WO2024079442A1 - Machine électrique à facteur de remplissage élevé - Google Patents

Machine électrique à facteur de remplissage élevé Download PDF

Info

Publication number
WO2024079442A1
WO2024079442A1 PCT/GB2023/052607 GB2023052607W WO2024079442A1 WO 2024079442 A1 WO2024079442 A1 WO 2024079442A1 GB 2023052607 W GB2023052607 W GB 2023052607W WO 2024079442 A1 WO2024079442 A1 WO 2024079442A1
Authority
WO
WIPO (PCT)
Prior art keywords
conductor sections
slot
core
conductor
electromagnetic device
Prior art date
Application number
PCT/GB2023/052607
Other languages
English (en)
Inventor
Nabeel Ahmed Shirazee
Original Assignee
Epropelled 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 Epropelled Inc. filed Critical Epropelled Inc.
Publication of WO2024079442A1 publication Critical patent/WO2024079442A1/fr

Links

Classifications

    • 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
    • H02K3/50—Fastening of winding heads, equalising connectors, or connections thereto
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • 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
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/0056—Manufacturing winding connections
    • H02K15/0068—Connecting winding sections; Forming leads; Connecting leads to terminals
    • H02K15/0081—Connecting winding sections; Forming leads; Connecting leads to terminals for form-wound windings
    • 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
    • H02K3/12—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
    • 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
    • H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
    • H02K2203/03—Machines characterised by the wiring boards, i.e. printed circuit boards or similar structures for connecting the winding terminations
    • 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
    • H02K2213/09—Machines characterised by the presence of elements which are subject to variation, e.g. adjustable bearings, reconfigurable windings, variable pitch ventilators

