WO2014080183A1 - Machines électriques à flux axial - Google Patents
Machines électriques à flux axial Download PDFInfo
- Publication number
- WO2014080183A1 WO2014080183A1 PCT/GB2013/053008 GB2013053008W WO2014080183A1 WO 2014080183 A1 WO2014080183 A1 WO 2014080183A1 GB 2013053008 W GB2013053008 W GB 2013053008W WO 2014080183 A1 WO2014080183 A1 WO 2014080183A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- stator
- cover
- machine
- housing
- shaft
- Prior art date
Links
- 238000004804 winding Methods 0.000 claims abstract description 51
- 230000004907 flux Effects 0.000 claims abstract description 28
- 238000004519 manufacturing process Methods 0.000 claims abstract description 23
- 239000004020 conductor Substances 0.000 claims abstract description 10
- 239000000463 material Substances 0.000 claims description 17
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 8
- 239000004033 plastic Substances 0.000 claims description 8
- 229920003023 plastic Polymers 0.000 claims description 8
- 239000002131 composite material Substances 0.000 claims description 7
- 239000012530 fluid Substances 0.000 claims description 7
- 238000000034 method Methods 0.000 claims description 5
- 239000011347 resin Substances 0.000 claims description 5
- 229920005989 resin Polymers 0.000 claims description 5
- 238000001816 cooling Methods 0.000 claims description 4
- 229910052742 iron Inorganic materials 0.000 claims description 4
- 229910000576 Laminated steel Inorganic materials 0.000 claims description 3
- 239000012809 cooling fluid Substances 0.000 claims description 3
- 239000000499 gel Substances 0.000 claims description 3
- 239000012782 phase change material Substances 0.000 claims description 3
- 239000000843 powder Substances 0.000 claims description 3
- 230000004888 barrier function Effects 0.000 claims description 2
- 238000001746 injection moulding Methods 0.000 claims description 2
- 239000011810 insulating material Substances 0.000 claims description 2
- 238000010276 construction Methods 0.000 abstract description 5
- 238000013461 design Methods 0.000 description 7
- 239000007767 bonding agent Substances 0.000 description 5
- 239000000835 fiber Substances 0.000 description 5
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 3
- 239000002826 coolant Substances 0.000 description 3
- 238000012546 transfer Methods 0.000 description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- 229910052802 copper Inorganic materials 0.000 description 2
- 239000010949 copper Substances 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
- 239000007924 injection Substances 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 238000010248 power generation Methods 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 238000004382 potting Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
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
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/22—Rotating parts of the magnetic circuit
- H02K1/27—Rotor cores with permanent magnets
- H02K1/2793—Rotors axially facing stators
- H02K1/2795—Rotors axially facing stators the rotor consisting of two or more circumferentially positioned magnets
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/12—Stationary parts of the magnetic circuit
- H02K1/14—Stator cores with salient poles
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/12—Stationary parts of the magnetic circuit
- H02K1/14—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
- 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
- H02K1/18—Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
- H02K1/182—Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures to stators axially facing the rotor, i.e. with axial or conical air gap
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
- H02K11/20—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection for measuring, monitoring, testing, protecting or switching
- H02K11/25—Devices for sensing temperature, or actuated thereby
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
- H02K11/30—Structural association with control circuits or drive circuits
- H02K11/35—Devices for recording or transmitting machine parameters, e.g. memory chips or radio transmitters for diagnosis
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
- H02K15/021—Magnetic cores
- H02K15/022—Magnetic cores with salient poles
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K5/00—Casings; Enclosures; Supports
- H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
- H02K5/12—Casings or enclosures characterised by the shape, form or construction thereof specially adapted for operating in liquid or gas
- H02K5/128—Casings or enclosures characterised by the shape, form or construction thereof specially adapted for operating in liquid or gas using air-gap sleeves or air-gap discs
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K5/00—Casings; Enclosures; Supports
- H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
- H02K5/18—Casings or enclosures characterised by the shape, form or construction thereof with ribs or fins for improving heat transfer
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K5/00—Casings; Enclosures; Supports
- H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
- H02K5/20—Casings or enclosures characterised by the shape, form or construction thereof with channels or ducts for flow of cooling medium
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
- H02K15/03—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/06—Embedding prefabricated windings in the machines
- H02K15/062—Windings in slots; Salient pole windings
- H02K15/065—Windings consisting of complete sections, e.g. coils or waves
- H02K15/067—Windings consisting of complete sections, e.g. coils or waves inserted in parallel to the axis of the slots or inter-polar channels
Definitions
- the present invention relates to axial flux electrical machines.
