WO2011047425A1 - Machine électrique tournante améliorée et son procédé de fabrication - Google Patents

Machine électrique tournante améliorée et son procédé de fabrication Download PDF

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Publication number
WO2011047425A1
WO2011047425A1 PCT/AU2010/001391 AU2010001391W WO2011047425A1 WO 2011047425 A1 WO2011047425 A1 WO 2011047425A1 AU 2010001391 W AU2010001391 W AU 2010001391W WO 2011047425 A1 WO2011047425 A1 WO 2011047425A1
Authority
WO
WIPO (PCT)
Prior art keywords
magnetisable
electric machine
stator
series
pole
Prior art date
Application number
PCT/AU2010/001391
Other languages
English (en)
Inventor
David Gehlert
Matthew Smith
Nesimi Ertugrul
Original Assignee
Intelligent Electric Motor Solutions Pty Ltd
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
Priority claimed from AU2009905104A external-priority patent/AU2009905104A0/en
Application filed by Intelligent Electric Motor Solutions Pty Ltd filed Critical Intelligent Electric Motor Solutions Pty Ltd
Publication of WO2011047425A1 publication Critical patent/WO2011047425A1/fr

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
    • H02K1/148—Sectional cores
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
    • H02K2203/12—Machines characterised by the bobbins for supporting the windings

