WO2005109603A1 - Electrical machine and method for producing an electrical machine - Google Patents
Electrical machine and method for producing an electrical machine Download PDFInfo
- Publication number
- WO2005109603A1 WO2005109603A1 PCT/SE2005/000647 SE2005000647W WO2005109603A1 WO 2005109603 A1 WO2005109603 A1 WO 2005109603A1 SE 2005000647 W SE2005000647 W SE 2005000647W WO 2005109603 A1 WO2005109603 A1 WO 2005109603A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- soft magnetic
- electrical machine
- core
- magnetic material
- winding
- Prior art date
Links
Classifications
-
- 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
- H02K1/02—Details of the magnetic circuit characterised by the magnetic material
-
- 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
- H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
- H02K15/022—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies with salient poles or claw-shaped 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
- Y10T29/49009—Dynamoelectric machine
Definitions
- the present invention relates to a core for an electrical machine, an electrical machine, a method for producing a core for an electrical machine, and a method for producing an electrical machine.
- an electrical machine comprises a core, including a body of soft magnetic material, at least one winding arranged around at least a portion of said core, and a magnetic flux cross section area enlarging element substantially filling a space between said at least one winding and at least a portion of said body of the core, the magnetic flux cross section area enlarging element includes a composite of soft magnetic powder and a thermoplastic, the composite being injection molded.
- a method for producing an electrical machine comprising a body of soft magnetic material, said method comprising the acts of arranging at least one winding around at least a portion of the body of soft magnetic material, positioning the body of soft magnetic material and the at least one winding in a cavity of a mold, and injecting a composite of soft magnetic powder and a thermoplastic into the cavity of the mold.
- the above electrical machine and the above method may be advantageous in that they may make volumes of the electrical machine that did not contribute to the generation of power in prior art electrical machines, conduct magnetic flux and, thus, contribute to the generation of power. Accordingly, it may become possible to achieve an electrical machine having increased power density.
- the magnetic flux area enlarging element is arranged onto said tooth of said body by means of injection molding.
- This may be advantageous in that it may facilitate arranging of said magnetic flux area enlarging element onto said tooth and in that it may facilitate the filling of non contributing spaces, i.e. volumes of air having very low permeability.
- injection molding the composite as described above may also make it possible to in the same step as forming the magnetic flux cross section enlarging element form and with the same material form functional features. The effect of this is that the production may be facilitated or speeded.
- Fig la shows a schematic top view of a prior art stator core of laminated sheets of soft magnetic material
- Fig lb shows a schematic view of a section of the stator core of Fig la
- Fig lc shows a schematic view of a section of a tooth of the stator core of Fig la
- Fig 2a shows a schematic top view of a prior art stator core made from soft magnetic powder
- Fig 2b shows a schematic view of a section of the stator core of to Fig 2a
- Fig 2c shows a schematic view of a section of a tooth of the stator core of Fig 2a
- Fig 3a shows a schematic top view of a stator core according to one embodiment of the invention, the core is provided with windings
- Fig 3b shows a schematic view of a section of the stator core of Fig 3a
- Fig la-c a prior art laminated stator core 10 having teeth 16 is shown.
- the person constructing a core by using laminated soft magnetic sheets 12 is limited by the layered structure of the sheets 12 and may not freely and easily vary the shape in three dimensions.
- the skilled person is familiar with the manufacturing of laminated cores .
- Figs 2a-c a prior art stator 20 core made from soft magnetic powder is shown. In some cases it may be difficult to completely achieve the desired shape of the core, because of limitations relating to the tools used to compact the soft magnetic powder into the desired design.
- the stator core includes teeth 22 and the limitation of the tools used to compact the soft magnetic powder results in a geometrical discontinuity 24 in the teeth 22, seen in Fig 2c.
- the result presented in Figs 2a-c only shows an example, a limitation of the tools may result in other disadvantageous shapes.
- Such discontinuities 24 or disadvantageous shapes are seldom desired.
- Some geometries and shapes of cores or teeth 22 are difficult to produce without generating discontinuities 24 like the ones showed in Fig 2c.
