WO2011040982A1 - Moteur-générateur sans balais - Google Patents

Moteur-générateur sans balais Download PDF

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Publication number
WO2011040982A1
WO2011040982A1 PCT/US2010/002685 US2010002685W WO2011040982A1 WO 2011040982 A1 WO2011040982 A1 WO 2011040982A1 US 2010002685 W US2010002685 W US 2010002685W WO 2011040982 A1 WO2011040982 A1 WO 2011040982A1
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WO
WIPO (PCT)
Prior art keywords
generator
motor
armature
preform
windings
Prior art date
Application number
PCT/US2010/002685
Other languages
English (en)
Inventor
Christopher W. Gabrys
Original Assignee
Revolution Electric Motor Company, Inc.
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Revolution Electric Motor Company, Inc. filed Critical Revolution Electric Motor Company, Inc.
Publication of WO2011040982A1 publication Critical patent/WO2011040982A1/fr

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K21/00—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets
    • H02K21/12—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets
    • H02K21/24—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
    • H02K15/0407—Windings manufactured by etching, printing or stamping the complete coil
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/12—Impregnating, heating or drying of windings, stators, rotors or machines
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • H02K3/47—Air-gap windings, i.e. iron-free windings

Definitions

  • This invention pertains to motor-generators, and more particularly to a brushless, air core motor-generator that provides high power density and efficiency with a rigid, high strength armature construction that allows excellent armature cooling and is producible with low costs and reduced manufacturing time.
  • Brushless permanent magnet motor-generators can provide higher power density and efficiency compared to other types of electrical machines.
  • the permanent magnets create the field flux without the use of electric power, resulting in increased efficiency.
  • Rare earth magnets can be utilized to create higher flux densities for greater torque production.
  • Brushless permanent magnet motor-generators can have various different constructions.
  • motor-generators utilize a conventional, slot wound, laminated ferromagnetic stator. Although this configuration allows for traditional manufacturing of winding coils and inserting them into stator slots, it has drawbacks. The construction results in significant eddy current losses and hysteresis losses, predominantly in the ferromagnetic stator.
  • Another type of brushless permanent magnetic motor-generator utilizes slotless or air core construction. Coils are not inserted into slots in a laminated stator. Instead the coils are located within the actual magnetic airgap. In air core constructed motor-generators, magnetic induced losses in the ferromagnetic stator can reduced because of elimination of the slots and the losses that they cause.
  • One particular type of air core motor-generator provides the armature coils in a self- supporting structure that is located between two rotating surfaces of the rotor. No laminated ferromagnetic stator is utilized and circumferentially varying magnetic flux does not pass through any ferromagnetic stator to cause hysteresis or eddy current losses.
  • a dual rotor air core motor-generator configuration contains the magnetic flux within two spaced-apart rotor portions and a magnetic airgap that is formed between them. An example of this configuration is shown in U.S. Published Application No. 20080231131 entitled "Commercial Low Cost High
  • Dual rotor air core motor-generators eliminate the magnetic induced losses in a ferromagnetic stator, however they can create significant magnetic induced losses in the actual windings that are located within the magnetic airgap. Difficulties also arise in trying to simultaneously achieve a high windings density for high efficiency, with an accurate and rigid armature to resist electromagnetic torque, and that can be producible rapidly and at low cost. Accordingly, a new brushless permanent magnet motor-generator with air core construction is needed to overcome these deficiencies.
  • the invention provides a new motor-generator with air core armature and process for producing the armature.
  • the motor-generator affords high efficiency and power density with a low cost construction, including a stator and a rotor that is supported for rotation relative to the stator.
  • the rotor has two spaced apart rotor portions, and a circumferential array of alternating permanent magnet poles that drive magnetic flux back and forth between the rotor portions and defining an armature airgap therebetween.
  • the stator includes a stationary portion of the motor- generator, and an air core armature with a free end extending inside the armature airgap between the rotor portions, and a support end fixed to the stationary portion of the motor-generator for transferring torque.
  • the air core armature is wound with wire windings comprised of bundled multiple smaller individually insulated conductor strands that are electrically in parallel but are electrically insulated between each other along their length inside the armature airgap, and are precoated with an activatable top coat adhesive prior to assembly of the wire and prior to winding the air core armature.
  • the air core armature wire windings are in the form of a preform that is wound and compressed into windings shape and held in the windings shape by the top coat adhesive, activated after winding and compression into the windings shape.
  • the winding preform has spaces between the wire windings that are filled with a resin that is impregnated into the preform after the compression pressure is released from the preform and then cured to form a rigid structure about the circumference.
  • the rigid structure is capable of resisting the electromagnetic forces generated during operation of the motor-generator in said armature airgap.
  • the tooling used for compressing the windings during impregnation, impedes the actual impregnation process.