Definitions

  • the present invention relates to the field of electric machines and/or electromagnetic devices having one or more electromagnetic components having a high fill-factor.
  • Electromagnetic devices generally comprise one or more electromagnetic components each having a coil portion formed of a plurality of turns of an elongate conductor extending in slots around a ferromagnetic core portion.
  • Such electromagnetic devices are limited by the so-called fill-factor of the coil component(s).
  • the slot fill factor is a critical design parameter that enables an electromagnetic device to achieve high specific power densities.
  • Slot fill factor is defined as a portion of a slot cross-section that is occupied by conductive material, typically windings of circular-section copper wire.
  • one cross-section shape such as a circular conductor is used to fill a slot and it will be appreciated that a typical cross-sectional shape of the conductor means that the slot cannot be filled to its maximum efficiency.
  • slots In order to overcome this problem, it is known to provide windings of rectangular or square conductors which can be packed more densely inside the slots.
  • slots often have side walls which are not parallel to each other, or which are not perpendicular to the bottom wall and thus still have fill-factors which are not maximised.
  • slots cannot be densely packed because room has to be provided to enable bends in the conductors at the end of each slot where the conductor passes to another slot.
  • Such windings include a pre-formed U-shaped conductor section having parallel elongate conductive arms which are inserted to the machine to extend along respective slots.
  • Such machines are expensive because assorted sizes of hairpin are required and because each requires bending, insertion and termination.
  • an electromagnetic device that can comprise one or more electromagnetic components with an increased fill-factor.
  • an electromagnetic device having at least one electromagnetic component, the component comprising: an elongate core portion formed of ferromagnetic material; first and second slots extending axially of the core between first and second ends thereof; and a coil portion including an elongate conductor having a plurality of turns which extend around the core portion, the elongate conductor comprising a plurality of conductor sections extending along each slot, wherein an interconnect disposed at the first end of the core electrically interconnects ends of the conductor sections in the first slot being with ends of respective conductor sections in the second slot.
  • the elongate conductor sections in the slots are electrically interconnected end-to-end at the first end of the core by an interconnect, so as connect them end-to-end into a coil which extends around the core portion.
  • the use of an interconnect also avoids the need for bending the conductor sections at the first end of the core and alleviates the problem that additional space has to be provided to accommodate the bends. Furthermore, the embodiments consistent with the present disclosure alleviate the problem that bending a conductor section may break its outer insulative layers.
  • the component can comprise hairpin windings wherein each provide a said conductor section in the first slot integrally interconnected at the second end of the core to a said conductor section in the second slot. In this manner, pairs of conductor sections are pre-formed, and the conductor sections thereof can be inserted along respective slots. In some embodiments, pairs of conductor sections may be preformed in the manner of known so-called hairpin windings.
  • the conductor sections may be electrically interconnected at the second end of the core by another interconnect.
  • the interconnect at an end of the core comprises a printed circuit board carrying conductive interconnects which interconnect ends of the conductor sections and provide external connections to some of the conductor sections, for example so that a supply can be applied to the coil portion of the component.
  • the conductor sections may be connected to the printed circuit board by solder.
  • the interconnect at an end of the core comprises a 3D printed/molded structure having a printed/molded body of insulative material carrying printed/molded conductive interconnects which interconnect ends of the conductor sections and provide external connections to some of the conductor sections, for example so that a supply can be applied to the coil portion.
  • the structure may be biased against ends of the conductor sections, so that the printed/molded conductive interconnects thereof make appropriate electrical contact with the conductor sections.
  • the printed/molded conductive interconnects may be welded or bonded in contact with the conductor sections.
  • a 3D printed/molded structure can take various forms.
  • the insulated disc part can either be 3D printed using an insulation material with sufficient dielectric strength such as 6kV/mm 2 or it can be molded with material such as PEEKTM.
  • the 3D printed or a preformed busbar element(s) made from material such as copper that is coated with silver oxide forms the interconnect. This interconnect connects the conductor section ends to form a coil/winding.
  • this 3D printed/molded structure may comprise mechanical or semiconductor switches.
  • the electromagnetic device may comprise a plurality of said electromagnetic components and the interconnect of one electromagnetic component may be formed integrally with the interconnect of one or more other electromagnetic components of the device.
  • the slots of each component may extend parallel to each other and may have corresponding ends which terminate in the same plane.
  • the interconnect may carry electronic components which are electrically coupled to the conductor sections.
  • the components may comprise mechanical switches or semiconductors which can be controlled by control unit to vary the connections between or to the electromagnetic components of the device.
  • the electromagnetic components may be stator coils of an electrical machine such as a motor or generator, the machine comprising an annular former having radially extending stator teeth forming the respective core portions, the slots being disposed between the stator teeth and extending axially of the former between opposite ends thereof, a said interconnect being disposed at least one end of the former and carrying conductive interconnects which interconnect ends of the conductor sections in each slot and provide external connections to the electrical machine.
  • conductor sections in each slot may have different cross- sectional shapes from each other but may have same cross-sectional area.
  • the combined cross-sectional shape of all conductors in each slot may correspond with the cross-sectional shape of the slot in which they are disposed.
  • the interconnect may be circular or annular.
  • a method of forming an electromagnetic device having at least one electromagnetic component comprising: providing an elongate core portion formed of ferromagnetic material; inserting a plurality of conductor sections into each of first and second slots which extend axially of the core portion between first and second ends thereof; and electrically interconnecting the conductor sections at the first end of the core to form a coil portion having a plurality of turns extending around the core portion, the conductor sections being interconnected by connecting ends of the conductor sections in the first slot with ends of respective conductor sections in the second slot with an interconnect disposed at the first end of the core.