- Electrical machines including motors and generators, are important in a wide range of applications, including vehicle propulsion systems, power generation systems including wind, and water power generation systems, and in industrial applications.
- One particular application is in hybrid vehicle power systems in which an electric motor is used in combination with an internal combustion engine.
- Axial flux electrical machines are particularly suited to vehicle applications, due to their relatively high torque density.
- an axial flux electrical machine comprising a stator assembly, a shaft that extends through the stator assembly for rotation with respect to the stator assembly, and a rotor attached to the shaft so as to be rotatable with respect to the stator assembly
- the stator assembly comprises a stator housing which has first and second ends and which defines a substantially cylindrical aperture that extends from the first end to the second end, a stator winding assembly located in the aperture, and first and second covers which engage with the first and second ends of the stator housing respectively, so as to close the aperture, the first and second covers defining respective apertures through which the shaft extends, such that the first cover is located between the rotor and the stator winding assembly, wherein the first and second covers include respective bearing housings in which are located respective bearing for supporting the shaft, and wherein the shaft is supported by only such bearings.
- a method of manufacturing an axial flux electrical machine comprising the steps of providing a first cover having a first surface; locating a plurality of stator pole portions on the first surface of the first cover; locating a plurality of windings around respective pole portions; locating a bearing housing substantially centrally on the first cover; locating the first cover on a first end of a stator housing such that the stator pole portions components, the windings, and the bearing housing are located within a substantially cylindrical aperture defined by the stator housing; engaging a magnetic flux conductor element on the first stator pole portions; locating a second cover on a second end of the stator housing, so as to close the aperture, the second cover engaging with the second stator pole portion components and the bearing housing; engaging a rotor with a shaft; locating the shaft through the stator housing such that it is supported by at least one bearing located in the bearing housing, and such that the rotor is adjacent the first cover; and providing at least one external cover to enclose the
- a stator assembly for an axial flux electrical machine the stator assembly comprising a stator housing that defines a substantially cylindrical volume therein, an integrated stator cover affixed to a first end of the housing, thereby to close that first end of the volume, the integrated stator cover including a plurality of stator pole components which extend from the cover into the volume, and a bearing for supporting a shaft, a stator winding assembly located in the volume, and arranged such that the stator pole components extend at least partially into respective winding elements of the winding assembly, and a second cover affixed to the housing, so as to close a second end of the volume, the second cover including a bearing for supporting such a shaft.
- Figure 1 is an end view of an axial flux electrical machine embodying the present invention
- Figure 2 is a side view of the machine of Figure 1 ;
- Figure 3 is a side cross-sectional side view of the machine of Figure 1 ;
- Figure 4 is a side cross-sectional side view of a stator assembly of the machine of Figure 1 ;
- Figure 5 is an end view of the stator assembly of Figure 4.
- Figure 6 is a side view of part of a stator component
- Figure 7 is a perspective view of the part of Figure 6;
- Figure 8 is a side view of a rotor assembly of the machine of Figure 1 ;
- Figure 9 is a cross-sectional side view of the rotor assembly of Figure 8;
- Figure 10 illustrates a stator component;
- FIG 11 is a flowchart illustrating steps in an example method of manufacturing the stator component of Figure 10;
- Figure 12 illustrates an example winding component
- Figure 13 is a flowchart illustrating steps in an example method of manufacturing the winding component of Figure 12;
- Figure 14 illustrates a single sided stator assembly
- Figure 15 is a flowchart illustrating steps in an example method of manufacturing the stator assembly of Figure 14;
- FIGS 1 and 2 show an electric motor 1 embodying one aspect of the present invention, which motor 1 comprises a casing 10 provided with external covers 1 1a and 1 1 b. An output shaft 13 extends through the first external cover 11 b. An electrical terminal housing 12 is provided by the casing 10 and electrical connections 14 are provided in the housing 12. The casing 10 is provided with coolant connections 15, and a number of cooling fins 16. It will be readily appreciated that the coolant connection 15 and cooling fins 16 are not essential to the construction of the motor 1.