  • the resin cannot impregnate all of the winding turns and the resulting armature is weak or even fails to keep its shape when removed from the tooling.
  • a second serious deficiency with the process is the tooling capital costs for production in volume and the extensive tooling clean up time between manufacturing runs.
  • the windings can be constructed utilizing numerous smaller insulated conductor strands, but the windings are impregnated without compression pressure applied. This method increases the windings impregnation for greater strength and rigidity. However, the windings density is greatly reduced. The resistive losses in the armature are much higher than necessary without substantially increasing the magnetic airgap through use of additional magnet material.
  • the new motor-generator in accordance with the invention utilizes an armature that can be formed using small insulated strand wires that have been precoated with a thermoplastic top coat adhesive layer prior to assembly of multiple strands together to form the windings wire.
  • the wire is wound into the windings shape or pattern and compression pressure is applied to the wire in the pattern.
  • the top coat adhesive layer on the strands is activated.
  • the strands become partially bonded together by the thermoplastic adhesive such that they form a winding preform that can be removed from the compression tooling and will hold its dimensions. Because the adhesive was applied to the strands prior to bundling the wire and winding the wire, there is no impregnation problem as the adhesive is already in place.
  • thermoset resin to provide strength to the windings and form the armature.
  • the preform can be simply supported or hung inside a resin impregnation chamber for impregnating the strands with the thermoset resin. Because the preform is already compressed and formed to the correct shape, no compression tooling is required. The absence of compression tooling during liquid resin impregnation allows the preform to be fully impregnated easily from all sides and it eliminates any lengthy required clean up of tooling.
  • the impregnated preform is then cured to form the final armature, which is a structurally solid ring of high windings density with small diameter individually insulated conductor strands.
  • the top coat adhesive comprises a
  • thermoplastic polymer that is activated at a certain activation temperature
  • the liquid resin comprises a thermoset polymer having a gelling temperature that is below the activation temperature of the top coat adhesive.
  • thermoset adhesive is preferably gelled at a temperature that is below the activation temperature o the thermoplastic top coat adhesive, or the temperature at which the preform strands would spring loose in the preform. Curing can be accomplished with most conventional impregnation resins by using an extended cure cycle at lower temperature or alternatively, a lower temperature curing resin such as some epoxies can be utilized. Once gelled, or rigidly solidified in correct dimensions, the armature can be post cured at an elevated temperature if desired.
  • the windings of the air core armature can be wound as individual coils that are assembled together or alternatively as serpentine shaped windings.
  • the windings are preferably wound as serpentines that make a continuous undulating pass around the circumference of the magnetic airgap.
  • the windings can form a complete ring when compressed in the preform that readily holds the complete armature dimensions.
  • the use of serpentine windings can further simplify the electrical connections for the armature windings. Only one serpentine winding, with only two winding ends is required for each phase. Each phase comprises a separate serpentine winding. This is in contrast to the potential for 20 windings and 40 winding ends for a single phase of a 20 pole coil wound motor-generator. Manufacturing time and cost are both greatly reduced while the complete armature is more likely to maintain accurate dimensions.
  • phase armatures can be produced by assembling multiple individual phase winding performs, or alternatively multiple phase windings can be wound together in a single preform.
  • the motor-generator has multiple phases and the phases are all impregnated together with liquid resin as a unitary armature.
  • the benefit of assembling all phases together prior to impregnation with the liquid resin is that each phase winding becomes integrally bonded to each other.
  • the bonds between phase end turns and phase active lengths reinforce each other to provide a structurally rigid armature, desirable for self-supporting use in dual rotor motor-generators.
  • the motor-generator utilizes multiple phases electrically connected together in a wye configuration and the wye connection is made at the free end of the air core armature. In a wye configuration, one lead from each phase winding is connected together at a center leg, as shown in the schematic diagram in U.S. Provisional Application No.
  • Eddy current losses in the armature windings are limited by the use of multiple smaller individually insulated strands to form the wire instead of a single larger solid conductor.
  • the strands may be assembled by several means so long as the hold together sufficiently to facilitate the winding process and preform compression process.
  • An additional desire is for the windings to readily allow liquid resin impregnation after compressed into the winding preform.
  • the bundled strands are twisted in one direction and groups of twisted strands are twisted in the opposite direction to form the wire.
  • the winding wire holds itself together for easy winding and compression.
  • the drawback with this construction is the greater expansion of the wire or diametral springiness.
  • the wire is still readily compressible into the preform by compression tooling pressure.
  • An additional advantage of the wire construction is that it creates greater paths between the small strands that assist the liquid resin impregnation process.
  • the preform holds its shape but contains substantial spaces between the wire strands.
