WO2021118500A1 - A winding method for electrical machines - Google Patents

A winding method for electrical machines Download PDF

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Publication number
WO2021118500A1
WO2021118500A1 PCT/TR2020/051239 TR2020051239W WO2021118500A1 WO 2021118500 A1 WO2021118500 A1 WO 2021118500A1 TR 2020051239 W TR2020051239 W TR 2020051239W WO 2021118500 A1 WO2021118500 A1 WO 2021118500A1
Authority
WO
WIPO (PCT)
Prior art keywords
winding
electrical machine
electrical
bending point
windings
Prior art date
Application number
PCT/TR2020/051239
Other languages
French (fr)
Inventor
Gokhan CAKAL
Ozan Keysan
Original Assignee
Orta Dogu Teknik Universitesi
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 Orta Dogu Teknik Universitesi filed Critical Orta Dogu Teknik Universitesi
Priority to EP20900147.8A priority Critical patent/EP4055698A4/en
Publication of WO2021118500A1 publication Critical patent/WO2021118500A1/en

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/28—Layout of windings or of connections between windings
    • 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
    • H02K15/0414—Windings consisting of separate elements, e.g. bars, hairpins, segments, half coils
    • H02K15/0421—Windings consisting of separate elements, e.g. bars, hairpins, segments, half coils consisting of single conductors, e.g. hairpins
    • 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
    • H02K15/0435—Wound windings
    • H02K15/0464—Lap windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2213/00—Specific aspects, not otherwise provided for and not covered by codes H02K2201/00 - H02K2211/00
    • H02K2213/03—Machines characterised by numerical values, ranges, mathematical expressions or similar information
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2213/00—Specific aspects, not otherwise provided for and not covered by codes H02K2201/00 - H02K2211/00
    • H02K2213/12—Machines characterised by the modularity of some components

Definitions

  • the present invention relates to a winding method used in electrical machines, which is obtained by various cutting and bending processes of an electrically conductive sheet in the form of a U or V shape, using planar cutting tools such as a water jet, laser etc.
  • Electrical machines consist of two different parts, namely rotor and stator.
  • the force that causes rotation in electrical machines is obtained as a result of the interaction of the magnetic field created by the rotor and the stator.
  • the rotor or stator needs current carrying electrical machine windings in order to create magnetic field.
  • electrical machine windings consist of conductive stranded wires. These wires are covered with an insulating material called enamel to provide electrical insulation. The cross-sectional area of the wires used is determined based on the required current ratings.
  • wire thicknesses are standardized according to the American Wiring Gauge (American Wiring Gauge, AWG) system. Electrical machine windings are wound inside a slot or wound as air- cored depending on the type of topology.
  • Parameters such as wire thickness or number of turns are determined depending on the parameters such as voltage, current or the number of phases.
  • the first problem is the cost of the electrical machine windings and difficulty of winding. Wires used in the electrical machine windings are placed on the rotor or stator by motor winding machines. These machines are expensive and investment is needed. In addition, the price of the enameled wires is increasing day by day.
  • a second problem faced is related to the current requirement of the electrical machines. In electrical machines, the current rating and the force causing the rotation are related to each other. Today, especially with the developments in the automotive and energy industries, electrical machines with high current ratings are required. For example, in wind turbine or electric vehicle applications, electrical machines with high current ratings are at the forefront.
  • the main object of the invention is to reduce the cost of the electrical machine windings and to provide ease of production.
  • the electrical machine windings are made by cutting pieces from an electrically conductive and bendable sheet. Therefore, there is no need for any winding machine and thus ease of production is provided. The cost is also reduced since instead of the stranded wires, the aforementioned invention will be used in the electrical machine windings.
  • Another object of the invention is to meet high current ratings, which is an increasing need of the electrical machines. Since the electrical machine winding of the invention can operate at high currents, the need for paralleling or using thick wires to obtain high currents is eliminated.
  • Another object of the invention is to increase the efficiency of electrical machines. Since the end winding length of the electrical machine winding of the invention is shorter than the end winding length of the windings used in conventional electrical machines, the efficiency of the electrical machine increases.
  • Figure-1 The figure representing the production of the electrical machine winding of the invention from the electrically conductive bendable sheet.
  • Figure-2 The figure representing the electrical machine winding of the invention where said winding has been cut from an electrically conductive and bendable sheet and is ready for the bending process.
  • Figure-3 Front view of the electrical machine winding of the invention.
  • Figure-4 Front view of the configuration representing the multiple electrical machine winding obtained by using a number of electrical machine windings of the invention.
  • This invention is related to an electrical machine winding (9), which is one of the basic components of electrical machines. Contrary to the electrical machine winding consisting of stranded wires found in conventional electrical machines, the electrical machine winding (9) of the invention is produced from a thin electrically conductive bendable sheet (1). First of all, the material which has a small thickness (2) of thin electrically conductive bendable sheet is cut in a U or V shape with planar cutting tools such as laser or water jet etc. as seen on the cutting lines (3). The electrical machine winding (9) of the invention is obtained by bending the unbent electrical machine winding (4), which is obtained after cutting, with various bending tools at the lower bending point (5), middle bending point (6) and upper bending point (7) shown in Figure 2.
  • the width (8) of the electrical machine winding is determined with respect to the current rating requirement of the electrical machine.
  • the Fower bending angle (10), middle bending angle (11) and upper bending angle (12) take different values based on the pole number of the electrical machine.
  • the decrease in efficiency caused by the long end windings of the conventional electrical machines has been eliminated since the electrical machine winding (9) of the invention has a shorter end winding (13), thus providing higher efficiency.
  • multiple electrical machine windings (14) shown in Figure 4 are obtained by combining a plurality of electrical machine windings (9) around a circle. When a current is flowed over this multiple electrical machine winding (14), the magnetic field required for electrical machines to generate torque is created.
  • the electrical connection of the multiple electrical machine winding (14) to the outside of the electrical machine is achieved via the winding terminals (15).
  • the number of winding terminals (15) may increase depending on electrical machine topology (single phase, two phases, three phases, four phases, five phases etc.).
  • Electrical insulating material (16) is used on the multiple electrical machine winding (14) to electrically isolate the two adjacent electrical machine windings (9).
  • End winding connector (17) is used to connect the electrical machine windings (9) from the end windings (13) to each other. This element creates the current path by electrically connecting the electrical machine windings to each other.
  • the electrical machine windings (9) can be connected with the end winding connectors (17) in various combinations depending on the requirements of the electrical machine, such as the number of turns of the winding or the phase number.
  • the electrical machine industry has become a market, whose growth is accelerating. Electrical machines have gained importance due to the rapid growth of the electric vehicles or renewable energy industry, such as wind energy. Participants in the industry are conducting research on electrical machines. Due to the competition environment that has occurred, it is very important to reduce the production time and the cost of the electrical machines as well as to increase their efficiency. In this context, the electrical machine winding of the invention reduces the cost by providing ease of production with the help of developing automation systems. Meanwhile, the invention of interest can satisfy high current demands without an increase in costs. Therefore, the configuration of the invention can be preferred in order to increase the efficiency and to provide the ease of production in all areas where electrical machines are used including the energy industry and the automotive industry. In addition, it is of particular importance to introduce the invention of interest to the industry in terms of reducing international dependency, which is one of our highly valued policies in recent years, and developing domestic and national technologies that our country needs.