- Figure 3 illustrates a cross-sectional side view of the motor 1 of Figures 1 and 2, and shows a stator assembly 20 through which the shaft 13 extends, and a rotor 22 which is mounted on the shaft 13.
- the shaft 13 and rotor 22 are mounted to be rotatable with respect to the stator assembly 20, and casing 10.
- the motor of the Figure 1 , 2 and 3 incorporates a single stator assembly and a single rotor, located to one side of the stator assembly.
- the stator assembly incorporates bearings for supporting the shaft 13. These internal bearings provide the only support for the shaft 13 and rotor 22 inside the motor 1.
- the motor 1 shown in Figures 1 , 2 and 3 also includes a shaft encoder and processor 24 within the overall casing of the motor 1.
- the processor 24 receives shaft position
- the motor 1 includes a number of sensors (not shown for clarity) which operate to produce measurement signals in dependence upon operating characteristics of the motor 1.
- the sensors may include temperature sensors for determining the temperatures of the stator windings, stator pole portions, rotor components, rotor bearings, and other components of the motor 1.
- the processor 24 operates to receive such operating measurement signals and processes those signals to produce operating data which is stored in a memory device within the motor 1.
- the stored data can be used and processed by the processor to determine possible future wear or failure modes, such as local high temperatures indicative of a decaying electrical connection, and can be output, either fully, or as an alarm condition.
- Such data processing within the motor can serve to optimise the life of the motor by providing advance notification for servicing and maintenance requirements.
- the processor is preferably connected to an industry-standard shielded connector, such as a CAN (controller area network) bus connector, for enabling output of processed data and alarm condition data.
- the processor may be connected with a second output connector which can be accessed directly by a service technician to provide diagnostic information and servicing inputs.
- the processor may also be connected to a wireless transmitter/receiver which is operable to transmit and receive data for the processor. In such a manner, the motor 1 can be remotely accessed and can indicate status and alarm conditions remotely.
- a motor embodying the present invention is manufactured as a series of modules, which enable the manufacturing process to be kept straightforward, and hence less expensive than previous designs.
- a motor embodying the present invention also has the advantage that the manufacturing process works with the high forces provided by the magnets and stator, rather than working against them. Such a design enables the manufacturing process to be kept straightforward.
- the stator assembly 20 is shown in more detail in the cross-sectional view of Figure 4.
- the stator assembly 20 comprises a stator housing 201 (which also provides the motor casing 10, and the electrical connector housing 12 for the motor 1 of Figures 1 , 2 and 3).
- the stator housing 201 defines a cylindrical aperture 202 in which stator components are located.
- the cylindrical aperture 202 is defined between the casing 201 and first and second stator covers 203 and 213.
- the first and second stator covers 203, 213 are secured to the stator casing 201 via stator cover fixings 204 and 214 respectively.
- the fixings 204, 214 may be provided by any suitable means, such as bolts, screws or a bonding material.
- a rotor bearing assembly 205 Located centrally in the cylindrical aperture 202, and attached to the first and second stator covers 203, 213, is a rotor bearing assembly 205.
- the rotor bearing assembly 205 is attached to the first and second stator covers 203 and 213.
- the rotor bearing assembly 205 defines a cylindrical passage 208 therethrough to which the shaft 13 extends when the motor is assembled.
- Each of the stator covers 203 and 213 defines a circular aperture through which the shaft 13 can pass.
- the rotor assembly housing 205 defines bearing regions 207 and 217 into which support bearings for the rotor are located.
- the stator assembly 20 also comprises a plurality of stator pole portions 210 and a conductive element 212 around which stator windings 211 are located.
- the conductive element 212 is an annular member located coaxially with the cylindrical passage 208, and is in contact with the plurality of stator pole portions 210. Electrical connections 215 are provided with the housing 201.
- stator In line with conventional axial motor construction, the stator is provided with a plurality of windings, which when in use carry electric current to provide a rotating magnetic flux. This magnetic flux is reacted by the magnets on the rotors which causes the rotors and hence the drive shaft, to turn.