  • the spaces are preferably all filled with the liquid thermoset resin and cured for increased strength, stiffness and heat conduction in the armature.
  • the spaces between the wire strands in the preform are preferably evacuated of air and filled with liquid resin during the impregnation of the preform to maximize resin filling and minimize voids in the armature. This impregnation of the preform can be conducted by pulling a vacuum on the preform in a vacuum pressure impregnation chamber.
  • the chamber is back filled with the resin and pressure applied to force the resin into the winding preform spaces.
  • the preform can then be cured into the final armature.
  • the vacuum pressure impregnation of the thermoset resin can fill in these defects for high dielectric strength of the phase windings.
  • a resin permeable wrap such as thread wrap or paper wrap can also be included on the winding wire to maintain impregnation while increasing inter- turn or inter-phase dielectric strength.
  • An additional benefit of the impregnation is increased thermal conductivity to the armature surfaces for more effective convection heat removal.
  • thermoplastic top coat adhesive can be activated by dipping the windings into a solvent or spraying solvent into the strands during the winding process. Due to environment issues, it can be more preferable to activate the thermoplastic adhesive by application of heat, such as using heated tooling or an oven.
  • the activatable top coat adhesive is heat activated and is activatable by applying electric current to the windings. The winding ends can be dipped in solder to assure good electric connection between all the multiple individual strands at each end of the phase windings.
  • Air core armature windings can be wound as helical patterns that are at acute angles with rotational axis and magnetic airgap, or in non-helical patterns.
  • the windings comprise active regions and end turns, wherein the active lengths of multiple phases are compressed to lie in a single layer prior to activating the top coat adhesive.
  • the end turns of multiple phases preferably lie out side the magnetic airgap and are thicker in the direction of the airgap than the active lengths that lie in the magnetic airgap and produce electromagnetic torque. Because the cost of the magnets is typically higher than the costs for the copper armature windings, we have found that this configuration is economically advantageous.
  • the magnetic airgap to be made the thinnest and the amount of magnet material to be minimized for a given level torque and efficiency.
  • the active lengths of multiple phases may bond together and the end turns of multiple phases can bond together in a single preform.
  • the resulting preform is thereby significantly more rigid and able to hold accurate dimensions through the liquid resin
  • the motor-generator can comprise a rotor and a stator, wherein the rotor rotates and comprises two spaced apart rotor portions having a circumferential array of alternating permanent magnet poles that drive magnetic flux back and forth between the rotor portions and defining an armature airgap therebetween.
  • the stator is stationary and comprises an air core armature with a free end for extending inside the armature airgap between the rotor portions and a support end that couples to the stationary portion of the motor-generator for transferring torque.
  • the air core armature is with wound with wire windings, wherein the wire is comprised of bundled multiple smaller individually insulated conductor strands that are electrically in parallel but are electrically insulated between each other along their length inside the armature airgap.
  • the insulated conductor strands are precoated with an activatable top coat adhesive prior to assembly of the wire and prior to winding the air core armature.
  • the air core armature is produced by the wire windings being wound, compressed into a serpentine shape and the top coat adhesive activated to form a winding preform, the compression being released to form a rigid circumferential continuous stator phase ring.
  • this continuous stator phase ring may be sufficiently strong and rigid for operation.
  • the strength of stator phase ring is preferably increased by secondary bonding through impregnation with a liquid resin as an additional embodiment.
  • the top coat adhesive comprises a thermoplastic polymer and the liquid resin comprises a thermoset polymer.
  • a thermoplastic resin for the conductor strand top coat allows the wire strands to have a long or infinite life and to be bonded together rapidly to form the preform.
  • the use of the thermoset liquid resin for secondary impregnation allows a much lower viscosity so that the resin can fully penetrate into the compressed preform strands and fill the voids between the strands and provide much higher armature strength.
  • the use of a vacuum and subsequent pressure to the liquid thermoset resin has surprisingly been found to be able penetrate very thick winding preforms and even ones wound with hundreds of small diameter wire strands such as size 40 AWG.
  • the air core armature wire windings are wound, compressed into a shape with tooling and bonded into a self-supporting preform structure with the top coat adhesive activated to allow the windings to maintain shape without tooling compression applied.
  • the windings have interstices between the strands impregnated with a liquid resin after the preform structure is removed from compression. The liquid resin is then cured for increasing the structural strength of the armature.
  • the air core armature is produced by said wire windings being wound, compressed into a preform shape and bonded together into a rigid self-supporting structure with a two-part bond.
  • the two-part bond includes a first bond utilizing a thermoplastic adhesive pre-coated on said windings and activated while the windings are under compression in the preform shape to produce a preform structure, and a second bond utilizes a thermoset adhesive applied after activation of the first bond and removal of the preform structure from compression.