  • the method comprises providing hairpin windings each providing a pair of said conductor sections, inserting the conductor sections of each hairpin winding into the first and second slots respectively.
  • the method comprises electrically interconnecting the conductor sections at the second end of the core, the conductor sections being interconnected by connecting ends of the conductor sections in the first slot with ends of respective conductor sections in the second slot with another an interconnect disposed at the second end of the core.
  • the method may comprise electrically connecting ends of the conductor sections to the interconnect using solder.
  • the method may comprise biasing the interconnect into contact with the ends of the conductor sections.
  • Figure 1 is an isometric end view of the stator assembly of an embodiment of an electric motor
  • Figure 2 is an exploded isometric view of the stator assembly of Figure 1 ;
  • Figure 3 is a flow diagram illustrating the method of construction of the stator assembly of Figure 1 ;
  • Figure 4 is an isometric end view of the stator assembly of an electric motor
  • Figure 5 is a flow diagram illustrating the method of construction of the stator assembly of Figure 4;
  • Figure 6 is an isometric end view of the stator assembly of a third embodiment of an electric motor.
  • stator assembly 10 of an embodiment of an electric motor, although it will be appreciated that the assembly 10 could also be used in an electric generator or an electromagnetic device.
  • Assembly 10 may comprise former 11 , conductor sections 14, printed circuit board (PCBs 15,19) conductive tracks/busbars 16, terminals 17 and switches 18.
  • former 11 may comprise stator teeth 12 and slots 13.
  • One slot 13 may separate one stator tooth 12 from another stator tooth 12.
  • One or more printed circuit boards (e.g., PCBs 15, 19) may be attachable to the former 11.
  • PCB 15 may comprise one or more conductive tracks/busbars 16, one or more terminals 17, and one or more switches 18.
  • PCB 19 may include similar components to PCB 15.
  • PCB 19 may be disposed of on the opposite side of former 11 from PCB 15.
  • One or more switches 18 may include mechanical switches, electrical switches, and/or semiconductor switches.
  • a control circuit 50 of the kind disclosed in US7382103 is provided for controlling the switches 18 to connect winding sections of the motor in different configurations whilst the motor is running to alter the speed/torque characteristics of the motor.
  • the assembly 10 of Figures 1 and 2 can be constructed using a number of steps including steps 20, 21 , 22, 23, 24 and 25.
  • a method to produce assembly 10 may comprise one or more or a subset of steps 20, 21 , 22, 23, 24 and 25.
  • Assembly 10 can be constructed by
  • stator teeth 12 may be directed radially inwardly or outwardly according to the design requirements.
  • Stator slots 13 may be disposed between stator teeth 12.
  • the individual conductor sections 14 may be inserted into the slots 13.
  • sections 14 may extend axially between first and second ends of the former 11 .
  • the sections 14 may each have a length which is slightly greater than the length of each slot 13.
  • the conductor sections 14 may be electrically interconnected at the first end of the former 11 , for example, by soldering them to conductive lands/pads provided on a first annular printed circuit board (PCB) 15.
  • the lands/pads are disposed adjacent to apertures 24 in the PCB 15 through which the ends of the respective sections 14 extend or be flush.
  • Conductive tracks/busbar 16 may extend from the lands/pads and interconnect ends of the conductor sections 14 to each other or to terminals 17 that provide external connections, for example, so that a supply can be applied to the magnetic stator coils/winding of the assembly 10.
  • the PCB 15 also may comprise semiconductor switches 18 which are electrically coupled to the conductor sections 14. In some embodiments, the switches 18 can be controlled to vary the connections between or to each of the stator coils/winding of the assembly 10.
  • each slot 13 has sidewalls that lie parallel to each other and normal to the base of the slot.
  • the width (w) and thickness (t) (cross-section) of each conductor 14 can be equal so that the conductor sections 14 have a substantially square cross-sectional shape.
  • each conductor section 14 can be slightly less than the width of the slots 13 and power coating/slot liner (33).
  • the thickness (t) of each conductor section 14 can be approximately equal to 25% of the depth of each slot 13, for example, so that each slot is able to accommodate four conductor sections 14. It will be appreciated that the slot fill factor can be maximised according to the cross-sectional shape of the slot 13 where each slot 13 accommodates a proportional number of conductor sections 14.
  • the cross-sectional shape of each conductor section 14 can be adapted to suit the cross-sectional shape of the slot 13 in which they are provided. In some embodiments, the cross-sectional shape of the conductor sections
  • each slot 13 can be different from each other.
  • the cross- sectional area of all conductor sections 14 can be substantially equal.
  • the assembly 25 can be constructed in a similar manner to the stator assembly 10 of Figures 1 and 2 as described with reference to Figure 3 except where discussed below and like parts and steps are given like reference numerals and the method as shown in Figure 3 may comprise steps 100, 101 and 102 are similar to step 20, 21 and 22 of Figure 3.
  • Step 103 may comprise inserting each of the hairpin conductors 26 in the slots 13 of the former 11.
  • the hairpin conductor section 26 may be integrally interconnected at the second end of the former 11 to another conductor section 26 in an adjacent slot 16 forming a hairpin winding (not shown).
  • the ends of the hairpin conductors 26 of the relevant hairpins are soldered to create hairpin windings.
  • Stator assembly 30 may comprise teeth 27 of the former 31 that are T- shaped in section and each slot 32 between teeth 27 has sidewalls which are non- parallel and a concave back wall (inner diameter section of the back iron).
  • each slot may accommodate a slot liner 33 and four conductor sections 29.
  • the cross-sectional shape of each section 29 can be adapted to suit the irregular cross-sectional shape of the slot 32 in which they are disposed.
  • each slot may comprise radially inner and outer conductor sections 29, wherein each pair having a different cross-sectional shape than the other pair, all four of equal cross-sectional area.
  • the cross-sectional shape of both radially inner and outer conductor sections 29 can increase the slot fill factor such that it is maximised.
  • An electromagnetic device in accordance with embodiments of the present disclosure can include an increased slot fill factor, thus improving the efficiency of the device and allowing the device to operate at high currents and higher torque density, thereby increasing its specific power density.
  • Such electromagnetic devices may be cheap and inexpensive.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Windings For Motors And Generators (AREA)