- windings are located around central cores (or "stator pole portions"). These stator pole portions can be of an iron-based material. In an embodiment of the present invention are provided by grain oriented laminated steel sheets, or powder iron, or a combination of the two. Such constructions serves to reduce magnetic losses and, therefore, improve efficiency of the machine.
- FIGS 6 and 7 illustrate a stator pole component 2101 of a stator pole portion 210.
- the stator pole component 2101 has a body portion 2102 and an enlarged end portion 2103 which extends from the body portion 2102.
- the body portion 2102 and enlarged end portion 2103 define a winding receiving region 2104 in which the stator windings 211 are located.
- the end faces of the body portions 2102 of the stator pole portions 210 contact a face of the conductive element 212. This arrangement serves to provide a magnetic return path between the stator pole portions 210.
- the stator windings 21 1 are formed of relatively thick, flat copper bar which is bent into a suitable shape.
- the windings can be provided by the more conventional multi-wound copper wire type.
- the windings are pre-wound before being located onto the first part of the stator portions, before attachment of the second half of the stator portion.
- the required number of stator portions are produced, and can be produced in advance and stored ready for manufacture into a stator assembly, and then into a motor.
- the second stator cover 213 is placed in a jig with its inner surface accessible to a worker and/or assembly machine.
- the rotor bearing assembly 205 is located on the cover 213 and secured to it using the appropriate fixings or bonding.
- the plurality of stator pole portions 210 is placed in position on the cover 213 around the bearing assembly 205, and are bonded in place on the cover 213.
- the prefabricated windings 21 1 are then placed over the stator pole portions 210, and the appropriate electrical connections are made to the windings 211.
- the cover 213 is then secured to the stator housing, so that one end of the cylindrical aperture is closed, and so that the stator components and bearing housing are located within the stator housing.
- the conductive element 212 is located on the plurality of stator pole portions 210.
- the remaining cover 203 is then located on the casing and secured to the casing 210 using fixings (or suitable bonding material).
- the cover 203 holds the conductive element 212 in place in the stator assembly 20 in contact with the end faces of the stator pole portions 210. After the cover 213 is placed on the assembly, the assembly may be filled with a suitable potting material, such as gel, resin or phase-change material.
- the first and second covers 203, 213 are of a heat insulating material in order to provide a thermal barrier to reduce heat transfer to and from the stator assembly. Reducing heat transfer serves to help maintain the components within an appropriate temperature range.
- An optional feature of a motor embodying the present invention is the provision of a fluid conduit located in the stator housing.
- the conduit may be provided by a suitable flexible tube, for example of glass fibre.
- the conduit defines a fluid flow path around the internal space of the stator housing 201 through which cooling fluid, such as water, can be pumped.
- the fluid conduit is in fluid communication with the coolant connections 15, for transfer of cooling fluid in and out of the motor housing 10.
- the stator assembly is then ready for the introduction of the rotor assembly, which includes the rotor 22 and the shaft 13.
- the rotor assembly is illustrated in Figures 8 and 9, and comprises the shaft 13 onto which the rotor 22 is mounted.
- the rotor 22 is fixed to the shaft 13 and is rotatable with the shaft 13.
- the rotor assembly is shown mounted on the rotor bearing assembly housing 205, which is shown in the stator assembly described previously.
- Figure 9 shows a cross-sectional view of the rotor assembly of Figure 8.
- the shaft 13 extends through the rotor shaft bearing housing 205 and is supported by bearings 226 and 236.
- the shaft is solely supported by these internal bearings 226 and 236 in the motor.
- the rotor 22 comprises a steel, or otherwise magnetically conductible, rotor disk 221 and a plurality of magnets 222 mounted on a surface of the rotor disk 221.
- the rotor disk 221 provides a magnetic flux path between the magnets, thereby increasing the efficiency of the rotor.
- the rotor disk is of a composite material, such as carbon fibre composite, and is provided with magnetic flux conduit portions, to provide the magnetic flux path between the magnets 222 of the rotor 22.
- bearings 226 and 236 are inserted into the bearing locating regions 207 and 217 of the rotor bearing housing 205 in the stator assembly 20.