  • the thermoset adhesive has a gelling temperature that is lower than the glass transition temperature of the thermoplastic adhesive. Polymers start to rapidly lose stiffness and strength at increasing temperatures at or below their glass transition temperature for the specific polymer.
  • the curing of the thermoset resin preferably includes a gelation period where the thermoset resin solidifies and this gelation occurs at a temperature that is below the glass transition temperature for the thermoplastic top coat adhesive that holds the windings preform in shape.
  • the air core armature wire windings are wound, and compressed into a preform shape and bonded together into a rigid self-supporting preform structure.
  • the bonding comprises impregnating the strands with a liquid thermoset resin and curing the resin.
  • the penetration of the impregnation of the strands is facilitated by the windings being precompressed and prebonded with tooling and a top coat adhesive on the strands activated, wherein the compression tooling is removed prior to the impregnation.
  • the ability to remove the tooling used for compressing the windings preform because the preform is partially prebonded by the strand top coat adhesive allows unimpeded impregnation of the armature by the liquid thermoset resin.
  • a further embodiment of the invention is a process for making a motor-generator winding comprising a stator phase ring with wire windings made of wire comprised of bundled multiple smaller individually insulated conductor strands that are electrically in parallel and are electrically insulated between each other along their length, wherein the insulated conductor strands are pre-coated with a thermoplastic top coat adhesive prior to bundling of the conductor strands.
  • the wire windings are wound into a winding pattern, and compressed while activating the top coat adhesive to bond the wire windings into a self supporting winding preform of bonded wire windings having open interstices between the wire windings.
  • thermosetting resin is cured to form a rigid circumferential continuous stator phase ring by gelling the thermosetting resin at a temperature below the activation temperature of the thermoplastic top coat adhesive.
  • the stator is inserted into a rotor portion having a circumferential array of alternating permanent magnet poles that drive magnetic flux in a flux path back and forth through the stator phase ring without passing through a ferromagnetic stator.
  • the stator phase ring is attached to stationary structure of the electrical machine to transfer torque.
  • the thermoplastic top coat adhesive sets the preform shape under compaction, and the thermosetting resin impregnates the interstices with reduced impediment from tooling used for compaction.
  • stator of the motor-generator is particularly advantageous in dual rotor motor- generators or motor-generators where the armature windings are self supporting or designs where circumferentially varying magnetic flux does not pass through a stationary ferromagnetic stator.
  • Fig. 1 is a schematic drawing of an air core motor-generator in accordance with the invention
  • Fig. 2 A is a schematic cross sectional view of the windings wire for an air core motor- generator in accordance with the invention
  • Fig. 2B is a schematic drawing of the construction of the windings wire for an air core motor-generator in accordance with the invention
  • Fig. 3 is a schematic drawing of an apparatus for performing a preform winding process for an armature for an air core motor-generator in accordance with the invention
  • Fig. 4 is a schematic drawing of an apparatus for performing a preform compression process for an armature for an air core motor-generator in accordance with the invention
  • Fig. 5 is a schematic drawing of a winding preform for a single phase of an air core motor-generator in accordance with the invention
  • Fig. 6 is a schematic drawing of 3 assembled preform phases for an armature of an air core motor-generator in accordance with the invention
  • Fig. 7 is a schematic drawing of an impregnation process for an armature preform for an air core motor-generator in accordance with the invention.
  • Fig. 8A is a cross sectional view of three of the windings wires of an armature during the preform winding process for an air core motor-generator in accordance with the invention
  • Fig. 8B is a cross sectional schematic view of the windings wire of an armature during the preform compression process for an air core motor-generator in accordance with the invention
  • Fig. 8C is a cross sectional schematic view of the windings wire shown in Fig. 8B upon completion of the impregnation process;
  • Fig. 9 is a comparison plot of the armature windings density between prior art dual rotor air core motor generators and an air core motor-generator in accordance with the invention.
  • Fig. 10 is a comparison plot of the adhesive volume fractions in the windings between the preform and the finished resin impregnated armature for an air core motor-generator in accordance with the invention
  • Fig. 11 is a comparison plot of the armature bending strength of the windings between the preform and the finished resin impregnated armature for an air core motor-generator in accordance with the invention
  • Fig. 12 is a schematic drawing showing the steps of a manufacturing process for an air core motor-generator in accordance with the invention.
  • Fig. 13 is a schematic drawing of an alternate configuration of an air core motor- generator in accordance with the invention.
  • Fig. 14 is a comparison plot of the armature eddy current losses between a solid wire armature and an air core motor-generator in accordance with the invention.
  • Fig. 15 is a comparison plot of the manufacturing labor time between a prior art air core armature and an armature for an air core motor-generator in accordance with the invention. Description of the Preferred Embodiments
  • FIG. 1 shows an air core motor-generator 30 having a rotor 31 mounted for rotation on a shaft 37 relative to and a stator 32.