Landscapes

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

Abstract

The present invention relates to machine windings that are important components of electrical machines. The invention characterized in that it is cut from a thin electrically conductive sheet (1) and has at least one bending point such as the lower bending point (5), the middle bending point (6) and the upper bending point (7), and that the bending angles are at least 90° and not more than 180°. Another characterization of the invention is that more than one electrical machine windings (9) are connected with the end winding connectors (17) from the end windings (13), and an electrical insulating material (16) is placed between two adjacent electrical machine windings (9) to provide electrical insulation therebetween, thus obtaining the multiple electrical machine winding (14). While this winding method of the invention provides ease of production for electrical machine windings, it can also increase the efficiency with short end winding (13) and satisfy high current requirements.

Description

A WINDING METHOD FOR ELECTRICAL MACHINES
Technical Field The present invention relates to a winding method used in electrical machines, which is obtained by various cutting and bending processes of an electrically conductive sheet in the form of a U or V shape, using planar cutting tools such as a water jet, laser etc.
Prior Art
Electrical machines consist of two different parts, namely rotor and stator. The force that causes rotation in electrical machines is obtained as a result of the interaction of the magnetic field created by the rotor and the stator. The rotor or stator needs current carrying electrical machine windings in order to create magnetic field. In the conventional electrical machines, electrical machine windings consist of conductive stranded wires. These wires are covered with an insulating material called enamel to provide electrical insulation. The cross-sectional area of the wires used is determined based on the required current ratings. In literature, wire thicknesses are standardized according to the American Wiring Gauge (American Wiring Gauge, AWG) system. Electrical machine windings are wound inside a slot or wound as air- cored depending on the type of topology. Parameters such as wire thickness or number of turns are determined depending on the parameters such as voltage, current or the number of phases. In the prior art, three different problems stand out. The first problem is the cost of the electrical machine windings and difficulty of winding. Wires used in the electrical machine windings are placed on the rotor or stator by motor winding machines. These machines are expensive and investment is needed. In addition, the price of the enameled wires is increasing day by day. A second problem faced is related to the current requirement of the electrical machines. In electrical machines, the current rating and the force causing the rotation are related to each other. Today, especially with the developments in the automotive and energy industries, electrical machines with high current ratings are required. For example, in wind turbine or electric vehicle applications, electrical machines with high current ratings are at the forefront. In the prior art, either very thick wires must be used or a large number of wires must be connected in parallel to each other in order to obtain high current ratings. Both options significantly increase the cost and production time of electrical machine windings. Lastly, the problem encountered is the end winding length of the electrical machine windings. The end winding length does not contribute to torque generation that causes the revolutions in electrical machines and causes decrease in the machine efficiency. Therefore, the shorter the end winding length, the higher the efficiency of the electrical machine will be. Enameled wires used in the prior art have long end winding length and they decrease the machine efficiency. Technical Problems Aimed to be Solved by the Invention
The main object of the invention is to reduce the cost of the electrical machine windings and to provide ease of production. In the invention, unlike conventional electrical machines, the electrical machine windings are made by cutting pieces from an electrically conductive and bendable sheet. Therefore, there is no need for any winding machine and thus ease of production is provided. The cost is also reduced since instead of the stranded wires, the aforementioned invention will be used in the electrical machine windings. Another object of the invention is to meet high current ratings, which is an increasing need of the electrical machines. Since the electrical machine winding of the invention can operate at high currents, the need for paralleling or using thick wires to obtain high currents is eliminated. Another object of the invention is to increase the efficiency of electrical machines. Since the end winding length of the electrical machine winding of the invention is shorter than the end winding length of the windings used in conventional electrical machines, the efficiency of the electrical machine increases.
Description of the Drawings
An example of a winding method for electrical machines which is developed by the present invention is shown in the attached figure,