Definitions

  • This invention relates to an electric machine. While throughput this document description is provided for that suggests the machine is a motor, the reverse operation as an electric generator is equally as applicable. Therefore the term motor and generator should be read as being synonymous.
  • this invention relates more particularly to brushless DC electric motors and more particularly to the manufacturing of modulated electric DC motors that can be easily constructed to provide a variety of definable total power using the same single modulated pieces of the stator frame that are put together to construct the motor.
  • stator frame has major shortcomings, not the least being the significant amount of scrap that is generated in the punching operation. Still further, the conglomeration of laminated steel sheets, when constructed in its complete stator frame, then has to have wound coils positioned about the respective salient poles of the stator.
  • bonded or moulded iron is produced by mixing iron powder with a binder, to insulate the iron particles from one another, and t en subjecting the mixture to high pressures and temperature within a dye.
  • pressed powdered iron lacks the strength one would associate with conventional laminated steel structure of the stator.
  • a mould of a stator, or a stator frame is in fact just that.
  • one motor casing has a corresponding sized stator frame. That means for every electric motor casing there has to be a set stator frame which corresponds to a certain wattage capacity.
  • an electric motor having a series of independent stator magnetisable pole members made of soft magnetic composite material
  • each independent stator magnetisable pole member can be placed adjacent to another independent stator magnetisable pole member to provide a substantially cylindrical shape enclosable within a housing body;
  • stator magnetisable pole member wherein before each individual magnetisable pole member is configured into the cylindrical form, said stator magnetisable pole member is pre-wound with coiling to which current may be passed therethrough.
  • stator frame has now become modulated which means that the individual salient pole stators that make up. the stator frame can now be pre- wound before they are configured into their substantially cylindrical stator frame.
  • the pressing out of a substantially cylindrical steel laminated stator frame not only has cost problems associated with the wastage of cut steel, but also significantly the difficulties associated then winding the coils about the individual magnetisable pole members of the stator frame.
  • the or each stator magnetisable pole member has an inner inner rim and an outer rim separated by a longitudinal column to which the coil can then be pre-wound thereabouts said column before each stator pole member is fixedly supported within the enclosed housing body.
  • the longitudinal column is of a length so that the wound coil need not extend out over and above the inner inner rim and rim, thereby providing for a more compact stator frame.
  • the ability to reduce the dimensions of the longitudinal column joining together the outer and inner rims or shoulders of each pole member means that all the copper windings are being efficiently used.
  • the cylindricaHy formed stator frame constructed of the individual stator magnetisable pole members pre-wound with the coils as introduced above, are in electrical communication with a corresponding cylindrical stator frame constructed using the same sfator magnetisable pole members as introduced above.
  • stator frame made up of the individual stator magnetisable pole members can see longitudinal poles made up of separate magnetisable pole members, each with their own separate wound coils.
  • further individual moulds could be provided for that see the longitudinal column joining together the inner rim and the rim without the indent at the upper edge, thereby allowing a single wound coil about the entire longitudinal length of individual independent stator magnetisable pole members that have been stacked one onto the other.
  • any stacking of one cylindrical stator frame made up of the independent individual stator magnetisable pole members could also correlate in extending the length of the rotor which may or may not be made up of permanent magnetic pole pieces.
  • the rotor having permanent magnetic pole pieces is also of a modular configuration wherein the permanent magnetic pole pieces can be added in segments wherein the amount of segments of the permanent magnetic pole pieces of the rotor would be relative to the layers of cylindrical stator frames that have been constructed through use of the individual stator magnetisable pole members.
  • an insulating method and process for the pole pieces In preference also included is an insulating method and process for the pole pieces.
  • the conventional insulation used to insulate the windings from the core can be eliminated by providing a paint based insulation material that can be integrated into the manufacturing process.
  • the modulated pole pieces before or after winding maybe be potted into a form of adhesive to prevent these modulated pieces from parting one from the other within the configured stator, for example in the case of breaking when dropped or so forth or during excessive vibration.
  • Figures 1a to 1d is a perspective view of the pressed powdered iron formed individual stator magnetisable pole members in preferred embodiments of this invention.
  • Figure 2 is a top view of Figure 1a.
  • Figures 3a and 3b show the individual stator magnetisable pole members of Figure 1 without the longitudinal column with a reduced length, thereby allowing the wound coils to extend over and above the stator magnetisable pole members, which is similar to conventional machines of the prior art.
  • Figure 4 shows a perspective view of the individual stator magnetisable pole members with the coil pre-wound thereabouts the longitudinal column.
  • Figure 5 shows a perspective view of one preferred embodiment of this invention wherein individual stator magnetisable pole members are stacked one onto the other.
  • Figures 6 and 7 show part cutaway views of the electric motor of the formation of the substantially cylindrical stator frame being created about the rotor where the individual stator magnetisable pole members themselves can be of a varying longitudinal pole length or size.
  • Figure 8 shows a perspective view of the formation of an electric motor wherein the stator magnetisable pole members are stacked one on top of the other to increase the wattage capacity of the electric motor.
  • Figures 9a and 9b show how one longitudinal length of a cylindrical stator frame can be constructed using the individual module pieces.
  • Figures 10a to 10g schematically show a method of manufacturing of creating a substantially cylindrical stator frame using the individual stator magnetisable pole pieces.
  • Figures 11 a to 11 d show a further preferred embodiment of an alternative method of forming a substantially cylindrical stator frame made up of the stator magnetisable assembling pole pieces.
  • Figures 12a to 12d show various schematic representations of the rotor having in this preferred embodiment, modulated permanent magnetic pole pieces upon the rotating shaft.
  • Figure 13 shows an exploded view of the rotor being introduced into the cylindrical stator frame.