  • the rotor 31 is constructed of two spaced apart circular rotor portions 33, 34 with circumferential arrays of alternative polarity magnets 35, 36 that drive magnetic flux on a flux path back and forth across an armature airgap 43 defined between the two rotor portions 33, 34.
  • the shaft 37 is journaled for rotation by bearings 38, 39 that are mounted in housing end plates 40, 41.
  • the end plates 40, 41 are attached together by an outer cylindrical housing tube 42.
  • an air core armature 44 is attached at its outer periphery to the outer cylindrical housing tube 42 and extends into the armature airgap 43, terminating in an inner free end.
  • the electrical wires 45 from the armature 44 exit the housing tube 42 through a strain relief 46.
  • Fig. 2A illustrates windings wire for an air core motor-generator in accordance with the invention, such as the axial gap motor-generator shown in Fig. 1 and the radial gap motor generator shown in Fig. 13.
  • the winding wire 50 is comprised of a bundle of multiple smaller individually insulated conductor strands 51.
  • the strands 51 each include a top coat adhesive layer, indicated in Figs. 4 and 5 as a slight texturing of the surface of the windings wire 50.
  • the adhesive is preferably a thermoplastic or polymer with long shelf life such as polyvinyl butyral or polyamide.
  • the top coat adhesive is applied to the conductor strands 51 prior to assembly of the wire 50.
  • the wire 50 is constructed of bundled individually insulated fine gauge conductor strands 51.
  • the strands 51 may be bundled together in several different ways.
  • the wire 50 is bundled such that it holds together for the winding process.
  • the wire 50 is comprised of strands 51 that are twisted together in groups 52 and the groups 52 of twisted strands are twisted together to form the wire.
  • the groups of strands 52 can be twisted together to form the wire 50 in the opposite direction as the twisting of the individual strands 51 together to form the individual groups 52.
  • This configuration allows the conductors to be transposed for low losses and also holds the wire 50 together for easier winding.
  • the construction also provides channels for easier resin impregnation later.
  • This wire is made especially for use in motor-generators in accordance with this invention by New England Electric Wire Corp. in Lisbon, New Hampshire.
  • FIG. 3 schematically illustrates an apparatus 60 for performing a preform winding process for an armature for an air core motor- generator in accordance with the invention, such as that shown in Fig. 1.
  • the winding process (referred to herein as process 60')comprises drawing the wire 50 from a spool 61 onto a winding machine 64.
  • the winding machine 64 utilizes multiple retractable pins 63 that the wire 50 is wound around. After several passes around the diameter of the pins 63 equaling the number of winding turns, the pins 63 are retracted so that the wire 50 can be compressed onto a center tool 62 with profile in the desired shape of the finished windings.
  • FIG. 4 A schematic drawing of an apparatus 70 for performing a preform compression process for an armature for an air core motor-generator in accordance with the invention is shown in Fig. 4.
  • the compression process (referred to herein as 70') comprises compressing the windings wire 50 onto the center tool 62.
  • the wire 50 is compressed by outer tools 71 with the correct profile of the windings preform.
  • the outer tools 71 are pressed inward toward the center tool 62 by pneumatic cylinders 72.
  • the top coat adhesive on the wire strands is activated.
  • the activation can be done by application of a solvent but is more preferably completed by application of heat to the tooling.
  • the activation is conducted by passing a set electric current through the wire 50 for a set period of time that raises the wire temperature sufficiently to bond the strands together. After activation, the wire 50 is cooled and the outer tools 71 are retracted. The phase winding preform is removed from the center tool 62 and has a rigid accurate windings structure.
  • Fig. 5 illustrates a winding preform 80, such as the preform made by the process illustrated in Fig.4.
  • the winding preform 80 is a complete ring around the circumference of the magnetic airgap when later inserted into the motor generator.
  • the preform 80 can be a single phase, as shown, or alternatively multiple phases can be formed together in a single preform with a more involved winding process.
  • the preform 80 comprises the compressed and partially bonded windings wire 50 from activation of the top coat adhesive on the strands.
  • the preform 80 also comprises the two winding ends 81 and 82 for each phase.
  • Fig. 6 illustrates three assembled preform phases 90, such as the preform phase shown in Fig. 5, for an armature of an air core motor-generator in accordance with the invention, such as the motor generator shown in Fig. 1.
  • the phase preforms are fabricated individually, they are preferably assembled and secured together, for example with fiberglass tape, prior to the liquid resin impregnation. By assembly prior to impregnation, the impregnation resin can bond all the phases together for increases rigidity and strength.
  • the assembled preforms 90 can include three phase preforms 80 in most cases to produce a three phase motor-generator.