Figure-1: The figure representing the production of the electrical machine winding of the invention from the electrically conductive bendable sheet.
Figure-2: The figure representing the electrical machine winding of the invention where said winding has been cut from an electrically conductive and bendable sheet and is ready for the bending process.
Figure-3: Front view of the electrical machine winding of the invention.
Figure-4: Front view of the configuration representing the multiple electrical machine winding obtained by using a number of electrical machine windings of the invention.
Description of the Parts Shown with Reference Numbers in the Drawings
Parts in the drawing are numbered individually and the equivalents of these numbers are given below:
1. Thin electrically conductive bendable sheet
2. Thickness of the thin electrically conductive bendable sheet
3. Cutting lines
4. Unbent electrical machine winding
5. Lower bending point
6. Middle bending point
7. Upper bending point
8. Width of the electrical machine winding
9. Electrical machine winding
10. Lower bending angle
11. Middle bending angle
12. Upper bending angle
13. End winding
14. Multiple electrical machine winding
15. Winding terminal
16. Electrical insulating material 17. End winding connector
Description of the Invention
This invention is related to an electrical machine winding (9), which is one of the basic components of electrical machines. Contrary to the electrical machine winding consisting of stranded wires found in conventional electrical machines, the electrical machine winding (9) of the invention is produced from a thin electrically conductive bendable sheet (1). First of all, the material which has a small thickness (2) of thin electrically conductive bendable sheet is cut in a U or V shape with planar cutting tools such as laser or water jet etc. as seen on the cutting lines (3). The electrical machine winding (9) of the invention is obtained by bending the unbent electrical machine winding (4), which is obtained after cutting, with various bending tools at the lower bending point (5), middle bending point (6) and upper bending point (7) shown in Figure 2. The width (8) of the electrical machine winding is determined with respect to the current rating requirement of the electrical machine. The Fower bending angle (10), middle bending angle (11) and upper bending angle (12) take different values based on the pole number of the electrical machine. The decrease in efficiency caused by the long end windings of the conventional electrical machines has been eliminated since the electrical machine winding (9) of the invention has a shorter end winding (13), thus providing higher efficiency. By determining the number, depending on the voltage requirement of the electrical machine, multiple electrical machine windings (14) shown in Figure 4 are obtained by combining a plurality of electrical machine windings (9) around a circle. When a current is flowed over this multiple electrical machine winding (14), the magnetic field required for electrical machines to generate torque is created. The electrical connection of the multiple electrical machine winding (14) to the outside of the electrical machine is achieved via the winding terminals (15). The number of winding terminals (15) may increase depending on electrical machine topology (single phase, two phases, three phases, four phases, five phases etc.). Electrical insulating material (16) is used on the multiple electrical machine winding (14) to electrically isolate the two adjacent electrical machine windings (9). End winding connector (17) is used to connect the electrical machine windings (9) from the end windings (13) to each other. This element creates the current path by electrically connecting the electrical machine windings to each other. The electrical machine windings (9) can be connected with the end winding connectors (17) in various combinations depending on the requirements of the electrical machine, such as the number of turns of the winding or the phase number.
Industrial Applicability of the Invention
With the developments in automotive and energy industries, the electrical machine industry has become a market, whose growth is accelerating. Electrical machines have gained importance due to the rapid growth of the electric vehicles or renewable energy industry, such as wind energy. Participants in the industry are conducting research on electrical machines. Due to the competition environment that has occurred, it is very important to reduce the production time and the cost of the electrical machines as well as to increase their efficiency. In this context, the electrical machine winding of the invention reduces the cost by providing ease of production with the help of developing automation systems. Meanwhile, the invention of interest can satisfy high current demands without an increase in costs. Therefore, the configuration of the invention can be preferred in order to increase the efficiency and to provide the ease of production in all areas where electrical machines are used including the energy industry and the automotive industry. In addition, it is of particular importance to introduce the invention of interest to the industry in terms of reducing international dependency, which is one of our highly valued policies in recent years, and developing domestic and national technologies that our country needs.