- the discontinuities 24 have the effect that a lesser cross sectional area of the teeth is able to lead magnetic flux in relation to a corresponding tooth without discontinuities 24.
- stator/rotor and machine in relation to a stator not having such discontinuities and, thus, in relation to a machine including a stator not having such discontinuities.
- Another or additional effect may be that the power density becomes lower than the power density of a corresponding machine in which the core does not have such discontinuities.
- the power density is defined as produced power divided with volume of the machine.
- the skilled person is familiar with the production of cores from soft magnetic powder. Below the invention will be described in relation to a stator core of an electrical motor or an electrical generator. However, it is obvious for the skilled person to apply these teachings on any type of core, e.g.
- stator core a stator core, a rotor core, a moving core of a linear motor, stator core of a linear motor, etc., and any electrical machine, e.g. rotary motor, rotary generator, linear motor, linear generator, etc.
- a magnetic flux cross section area enlarging element 101, 102 is arranged onto a laminated stator body 103.
- the body might be a prior art laminated stator core as described in connection with Figs la-c or a roughly shaped laminated body, resembling the shape of the final core, acting as a basic structure from which the core is evolved.
- the magnetic flux cross section area enlarging element 101, 102 is made of a composite of a soft magnetic powder and a binder, as will be described below.
- the composite may be injection molded onto the stator body 103, as will be described below as well.
- the permeability of the composite of the magnetic flux cross section enlarging element 101, 102 is greater than the permeability of air and the core with the magnetic flux cross section area enlarging element 101, 102 form a larger cross sectional area, in respect of the direction of the magnetic flux when the electrical machine is running, than without the magnetic flux cross section area enlarging element 101, 102. Accordingly, areas or volumes in the path for the magnetic flux which in the prior art only included air, i.e.
- the magnetic flux cross section area enlarging element 102 may be used to produce more efficient cores by modeling the shape of specific portions of the core into more efficient shapes, e.g. the shape of a tip 106 of the teeth 108 as clearly shown in Fig 2b-c.
- the shape of the tip 106 of the teeth 108 in Fig 2b-c improves the magnetic interaction between a stator and a rotor in relation to the small square shaped tip of the stator shown in Figs lb-c in that it provides a greater magnetic flux cross section area for the magnetic interaction.
- the magnetic flux cross section area enlarging element may increase the heat transfer from the windings of a core by providing a thermal transfer path. This may be achieved if the compound of the magnetic flux cross section area element 101 is selected so that it is conducting heat better than air.
- the magnetic flux cross section area enlarging element 101 may also provide an increased heat conducting surface being in contact with the winding, in relation to the smaller contact areas of the prior art cores.
- the windings 112 may be provided around the teeth of the final core as in the Figs 3a-f, i.e. after the magnetic flux cross section area enlarging element 101 has been arranged onto the stator body 103, or before the application of the magnetic flux cross section area enlarging element 101.
- the cross section area of the magnetic flux cross section area enlarging element may fill additional potential spaces of low permeability and the heat transfer may be further enhanced.
- Figs 4a-b shows an embodiment that differs from the embodiment of Figs 3a-f in that it exposes the body 103 at the tip 106 of the teeth 108. This is achieved by not covering the end surface 120 of the portions of the body with the composite of soft magnetic powder and resin, said portions being the basic structure of the teeth 108.
- Fig 5a-f shows another embodiment of the core 200, in which the core 200 is based on a body 202 made of soft magnetic powder.
- the body 202 might be a prior art stator core made from soft magnetic powder as described in connection with Figs 2a-c or a roughly shaped body of soft magnetic powder resembling the shape of the final core and acting as a basic structure from which the core 200 is evolved.
- the magnetic flux cross section area enlarging elements 204 may be used to fill discontinuities 206 in the body or in a core and, thus, increase the cross sectional area of the magnetic flux path in a core having discontinuities 206 and consequently increase the permeance of the sections including the magnetic flux cross section area enlarging elements 204.
- the discontinuities 206 of a body or core may be filled, resulting in a continuous surface at the location of the undesired discontinuity.
- the discontinuities 206 are located in the teeth 208, showed in Fig 5d, and are efficiently filled by the magnetic flux cross section area enlarging elements 204.