- the rotor 22 is attached to the shaft 13, and then the shaft 13 is inserted into the stator assembly through the cylindrical aperture 208.
- the drive shaft 13 is supported in the stator assembly by the bearings 226 and 236.
- Such a motor design enables the shaft 13 to be located in the bearing in an accurate manner.
- provision of the internal bearing enables the shaft insertion to be completed without the need for complex manipulation tools, since the magnetic forces exerted between the rotor magnets and the stator assembly serve to pull the rotor and shaft into position. Any off centre forces are resisted by the shaft in the bearing.
- the first and second external covers 11 a and 1 1 b are attached to the casing 10.
- FIG. 10 illustrates a stator cover 213 having stator pole components 2101 integrated therein
- Figure 11 illustrates steps in a method of manufacturing such a stator cover 213.
- the stator cover 213 is manufactured so as to secure the stator pole components 2101 into the cover.
- the cover may be of a composite material, or may be of a plastics material. Steps in example manufacturing processes for both material types are illustrated in Figure 1 1.
- a predetermined number of stator pole components 2101 are arranged in a predetermined pattern in a jig or moulding tool ( Figure 11 , step 400).
- the cover is of a composite material
- the relevant fibre material for example carbon fibre
- the fibre lay-up is undertaken in such a manner as to provide the final cover with sufficient stiffness and strength.
- the fibre lay-up also provides the cover 213 with a bearing receiving feature 217, and defines a shaft aperture 208.
- the bearing receiving feature 217 is adapted to receive a bearing for carrying the rotor shaft of the machine.
- the composite material is then completed by injection of a suitable resin, vacuum, heating and curing steps in accordance with well-known and understood practice (step 404).
- a suitable resin vacuum, heating and curing steps in accordance with well-known and understood practice (step 404).
- the cover may be prefabricated and the stator pole positions attached thereto.
- cover is of a plastics material
- a chosen plastics material is injection moulded over the stator pole components 210 (step 402a), thereby forming the cover 213 and providing insulation for the stator components.
- the completed cover is removed from the mould tool (step 404a).
- the cover 213 can be formed in a single injection moulding step, without the need for additional processing to provide suitable insulation for the stator components.
- stator cover with integrated pole components is then ready for use in the manufacture of the stator assembly, as will be described below.
- the stator windings are provided by a single assembly, for example as illustrated in Figure 12.
- the assembly is manufactured from a continuous piece of winding material, such as copper bar, and provides a continuous winding assembly having a series of interlinked windings 2018, one for each stator pole.
- the windings 2018 are interlinked by connecting portions 2019.
- the winding assembly is manufactured from a series of separate windings that are connected together to provide separate phase connections for the stator. The result in both examples is a complete pre-assembled winding assembly.
- Figure 13 illustrates steps in an example method of manufacturing the winding component of Figure 12.
- the winding material is prepared (step 410), and then a single continuous winding component is wound (step 412), in one example using a computer controlled winding machine.
- the winding component is then ready (step 414) for use in the
- a single sided stator assembly 20 is illustrated in Figure 14, and Figure 15 illustrates steps in an example method of manufacturing the same.
- a previously-manufactured integrated stator cover 213 is located on a jig (step 430), and the stator housing 10 is bonded or otherwise attached thereto (step 432), such that the stator pole components 2101 of the cover 213 extend axially into an internal volume of the housing 10. In this manner, the cover, and hence pole components can be located accurately within the housing 10.
- a pre-manufactured winding component 21 1 is then inserted into the housing 10 (step 434), such that each pole components 2101 extends at least partially into a winding element 211 1A of the winding component 21 1.
- the winding component 21 1 is dimensioned such that it extends only partially into the internal volume of the housing, and so that the pole components of the integrated cover 213 extend substantially fully into respective winding elements 211 1.
- the magnetic flux conductor 212 in this example in the form of and annular ring, is then located (step 236) in the internal volume of the housing 10, and the open end of the housing is closed with a cover 242 (step 438).
- the cover 242 may be secured with bolts, or by bonding with an appropriate bonding material.
- the conductor 240 may be attached, by bonding or other means, to the cover 242, such that the cover 242 and conductor 240 are located on the housing in the same single step.