  • the free end winding leads are all coupled together at 82 at the unsupported end of the finished armature as the center of a wye connection. This eliminates the need for overlapping of the winding turns to run all leads out of the armature airgap and simplifies construction by eliminating the need for any lead to connect the free end of the three phases to the electrical wire 45 for the armature.
  • FIG. 7 A schematic drawing of an apparatus 100 for performing an impregnation process for an armature preform for an air core motor-generator in accordance with the invention is shown in Fig. 7.
  • impregnation of the preform with liquid thermoset resin could be done by trickle impregnation, we have found that it is difficult to get complete impregnation of all the tightly compacted strands that are partially prebonded together.
  • the preform is completely impregnated for highest strength by vacuum pressure impregnation.
  • impregnation process (referred to herein as 100') as performed by the apparatus 100 comprises hanging the preform inside a vacuum pressure impregnation chamber 101.
  • a vacuum pump 102 pulls a vacuum on the chamber 101 and thereby pulls all the air out of the spaces within the preform.
  • An attached resin reservoir 103 then back fills the chamber with the thermoset resin so that the preform is submerged.
  • a pressure pump 104 applies additional pressure to the resin to force resin into all the spaces between the preform strands. Heat may also be applied during the impregnation process to drive out moisture.
  • the preform can be moved to a curing oven 105.
  • the impregnated preform is preferably gelled at a temperature below the activation temperature of the thermoplastic resin so that the preform does not lose its shape prior to the thermoset resin hardening.
  • FIGs. 8A, 8B and 8C Schematic drawings of the windings wire 50 of an armature during the preform winding process 60', preform compression process 70', and completion of the impregnation process 100' for an air core motor-generator in accordance with the invention are shown in Figs. 8A, 8B and 8C.
  • the winding process 60' lays together multiple turns of the winding wire 50 that has loosely held individual strands 51.
  • the preform compression process 70' compressed the strands 51 tightly together in the desired finished armature shape and windings density.
  • the top coat adhesive on the strands is activated so that the windings hold their shape after the compression pressure is released.
  • the impregnation process 100' fills the spaces between the strands 51 with a liquid thermoset resin which is cured to form the rigid, high strength and high efficiency self supporting air core armature.
  • FIG. 9 A comparison plot of the armature windings density between prior art dual rotor air core motor generators and an air core motor-generator in accordance with the invention is shown in Fig. 9.
  • the comparison plot 110 shows a prior art air core armature wound with multiple individually electrically insulated strand conductors that do not have a top coat activatable adhesive. The strands are not able to be precompressed and prebonded into a windings preform prior to liquid resin impregnation.
  • the prior art armature windings density 111 in the finished armature is 28%.
  • the armature in accordance with the invention is formed in a multiple step process utilizing a top coat adhesive on the conductor strands.
  • the wire is compressed and prebonded into a high density winding preform.
  • the preform is impregnated with a liquid thermoset resin to form the completed armature.
  • the armature in accordance with the invention 112 has a windings density of 64%.
  • the higher windings density allows for increased copper per magnetic airgap or higher efficiency and power density per cost. Higher windings density also improves thermal conductivity through the windings for better heat removal.
  • FIG. 10 A comparison plot of the adhesive volume fractions in the windings between the preform and the finished armature for an air core motor-generator in accordance with the invention is shown in Fig. 10.
  • the comparison 120 shows that the adhesive volume fraction in the preform 121, which consists of only the top coat adhesive on the strands, is about 11%. This amount of adhesive is sufficient to hold the strands together in the preform shape as compressed, such that compression pressure can be released without the windings deforming.
  • the preform adhesive After the preform adhesive has set, the preform is removed from compression and is impregnated with a liquid thermoset resin to fully impregnate the windings for high strength.
  • the finished armature 122 has an adhesive volume fraction preferably several times higher than the preform, such as 40%, for some completed armatures.
  • FIG. 11 A comparison plot of the armature bending strength of the windings between the preform and the resin impregnated and cured armature for an air core motor-generator in accordance with the invention is shown in Fig. 11.
  • a section of an air core armature winding preform was cut and strength measured in a three point bending fixture and compared with the strength of a section of the finished armature.
  • the section of preform 131 had a bending strength of 7.1 lbs offeree.
  • the section of finished armature 132 had a bending strength about five times higher at 37.6 lbs.
  • FIG. 12 A schematic drawing of the motor manufacturing process for an air core motor-generator in accordance with the invention is shown in Fig. 12.
  • the process 140 comprises soldering the wire winding ends 141 by dipping the bundle of multiple individually insulated conductor strands into a solder pot so that the strands are all electrically connected together in parallel but are electrically insulated between each other along their length where they will be in the magnetic airgap.
  • the wire is then wound with tooling in step 142, such as the winding apparatus 60 shown in Fig. 3, to the winding pattern.