- the advantage of increased heat transfer discussed in connection with Figs 3a-f may also be applicable to this embodiment.
- the three dimensional feature may for example be a tooth tip of the teeth 208.
- the windings 212 may be provided around the teeth 208 of the final core as in the Figs 5a-f or before the application of the magnetic flux cross section area enlarging element 204.
- the composite used for the magnetic flux cross section area enlarging elements includes soft magnetic powder and a binder. The amount and properties of the soft magnetic powder and the binder are to be selected so that the permeability of the composite are at least greater than the permeability of air ( ⁇ 0 ) and so that the structural strength required by the specific application in which the core is to be used is achieved.
- the amount and properties of the soft magnetic powder and the binder so that the composite is possible to injection mold.
- the advantages of injection molding may be that it becomes possible to make complicated and close toleranced 3D-structures, that it becomes possible to effective utilize the volume of the electrical machine by reconfigure volumes not conducting magnetic flux to volumes conducting magnetic flux, that the injection molded features are mechanically robust without the need of any complementary work. It is desired to get as high permeability as possible, however, the requirement of structural strength and the requirement regarding the composite being possible to injection mold may limit the permeability.
- the amount of binder used is determined by the amount required to achieve the required structural strength of the core in a specific application and/or required to make it possible to injection mold.
- the relation between soft magnetic powder and thermoplastic binder for a composite may be approximately 83-95 percentage by weight (w.p.) soft magnetic powder and approximately 5-17 w.p. thermoplastic. In one embodiment approximately 90-95 w.p. soft magnetic powder is preferred in order to optimize the magnetic performance of the composite.
- the soft magnetic powder may for example be a powder including particles of iron, nickel, cobalt, or any combination of these materials. Also, it may be a powder of a cobalt-iron alloy, a cobalt-nickel alloy, a nickel-iron alloy, or a cobalt-nickel-iron alloy.
- the particles may be essentially spherical, irregular, or in the shape of flakes.
- the particles may be coated or non-coated.
- the composite may be used as electric insulation even if non coated particles are used.
- the binder may be a thermoplastic material or a thermosetting material.
- Thermoplastic material may be advantageous when the price of the core is important or when the material of the core are to be recyclable, the latter is possible by heating the core and allowing the thermoplastic to be drained away.
- Thermosetting material may be advantageous when the strength of the component is important. Many representatives of the respective groups are known. From the group of thermoplastic materials one or a combination of the following materials may be selected: Polyamides, Sulfur Containing Polymers, e.g. PPS, etc., for further thermoplastic materials see J.F.
- a body 402 is produced or provided.
- the body 402 may be seen as a semi-finished core or as a core which might be improved by means of applying the invention. Accordingly, as mentioned above, the body 402 might be a known laminated core, e.g. as described in connection with Figs la-c, a known core made of soft magnetic powder, e.g. as described in connection with
- Figs 2a-c or a roughly shaped body, of either laminated soft magnetic sheets or soft magnetic powder, resembling the shape of the final core. Said roughly shaped body is then acting as a basic structure from which the core is evolved.
- a mold 404 is produced or provided. The mold is provided with a cavity 406 for receiving the body 402 and the composite 408 to be arranged onto the body and with one or a plurality of inlets 410 for input of the composite 408 to the cavity 406 during the injection molding, see Fig 6. Then the body 402 is positioned in the mold, see Fig 7.
- the mold is designed to accommodate the body 402 and leave a cavity 412 at the positions where magnetic flux cross section area enlarging elements 414 are to be arranged onto the body 402.
- the composite 408 is injected into the mold via an injection conduit 416 and fills the cavities 412 between the body 402 and the walls 418 of the mold 404, see Fig 8.
- the body 402 may be provided with windings or coils before it is inserted into the mold 404.
- the composite 408 When the composite 408 is injected into the mold 404 the composite 408 fills not only the cavities 412 between the body 402 and the walls 418 of the mold 404, but also cavities 424 between the winding and the body 402 and the winding and the walls 418 of the mold 404.
- the advantages of this are, in addition to increasing the magnetic flux cross section area, that the thermal conduction from the winding may be further improved.