Claims

1. The invention is a winding method for electrical machines that provides ease of production, high efficiency and high current ratings in electrical machines, characterized in that it is obtained from a thin electrically conductive bendable sheet (1) in a U or V shape; where the unbent electrical machine winding (4) resulting from this process, is bent at various points such as the lower bending point (5), the middle bending point (6) and the upper bending point (7).
2. A winding method for electrical machines according to Claim 1, characterized in that the multiple electrical machine windings (14) are obtained by connecting at least two electrical machine windings (9) around a circle in different combinations depending on the requirements of the electrical machine to be designed.
3. A winding method for electrical machines according to Claim 1, characterized in that an electrical insulating material (16) is placed between two adjacent electrical machine windings (9) located on the multiple electrical machine winding (14) to provide electrical insulation therebetween; wherein the electric machine windings (9) located on the multiple electrical machine winding (14) are electrically connected to each other with the end winding connector (17).
4. The invention is type of winding providing high efficiency and high current ratings for electrical machines, characterized in that the electrical machine winding (9) has at least one bending point such as the lower bending point (5), the middle bending point (6) and the upper bending point (7); and has a width (8) that is larger in size than the thickness (2) of the thin electrically conductive bendable sheet.
5. A winding type for electrical machines according to Claim 4, characterized in that it has obtuse angles of at least 90° and not more than 180°, formed at the corners where the bending occurs such as the lower bending angle (10), the middle bending angle (11) and the upper bending angle (12).
PCT/TR2020/051239 2019-12-09 2020-12-07 A winding method for electrical machines WO2021118500A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP20900147.8A EP4055698A4 (en) 2019-12-09 2020-12-07 A winding method for electrical machines

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
TR201919533 2019-12-09
TR2019/19533 2019-12-09

Publications (1)

Publication Number Publication Date
WO2021118500A1 true WO2021118500A1 (en) 2021-06-17

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PCT/TR2020/051239 WO2021118500A1 (en) 2019-12-09 2020-12-07 A winding method for electrical machines

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EP (1) EP4055698A4 (en)
WO (1) WO2021118500A1 (en)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1143459A2 (en) * 2000-04-07 2001-10-10 Goto Electronic Co., Ltd. Method of successively manufacturing slender square conductive wires
US20090178270A1 (en) * 2007-03-22 2009-07-16 Tecnomatic, S.P.A. Method and apparatus for forming motor winding conductors
KR20140083770A (en) * 2012-12-26 2014-07-04 현대모비스 주식회사 Hairpin and hairpin winding motor having the same
KR20160051408A (en) * 2014-11-03 2016-05-11 현대모비스 주식회사 Apparatus of hairpin winding motor using stator plate and method of construction thereof

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE202005014302U1 (en) * 2004-09-20 2005-11-24 Ebm-Papst St. Georgen Gmbh & Co. Kg Motor especially for low voltage has shaped piece to insulate stator windings from stator poles and from one another
US20170025907A1 (en) * 2014-03-31 2017-01-26 Honda Motor Co., Ltd. Stator for electric rotary machine
US20160254718A1 (en) * 2015-02-26 2016-09-01 Nidec Copal Corporation Segment conductors, stator, rotating electrical machine, and vehicle and method of manufacturing the segment conductors

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1143459A2 (en) * 2000-04-07 2001-10-10 Goto Electronic Co., Ltd. Method of successively manufacturing slender square conductive wires
US20090178270A1 (en) * 2007-03-22 2009-07-16 Tecnomatic, S.P.A. Method and apparatus for forming motor winding conductors
KR20140083770A (en) * 2012-12-26 2014-07-04 현대모비스 주식회사 Hairpin and hairpin winding motor having the same
KR20160051408A (en) * 2014-11-03 2016-05-11 현대모비스 주식회사 Apparatus of hairpin winding motor using stator plate and method of construction thereof

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See also references of EP4055698A4 *

Also Published As

Publication number Publication date
EP4055698A1 (en) 2022-09-14
EP4055698A4 (en) 2022-12-21

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