  • the preferred winding shape is a serpentine pattern like that shown in Fig. 5, that allows the minimum number of winding ends and electrical connections.
  • the windings are compressed in step 143 into a compacted and accurate windings shape, for example, using the apparatus 70 shown in Fig. 4.
  • the top coat adhesive on the strands is activated in step 144 to prebond the strands together.
  • the compression is removed in step 145 resulting in a windings preform with the correct winding shape and dimensions.
  • Multiple phase preforms are assembled together in step 146.
  • the assembled preforms are hung in an impregnation chamber in step 147 and a vacuum is applied in step 148 to the winding preforms to remove air from the interstices between the strands.
  • the windings are impregnated in step 149 with a thermoset liquid resin.
  • the impregnated preform is oven cured in step 150 to form the completed armature.
  • the air core armature is installed 151 in the magnetic airgap of the motor-generator.
  • FIG. 13 A schematic drawing of an alternate configuration of an air core motor-generator 160 in accordance with the invention is shown in Fig. 13.
  • the motor-generator 160 utilizes a radial magnetic airgap and has an air core armature 174 that is constructed as a tube instead of as a disc, which is the shape of the armature of the axial magnetic airgap motor-generator 30 shown in Fig. 1.
  • the motor-generator 160 is comprised of a rotor 161 having two spaced apart cylindrical rotor portions 162, 163.
  • the rotor portions have circumferential arrays of alternating permanent magnet poles 164, 165 that drive magnetic flux back and forth in a flux path through the air core armature 174.
  • the air core armature 174 is located within the magnetic armature airgap 166 between thee two rotor portions 162, 163.
  • the rotor could alternatively utilize only a single rotor portion with the air core armature so long circumferentially varying magnetic flux does not pass through a stationary ferromagnetic stator.
  • the use of two rotor portions typically provides a much higher magnetic flux density through the windings because the magnetic flux jumps a smaller and defined air path for higher efficiency and power density.
  • the two rotor portions 162, 163 are coupled together by a hub 167 that attaches to a center shaft 168.
  • the shaft 168 is journaled for rotation by bearings 169, 170.
  • the bearings 169, 170 are mounted in stator housing endplates 171, 172.
  • the endplates 171, 172 are attached together by an outer stator housing tube 173.
  • Electromagnetic toque production is created by the air core armature 174 that has a fixed end supported by the stator housing endplate 172.
  • the armature 174 comprises multiple phases and the winding active lengths of each of the phases are compressed to lie in a single layer 175 where in the magnetic airgap 166.
  • the end turns 176, 177 of multiple phases overlap and are thicker outside the magnetic airgap 166.
  • Armature leads 178 exit the stator housing 172 through a strain relief connector 179.
  • Air core motor-generators have been constructed with high winding density through use of solid conductor wmdings.
  • Solid conductor winding wire can provide low resistive losses and can be bent to more accurately hold a desired winding pattern for unsupported resin
  • FIG. 14 A comparison plot of the armature eddy current losses between a solid wire armature and an air core motor-generator in accordance with the invention is shown in Fig. 14.
  • the comparison 190 is for a 1 hp, 3600 rpm motor, both with the same rotor and armature windings pattern.
  • the solid wire motor 191 using a single 14 AWG size wire generates 421 watts of armature eddy current losses.
  • the motor-generator in accordance with the invention 192 using 90 individually insulated strands of 36 AWG wire, produces only 2.3 watts of armature eddy current loss.
  • FIG. 15 A comparison plot of the process labor time between a prior art air core armature and an armature for an air core motor- generator in accordance with the invention is shown in Fig. 15.
  • the comparison 200 shows the prior art manufacturing of particular armature utilizing molding tooling is about 180 minutes.
  • the process labor includes inserting windings into a mold, removing the armature after impregnated and cured and cleaning up and preparing the mold tooling.
  • the process labor time for the new motor-generator 202 is in comparison only 10 minutes.
  • the process labor includes transferring the preform from the winding and compression machine to the impregnation tank and later removing the finished armature from the impregnation tank.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

L'invention porte sur un moteur-générateur comprenant un stator fixe, un rotor qui est supporté pour tourner par rapport au stator et qui a deux parties rotor espacées ayant elles- mêmes une série circonférentielle de pôles d'aimant permanent alternés qui engendrent un flux magnétique alternant entre lesdites parties rotor, et qui définissent un entrefer d'armature entre les pôles. Le stator comprend une armature à noyau d'air comportant une extrémité libre qui s'étend à l'intérieur d'un entrefer d'armature et une extrémité support fixée à la partie fixe du moteur-générateur pour la transmission du couple. L'armature à noyau d'air est bobinée avec des enroulements de fil faits de multiples torons conducteurs de petites dimensions isolés individuellement qui sont pré-revêtus d'un adhésif de revêtement supérieur pouvant être activé, avant d'assembler ledit fil et pour le bobinage de ladite armature à noyau d'air. Les enroulements de fil sont enroulés et comprimés sous une forme de bobines préformées et ils sont maintenus sous la forme de bobine par l'adhésif de revêtement supérieur qui est activé après le bobinage et la compression.
