012061270A2 (fr) |
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US20110260672A1 (en) * | 2010-04-26 | 2011-10-27 | Krishnan Ramu | High power density switched reluctance machines with hybrid excitation |
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CN113489203A (zh) * | 2021-07-01 | 2021-10-08 | 南京航空航天大学 | 一种四相电励磁双凸极电机 |
Also Published As
Publication number | Publication date |
---|---|
WO2012061273A2 (fr) | 2012-05-10 |
US20120104984A1 (en) | 2012-05-03 |
WO2012061273A3 (fr) | 2014-04-03 |
US20120104980A1 (en) | 2012-05-03 |
WO2012061271A2 (fr) | 2012-05-10 |
WO2012061270A2 (fr) | 2012-05-10 |
WO2012061456A1 (fr) | 2012-05-10 |
WO2012061458A1 (fr) | 2012-05-10 |
US8716961B2 (en) | 2014-05-06 |
WO2012061270A3 (fr) | 2012-05-31 |
US9312733B2 (en) | 2016-04-12 |
US8952591B2 (en) | 2015-02-10 |
US20120104988A1 (en) | 2012-05-03 |
WO2012061271A3 (fr) | 2014-07-10 |
CN103190069A (zh) | 2013-07-03 |
WO2012061270A4 (fr) | 2012-06-28 |
US8754605B2 (en) | 2014-06-17 |
US9054567B2 (en) | 2015-06-09 |
US20120104982A1 (en) | 2012-05-03 |
US20120104895A1 (en) | 2012-05-03 |
EP2636141A1 (fr) | 2013-09-11 |
US20150124267A1 (en) | 2015-05-07 |
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