- the body in which the winding or coils also are provided to the body before the body is inserted into the mold 404, the body may be provided with spacers between the body and the windings or coils, thus, providing a cavity between the body 402 and the entire winding.
- the advantage of this embodiment is that it may combine the advantages of the two previously mentioned embodiments. For example, it may make the magnetic flux cross section area enlarging element function as electrical insulation between the body 402 and the winding or coil, it may increase the magnetic flux cross section area, and it may improve the thermal conduction from the winding.
- injection molding of three dimensional features makes it possible to design the free end 502 of the teeth 504 of a core 506 as shown in Fig 9.
- the free end 502 of the teeth 504 are provided with an interaction surface 508, for magnetically interaction with a stator or rotor/mover depending on whether the teeth 504 are arranged on a rotor/mover or a stator.
- the interaction surface 508 is defined by two circumferentially directed edges 510, 512 and two edges 514, 516 that essentially extends axially.
- the essentially axial edges 514, 516 are arranged so that one end 518, 520 of the axial edge 514,516 is arranged closer to the main body of the tooth 504 than the other edge 524, 526 of the same axial edge 514, 516, while all the four edges 510, 512, 514, 516 are arranged at an essentially equal distance from the geometric axis of the core 506.
- the three dimensional extensions and/or magnetic flux cross section area enlarging elements made of said composite and injection molded onto a core may be extended and shaped to perform application specific functions in addition to the ordinary functions of the core.
- the three dimensional extensions and/or magnetic flux cross section area enlarging elements may be extended into features for engaging with systems external to the electrical machine and be molded simultaneously using the same composite as the three dimensional extensions and/or magnetic flux cross section area enlarging elements. Accordingly, the extended feature is produced in the same step and in the same mold as the core, with or without windings.
- a wave winding may be arranged at the teeth of the body of a core before the core is finalized by injection molding the magnetic flux area cross section enlarging elements and/or three dimensional features. This, simplifies the production of electrical machines including wave windings and three dimensional features.
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Iron Core Of Rotating Electric Machines (AREA)
- Manufacture Of Motors, Generators (AREA)
Abstract
Description
Claims
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CN200580015080.7A CN1954473B (en) | 2004-05-11 | 2005-05-04 | Electrical machine and method for producing an electrical machine |
EP05749846A EP1745538A1 (en) | 2004-05-11 | 2005-05-04 | Electrical machine and method for producing an electrical machine |
US11/578,941 US8110959B2 (en) | 2004-05-11 | 2005-05-04 | Method for producing an electrical machine with a body of soft magnetic material |
JP2007513102A JP2007536889A (en) | 2004-05-11 | 2005-05-04 | Electric machine and method for manufacturing an electric machine |
CA2563028A CA2563028C (en) | 2004-05-11 | 2005-05-04 | Electrical machine and method for producing an electrical machine |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
SE0401217-5 | 2004-05-11 | ||
SE0401217A SE0401217D0 (en) | 2004-05-11 | 2004-05-11 | Electrical machine and method for producing an electrical machine |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2005109603A1 true WO2005109603A1 (en) | 2005-11-17 |
Family
ID=32390921
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/SE2005/000647 WO2005109603A1 (en) | 2004-05-11 | 2005-05-04 | Electrical machine and method for producing an electrical machine |
Country Status (8)
Country | Link |
---|---|
US (1) | US8110959B2 (en) |
EP (1) | EP1745538A1 (en) |
JP (1) | JP2007536889A (en) |
CN (1) | CN1954473B (en) |