  • Figures 14a to 14d show various numbered slots for the stator to disappear into the cylindrical stator frame made up of the individual stator magnetisable pole pieces forming the electric motor.
  • Figure 15a shows a further preferred embodiment where in this embodiment the individual stator magnetisable pole pieces has the inner rim pole slightly skewed to reduced effects of cogging and figure 15b has both the pole and the stator configuration skewed.
  • FIG. 1 a perspective view of the individual stator magnetisable pole piece which is made of soft magnetic composite flexible material shown generally as ( 0).
  • this kind of pole piece (10) would be formed from some type of pressed powdered iron into its moulded or shaped form. As can be seen clearly, at least with reference to Figures 1a and 4, the pole piece (10) has a inner inner rim (14) and an outer rim or edge (12).
  • the inner inner rim (14) has a main face (23) orientated such that when the substantially cylindrical stator frame has been created by bringing together the individual stator magnetisable pole pieces (10), it will align itself radially about part of the rotor with the permanent magnetic pole pieces.
  • the stator magnetisable pole piece (10) has its external inner surface (22) which includes longitudinal tabs (24a) and (24b) which may or may not be used to support the individual stator magnetisable pole member when the cylindrical stator frame was being constructed as it becomes enclosed in its steel or metal enclosure within the electric motor.
  • tabs 24a
  • 24b longitudinal tabs
  • FIG 1c this embodiment has a slot (29) which can engage a protrusion (not shown) to hold in place.
  • figure 1d shows not tabs or slots and presents a flat face (33).
  • the longitudinal column (16) connecting both the rim and the inner rim (12) and (14) respectively is that this longitudinal column (16) has a reduced length thereby creating spacings (18) and (20) such that when the windings (32), as best seen in Figure 4, are wound about this longitudinal column (16), the copper wires do not extend beyond the magnetisable pole member which is the case in Figures 3a and 3b.
  • the modulated pieces do not have the longitudinal column of a varying length and therefore the copper windings extend well beyond the longitudinal length of individual stator magnetisable pole members.
  • the embodiment shown in Figures 3a and 3b would mean that there is a substantial wastage of copper and also the size of cylindrical stator frame is increased, thereby meaning that any motor will be of a larger length, corresponding to a larger size and therefore greater weight.
  • the copper windings (28) shown in Figures 3a and 3b make no electric use in relation to the copper extending as shown on the figures as (30a) and (30b) and therefore a waste of copper which contributes to an unnecessarily larger sized cylindrical stator frame.
  • the top view of Figure 2 also shows some of the unique curvature which is allowed for by being able to individually mould the stator magnetisable pole members using the pressed powdered soft iron.
  • the improved curvature provided means that windings can be made bout the pole members without sharp corners which is more the case when laminated steel is used for the stator frame.
  • statpr magnetisable pole members by having the curved surfaces of the moulded individual statpr magnetisable pole members means that less insulation can then be afforded to the copper wiring which forms the wound coil about each of the respective stator magnetisable pole members. With less insulation more copper can be used, and hence better efficiency.
  • Insulation can be in the form of paint with a method of insulation including dipping the article into the paint and covering up those section not requiring insulation.
  • Figures 5 and 8 show that the individual magnetisable pole members (10) have been pre-wound with the coil (32) make for a compact modulated piece which can be stacked one onto the other and thereby present a stator frame almost layered in structure to increase wattage capacity of the electric motor.
  • the rotor (50) of the electric motor can also have modulated pieces of the permanent magnetic pole pieces that make up the rotor (50) portion of the electric motor.
  • the rotor so too can be constructed with individual permanent magnetic pole pieces as shown at (46) and (48).
  • FIGs 6 and 7 are fairly similar in construction with the only point of difference being that the individual stator magnetic pole piece (10) and the only difference being the length of the pole pieces and related dimensions.
  • stator magnetisable pole pieces need not be of one longitudinal length they can also be extended in length or as shown in Figure 8 they can simply have an increased longitudinal length by stacking one stator magnetisable pole member on top of another.
  • stator frame made up of the stator magnetisable pole members relative to a layer below is that the corresponding upper and lower stator magnetisable pole members could be slightly offset radially thereby altering the magnetic flux orientation presenting itself to the rotating permanent magnets of the rotor thereby reducing a certain amount of the cogging effect lowering the motor performance.
  • Figures 9a and 9b show how the height of the cylindrical stator frame can be constructed.
  • Respective pieces can then be joined end to end as shown in Figure 9b with the coils (56) then being wound thereabout.
  • This prepared length shown generally as (58) in Figures 10a through to 10g can be then formed into this substantial cylindrical stator frame.
  • the individual module pieces (10) will be placed and glued on a soft plastic thermally conductive mat (60).
  • the flat mat (60) could also be used to perform winding configurations to the coils about these modulated stator magnetisable pole members.
  • the mat (60) will have male dovetails as an integral part of the mat which will be positioned to the correct distance to slide or push the adjacent poles together. All the long pole pieces will be attached to the mat to achieve a given motor size as illustrated best in Figures 10a through to 10g.
  • the mat (60) will be of a slightly smaller dimension than the total flat surface occupied by the poles.
  • the motor housing will be made from a steel tube or an aluminum tube (62).
  • pole pieces with the mat (60) will be inserted into the stator steel enclosure (62) with this steel enclosure off slightly longer dimension than the poles on both sides to assemble the end caps.
  • the enclosed steel frame can then under suitable pressure be joined using a variety of conventional wires including a welding line (64).
  • FIGS 11a through to 11d show another method of forming the substantially cylindrical stator frame wherein there would be a holding magnetisable bracket (61) with ends (63) and (65) to which the length (58) of the stator magnetisable pole members would be positioned thereabout.
  • Ends (63) and (65) can be made permanent magnets or electromagnets.
  • Figures 12a through to 12b simply show that the rotor (72) can be constructed using modulated permanent magnetic pole pieces (68) to form the single length (70) required to be included onto the shaft (72) which as shown in Figure 13 can then be inserted into the cylindrical stator frame.
  • Figures 14a through to 14d show varying number of slotted pole members including eight pole (80), a ten pole (82), twelve pole (83) and a fourteen pole (86).