PCT/US2010/002685 2009-10-02 2010-10-04 Moteur-générateur sans balais WO2011040982A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US27817409P 2009-10-02 2009-10-02
US61/278,174 2009-10-02
US34347710P 2010-04-28 2010-04-28
US61/343,477 2010-04-28

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WO2013169945A1 (fr) * 2012-05-09 2013-11-14 Thingap, Llc Stator composite pour une conversion de puissance électromécanique
EP2810360A4 (fr) * 2012-02-02 2016-01-27 Smartmotor As Segment moulé pour un système de conversion d'énergie et production de ce segment
US9461508B2 (en) 2012-05-30 2016-10-04 Prototus, Ltd. Electromagnetic generator transformer
US10243440B2 (en) 2010-12-08 2019-03-26 Floor 36, Inc. Electromagnetic generator and method of using same
DE102018208414A1 (de) * 2018-05-28 2019-11-28 Thyssenkrupp Ag Verfahren zur Herstellung von Formlitze, Verfahren zur Herstellung eines Elektromotors, sowie Verwendung von Formlitze

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US6066908A (en) * 1998-09-14 2000-05-23 Woodward, Jr.; Richard C. Disc-type brushless alternator
US20050099085A1 (en) * 2003-09-05 2005-05-12 Du Hung T. Electric motor having a field assembly with slot insulation
US20090200889A1 (en) * 2008-02-08 2009-08-13 Empire Magnetics Inc. Nested Serpentine Winding for an Axial Gap Electric Dynamo Machine
US20090224092A1 (en) * 2008-03-05 2009-09-10 Denso Corporation Weaving machine for coil assembly of rotary electric machine

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US5319844A (en) * 1985-12-23 1994-06-14 Unique Mobility, Inc. Method of making an electromagnetic transducer
US6066908A (en) * 1998-09-14 2000-05-23 Woodward, Jr.; Richard C. Disc-type brushless alternator
US20050099085A1 (en) * 2003-09-05 2005-05-12 Du Hung T. Electric motor having a field assembly with slot insulation
US20090200889A1 (en) * 2008-02-08 2009-08-13 Empire Magnetics Inc. Nested Serpentine Winding for an Axial Gap Electric Dynamo Machine
US20090224092A1 (en) * 2008-03-05 2009-09-10 Denso Corporation Weaving machine for coil assembly of rotary electric machine

Cited By (13)

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Publication number Priority date Publication date Assignee Title
US11139726B2 (en) 2010-12-08 2021-10-05 Prototus, Ltd. Electromagnetic generator and method of using same
US10243440B2 (en) 2010-12-08 2019-03-26 Floor 36, Inc. Electromagnetic generator and method of using same
US11705797B2 (en) 2010-12-08 2023-07-18 Prototus, Ltd. Electromagnetic generator and method of using same
EP2810360A4 (fr) * 2012-02-02 2016-01-27 Smartmotor As Segment moulé pour un système de conversion d'énergie et production de ce segment
US9425664B2 (en) 2012-05-09 2016-08-23 Thingap, Llc Composite stator for electromechanical power conversion
WO2013169945A1 (fr) * 2012-05-09 2013-11-14 Thingap, Llc Stator composite pour une conversion de puissance électromécanique
US9461508B2 (en) 2012-05-30 2016-10-04 Prototus, Ltd. Electromagnetic generator transformer
US10978922B2 (en) 2012-05-30 2021-04-13 Prototus, Ltd. Electromagnetic generator transformer
US11699927B2 (en) 2012-05-30 2023-07-11 Prototus, Ltd. Electromagnetic generator transformer
US10250086B2 (en) 2012-05-30 2019-04-02 Prototus, Ltd. Electromagnetic generator transformer
WO2019228923A1 (fr) * 2018-05-28 2019-12-05 Thyssenkrupp Ag Procédé pour la fabrication d'un toron profilé, procédé pour la fabrication d'un moteur électrique ainsi qu'utilisation d'un toron profilé
DE102018208414A1 (de) * 2018-05-28 2019-11-28 Thyssenkrupp Ag Verfahren zur Herstellung von Formlitze, Verfahren zur Herstellung eines Elektromotors, sowie Verwendung von Formlitze
US11728714B2 (en) 2018-05-28 2023-08-15 Jheeco E-Drive Ag Method for producing compressed strand

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