CA (1) | CA2563028C (en) |
SE (1) | SE0401217D0 (en) |
TW (1) | TWI291277B (en) |
WO (1) | WO2005109603A1 (en) |
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EP1855369A2 (en) | 2006-05-12 | 2007-11-14 | JTEKT Corporation | Stator core of an electric motor |
JP2008042972A (en) * | 2006-08-02 | 2008-02-21 | Mitsubishi Electric Corp | Core applied with windings |
US20140217836A1 (en) * | 2013-02-04 | 2014-08-07 | Miba Sinter Austria Gmbh | Arrangement having at least one electrical winding and electric machine with this arrangement |
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KR101092320B1 (en) * | 2005-11-23 | 2011-12-09 | 주식회사 동서전자 | Stator used in a motor and formed from soft magnetic powder material |
JP5172367B2 (en) * | 2008-01-23 | 2013-03-27 | 三菱電機株式会社 | Laminated core, laminated core manufacturing method, laminated core manufacturing apparatus, and stator |
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JP6071275B2 (en) * | 2012-06-29 | 2017-02-01 | 株式会社東芝 | Permanent magnet motor and method of manufacturing permanent magnet motor |
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KR101406360B1 (en) | 2012-12-11 | 2014-06-13 | 현대자동차주식회사 | Motor core |
KR20140093559A (en) * | 2013-01-18 | 2014-07-28 | 엘지전자 주식회사 | motor |
US9653967B2 (en) * | 2013-03-15 | 2017-05-16 | Techtronic Power Tools Technology Limited | Cooling arrangement for an electric motor |
JP5681232B2 (en) * | 2013-05-10 | 2015-03-04 | ファナック株式会社 | Electric motor stator injecting resin by injection molding |
JP6230292B2 (en) * | 2013-06-21 | 2017-11-15 | 東芝ライフスタイル株式会社 | Motor stator, motor, and washing machine |
US9948150B2 (en) * | 2014-09-08 | 2018-04-17 | Baker Hughes Incorporated | Systems and methods for constructing laminations for electric motors |
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JP6389793B2 (en) * | 2015-04-09 | 2018-09-12 | 株式会社三井ハイテック | Inspection method and inspection apparatus for laminated iron core |
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 |
US9748803B2 (en) | 2015-08-11 | 2017-08-29 | Genesis Robotics LLC | Electric machine |
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- 2005-05-04 CA CA2563028A patent/CA2563028C/en not_active Expired - Fee Related
- 2005-05-04 US US11/578,941 patent/US8110959B2/en not_active Expired - Fee Related
- 2005-05-04 EP EP05749846A patent/EP1745538A1/en not_active Withdrawn
- 2005-05-04 CN CN200580015080.7A patent/CN1954473B/en not_active Expired - Fee Related
- 2005-05-04 JP JP2007513102A patent/JP2007536889A/en active Pending
- 2005-05-11 TW TW094115274A patent/TWI291277B/en not_active IP Right Cessation
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Cited By (7)
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EP1855369A2 (en) | 2006-05-12 | 2007-11-14 | JTEKT Corporation | Stator core of an electric motor |
EP1855369A3 (en) * | 2006-05-12 | 2009-04-15 | JTEKT Corporation | Stator core of an electric motor |
US7705494B2 (en) | 2006-05-12 | 2010-04-27 | Jtekt Corporation | Electric motor |
JP2008042972A (en) * | 2006-08-02 | 2008-02-21 | Mitsubishi Electric Corp | Core applied with windings |
US20140217836A1 (en) * | 2013-02-04 | 2014-08-07 | Miba Sinter Austria Gmbh | Arrangement having at least one electrical winding and electric machine with this arrangement |
US9735655B2 (en) * | 2013-02-04 | 2017-08-15 | Miba Sinter Austria Gmbh | Arrangement having at least one electrical winding and electric machine with this arrangement |
EP4050760A1 (en) * | 2021-02-22 | 2022-08-31 | Sanyo Denki Co., Ltd. | Motor armature structure and motor armature manufacturing method |
Also Published As
Publication number | Publication date |
---|---|
EP1745538A1 (en) | 2007-01-24 |
US8110959B2 (en) | 2012-02-07 |
CN1954473B (en) | 2010-10-13 |
CN1954473A (en) | 2007-04-25 |
US20070222306A1 (en) | 2007-09-27 |
CA2563028C (en) | 2013-02-19 |
TW200608670A (en) | 2006-03-01 |
CA2563028A1 (en) | 2005-11-17 |
TWI291277B (en) | 2007-12-11 |
SE0401217D0 (en) | 2004-05-11 |
JP2007536889A (en) | 2007-12-13 |
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