- a bearing is then bonded into the bearing receiving feature (step 439) using a bonding agent.
- the bearing bonding agent may be thermally activated, such that the bearing can be removed from the cover by application of heat to the bonding agent.
- the choice of bonding agent is made so that the bonding agent is released at a lower temperature than the composite material resin.
- the single sided stator assembly is then available for manufacture into an electrical machine, as will be described below.
- This single sided stator assembly 210 can then be considered as a pre- manufactured module, and can be manufactured independently of other components of the machines.
- the rotor assembly In order to complete the electrical machine, the rotor assembly is located in the stator assembly, such that the shaft is supported by the internal bearings.
- the external covers are then attached to the casing in order to complete the machine.
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Manufacture Of Motors, Generators (AREA)
- Motor Or Generator Frames (AREA)
Abstract
La présente invention concerne une machine électrique à flux axial dans laquelle une construction modulaire est utilisée afin de réduire la complexité, et donc le coût, de fabrication.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB1220831.0 | 2012-11-20 | ||
GB1220831.0A GB2508026B (en) | 2012-11-20 | 2012-11-20 | Axial flux electrical machines |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2014080183A1 true WO2014080183A1 (fr) | 2014-05-30 |
Family
ID=47521420
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/GB2013/053008 WO2014080183A1 (fr) | 2012-11-20 | 2013-11-14 | Machines électriques à flux axial |
Country Status (2)
Country | Link |
---|---|
GB (1) | GB2508026B (fr) |
WO (1) | WO2014080183A1 (fr) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN105896802A (zh) * | 2016-05-31 | 2016-08-24 | 德州杰诺新能源有限公司 | 一种电机端盖及设有该端盖的电机 |
US11799342B2 (en) | 2020-02-20 | 2023-10-24 | Kohler Co. | Printed circuit board electrical machine |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP6270213B2 (ja) * | 2014-06-05 | 2018-01-31 | 株式会社神戸製鋼所 | 電動機 |
JP6254926B2 (ja) * | 2014-11-06 | 2017-12-27 | 株式会社神戸製鋼所 | アキシャルギャップ型ブラシレスモータ |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
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GB1208661A (en) * | 1967-04-24 | 1970-10-14 | Jean Gangloff | Motor-pump assemblies |
EP0266862A1 (fr) * | 1986-08-11 | 1988-05-11 | Maghemite Inc. | Machine dynamo-électrique à courant continu sans balais |
WO2010092400A2 (fr) * | 2009-02-13 | 2010-08-19 | Isis Innovation Ltd | Machine électrique - refroidissement |
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Publication number | Priority date | Publication date | Assignee | Title |
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IT1312180B1 (it) * | 1999-04-15 | 2002-04-09 | Rcv S R L | Motore brushless a traferro assiale e metodo per la sua fabbricazione. |
GB201108298D0 (en) * | 2011-05-18 | 2011-06-29 | Ashwoods Automotive Ltd | Axial flux electrical machines |
-
2012
- 2012-11-20 GB GB1220831.0A patent/GB2508026B/en not_active Expired - Fee Related
-
2013
- 2013-11-14 WO PCT/GB2013/053008 patent/WO2014080183A1/fr active Application Filing
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB1208661A (en) * | 1967-04-24 | 1970-10-14 | Jean Gangloff | Motor-pump assemblies |
EP0266862A1 (fr) * | 1986-08-11 | 1988-05-11 | Maghemite Inc. | Machine dynamo-électrique à courant continu sans balais |
WO2010092400A2 (fr) * | 2009-02-13 | 2010-08-19 | Isis Innovation Ltd | Machine électrique - refroidissement |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN105896802A (zh) * | 2016-05-31 | 2016-08-24 | 德州杰诺新能源有限公司 | 一种电机端盖及设有该端盖的电机 |
US11799342B2 (en) | 2020-02-20 | 2023-10-24 | Kohler Co. | Printed circuit board electrical machine |
Also Published As
Publication number | Publication date |
---|---|
GB2508026A (en) | 2014-05-21 |
GB201220831D0 (en) | 2013-01-02 |
GB2508026B (en) | 2015-11-11 |
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