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

L'invention porte sur une machine électrique, qui comporte une série d'éléments de pôle magnétisables de stator indépendants réalisés à l'aide d'un élément de pôle en matériau composite magnétique doux, qui peut être disposé au voisinage d'un autre élément de pôle de façon à produire une forme sensiblement cylindrique lorsque la série d'éléments de pôle magnétisables de stator indépendants sont arrondis ou configurés sous la forme sensiblement cylindrique, et dans laquelle, ensuite, les éléments de pôle peuvent être renfermés à l'intérieur d'un corps de boîtier de la machine électrique, de telle sorte que, avant que chaque élément de pôle magnétisable individuel de la série d'éléments de pôle magnétisables de stator indépendants soit configuré ou arrondi sous la forme sensiblement cylindrique, ladite série d'éléments de pôle magnétisables de stator indépendants sont pré-bobinés avec des enroulements dans lesquels un courant peut circuler à travers ledit enroulement lorsque ladite machine est en utilisation.
PCT/AU2010/001391 2009-10-20 2010-10-20 Machine électrique tournante améliorée et son procédé de fabrication WO2011047425A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2009905104 2009-10-20
AU2009905104A AU2009905104A0 (en) 2009-10-20 An improved rotating electric machine and method of manufacture thereof

Publications (1)

Publication Number Publication Date
WO2011047425A1 true WO2011047425A1 (fr) 2011-04-28

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2511421A (en) * 2013-01-24 2014-09-03 Gkn Evo Edrive Systems Ltd Electrical machines
WO2018025035A1 (fr) * 2016-08-03 2018-02-08 Intelligent Electric Motor Solutions Pty Ltd Machines électriques

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20020093269A1 (en) * 2001-01-16 2002-07-18 Harter Bernard G. Slot area undercut for segmented stators
US20080174200A1 (en) * 2007-01-19 2008-07-24 Fanuc Ltd Method of manufacturing rotor of electric motor and electric motor
US7567010B1 (en) * 2008-04-10 2009-07-28 Burgess-Norton Mfg. Co., Inc Modular electric motor with stackable stator poles

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20020093269A1 (en) * 2001-01-16 2002-07-18 Harter Bernard G. Slot area undercut for segmented stators
US20080174200A1 (en) * 2007-01-19 2008-07-24 Fanuc Ltd Method of manufacturing rotor of electric motor and electric motor
US7567010B1 (en) * 2008-04-10 2009-07-28 Burgess-Norton Mfg. Co., Inc Modular electric motor with stackable stator poles

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2511421A (en) * 2013-01-24 2014-09-03 Gkn Evo Edrive Systems Ltd Electrical machines
GB2511421B (en) * 2013-01-24 2015-08-12 Gkn Evo Edrive Systems Ltd Stators for electrical machines
WO2018025035A1 (fr) * 2016-08-03 2018-02-08 Intelligent Electric Motor Solutions Pty Ltd Machines électriques
US10951076B2 (en) 2016-08-03 2021-03-16 Intelligent Electric Motor Solutions Pty Ltd Electric machines

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