Abstract

La présente invention concerne un ensemble stator (10) qui comprend un gabarit de stator stratifié annulaire (11) en matériau ferromagnétique ayant des dents de stator (12) qui sont dirigées radialement vers l'intérieur et forment des fentes de stator (13) entre des dents de stator (12), les fentes de stator (13) pouvant recevoir des bobines de stator. Chaque bobine de stator peut comprendre un conducteur allongé ayant une pluralité de spires qui s'étendent autour d'une dent de stator respective (12), le conducteur allongé comprenant une pluralité de sections conductrices connectées en série (14) insérées dans chaque fente (13). Une carte de circuit imprimé (PCB) ou une structure en impression 3D débarrassée d'une extrémité ou des deux extrémités du gabarit (11) connecte électriquement les extrémités des sections conductrices (14) pour former n une bobine. L'agencement offre l'avantage que les sections conductrices (14) dans chaque fente peuvent avoir des formes de section transversale différentes les unes des autres, de façon à augmenter le facteur de remplissage de fente en fonction de la forme de section transversale de la fente.
PCT/GB2023/052607 2022-10-14 2023-10-10 Machine électrique à facteur de remplissage élevé WO2024079442A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202263379578P 2022-10-14 2022-10-14
US63/379,578 2022-10-14

Publications (1)

Publication Number Publication Date
WO2024079442A1 true WO2024079442A1 (fr) 2024-04-18

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7382103B2 (en) 2003-10-24 2008-06-03 Electronica Products Limited Magnetic gearing of permanent magnet brushless motors
WO2016190161A1 (fr) * 2015-05-22 2016-12-01 三菱電機株式会社 Machine tournante électrique et procédé de fabrication de machine tournante électrique
CA3090211A1 (fr) * 2018-02-12 2019-08-15 Epropelled Limited Dispositifs electromagnetiques
WO2020186014A1 (fr) * 2019-03-14 2020-09-17 Hendricks Robert C Moteur à conducteur axial à commutation électronique
US10951080B2 (en) * 2016-02-18 2021-03-16 Abb Schweiz Ag Windings for an electric machine
US20220329124A1 (en) * 2021-04-09 2022-10-13 Borgwarner Inc. Stator With Printed End Turns and Methods of Making the Same

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7382103B2 (en) 2003-10-24 2008-06-03 Electronica Products Limited Magnetic gearing of permanent magnet brushless motors
WO2016190161A1 (fr) * 2015-05-22 2016-12-01 三菱電機株式会社 Machine tournante électrique et procédé de fabrication de machine tournante électrique
US10951080B2 (en) * 2016-02-18 2021-03-16 Abb Schweiz Ag Windings for an electric machine
CA3090211A1 (fr) * 2018-02-12 2019-08-15 Epropelled Limited Dispositifs electromagnetiques
WO2020186014A1 (fr) * 2019-03-14 2020-09-17 Hendricks Robert C Moteur à conducteur axial à commutation électronique
US20220329124A1 (en) * 2021-04-09 2022-10-13 Borgwarner Inc. Stator With Printed End Turns and Methods of Making the Same

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