EP4454111A1 - Procédé de fabrication d'un enroulement sans fer multiphasé à double couche et enroulement ainsi obtenu - Google Patents

Procédé de fabrication d'un enroulement sans fer multiphasé à double couche et enroulement ainsi obtenu

Info

Publication number
EP4454111A1
EP4454111A1 EP22912070.4A EP22912070A EP4454111A1 EP 4454111 A1 EP4454111 A1 EP 4454111A1 EP 22912070 A EP22912070 A EP 22912070A EP 4454111 A1 EP4454111 A1 EP 4454111A1
Authority
EP
European Patent Office
Prior art keywords
winding
phase
wires
ironless
layer
Prior art date
Legal status (The legal status 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 status listed.)
Pending
Application number
EP22912070.4A
Other languages
German (de)
English (en)
Other versions
EP4454111A4 (fr
Inventor
ZhaoQiang Zhang
Oddvin Agnalt Østmo
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Alva Industries AS
Original Assignee
Alva Industries AS
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 Alva Industries AS filed Critical Alva Industries AS
Publication of EP4454111A1 publication Critical patent/EP4454111A1/fr
Publication of EP4454111A4 publication Critical patent/EP4454111A4/fr
Pending legal-status Critical Current

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
    • H02K3/47—Air-gap windings, i.e. iron-free windings
    • 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
    • H02K15/04—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
    • 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
    • H02K15/04—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
    • H02K15/044—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines winding non-flat conductive wires, e.g. cables or cords
    • H02K15/047—Distributed windings
    • H02K15/048—Distributed windings of the wave winding type
    • 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
    • H02K15/061—Air-gap windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/02—Windings characterised by the conductor material

Definitions

  • the present invention is related to a method for production of a double-layer multiphase ironless winding, according to the preamble of claim 1.
  • the present invention is also related to a double-layer multiphase ironless winding, according to the preamble of claim 5.
  • Ironless and slotless permanent magnet electric machines gain an increasing attention of both the research and the industrial communities. Having certain advantages over the conventional technologies ironless and slotless machines are attractive for use in automation, robotics, medical devices, drones, etc.
  • the main enabling component of an ironless/slotless machine is the part creating alternating/rotating magnetic field, containing just conductors and not containing any iron/ferromagnetic parts, such as teeth.
  • This component is commonly known as an ironless winding.
  • One of the ways to create an ironless winding is to first make a so-called multiphase electromagnetic mat (consisting of conductors and some support elements), then bend it into a circular element, connect the ends, and finally consolidate it by, e.g., moulding it in some sort of epoxy.
  • the ironless windings can have one or more layers. In some cases, double-layer windings are preferable. However, if the end-windings of different phases are crossing, the end-windings of the double-layer windings become even bigger than in the case with single-layer windings. This is well illustrated in GB1526614A ("Dynamoelectric machine two-layer stator windings") where a slotless electric machine has a two-layer (double-layer) stator winding.
  • US2010117481A1 is considered to be the closest prior art to the present invention.
  • Ironless/coreless machines are an attractive alternative to the conventional technologies even with the present level of their performances. Further improvement of the performances of ironless/coreless machines would provide the end-users with a superior electric machine technology enabling higher degree of electrification of the world.
  • Reducing the size of the end-windings can have two positive effects: lower phase resistance and the possibility of making a substantially flat winding where the winding thickness will be approximately the same in the active area and in the end-winding area.
  • the flat winding is easier to integrate with the rest of stator and rotor parts of the machine.
  • Winding having many wire ends that need termination is not easy to handle during production of the machine. Termination of the wire ends may require soldering, welding of other complex processes which are not easy to automate. In case of moulding of the ironless winding, the numerous wire ends will make the process of placing the electromagnetic mat into the mould complex and time consuming.
  • Wire ends coming from the winding need to be insulated from each other and when the limited space is already tightly packed with wire ends, adding insulation to each wire end is challenging.
  • the main object of the present invention is to provide a method for production of a double-layer multiphase ironless winding for electric machines and a winding resulting therefrom partly or entirely solving the above-mentioned drawbacks of prior art. It is further an object of the present invention to provide a method for production of a double-layer multiphase ironless winding for electric machines and a winding resulting therefrom enabled by an electromagnetic mat that can be moulded with a curable liquid potting material, as epoxy/resin, to ensure higher mechanical strength, improved heat transfer, etc. for a stator or rotor component.
  • An object of the present invention is to provide a method for production of a double-layer multiphase ironless winding for electric machine and winding resulting therefrom enabling smaller end-windings compared to prior art solutions.
  • An object of the present invention is to provide a method for production of a double-layer multiphase ironless winding for electric machine and winding resulting therefrom enabling a substantially flat double-layer ironless winding.
  • An object of the present invention to provide a method for production of a double-layer multiphase ironless winding for electric machine and a winding resulting therefrom resulting in lower production costs, both for mass production and low volume products.
  • a method for production of a double-layer multiphase ironless winding according to the present invention is defined by the technical features of claim 1. Preferable features of the method are described in the dependent method claims.
  • a double-layer multiphase ironless winding according to the present invention is defined by the technical features of claim 5. Preferable features of the winding are described in the dependent winding claims.
  • a winding according to the present invention has two ends in the longitudinal or circumferential (tangential) direction.
  • the winding according to the present invention comprises multiple phase wires having respective first and second ends.
  • all the phase wire ends are positioned on the one and same end of the winding. Accordingly, in the present invention all the phase wires have both their ends on the same end of the winding. On the other end of the winding, the phase wires are continuous and have no interruptions or connections.
  • the mentioned two wire ends of the same phase wire when going in longitudinal or circumferential direction from the one end of the winding (where all the phase wire ends are positioned) to the other end, change transversal direction and cross each other in end-winding region of the winding arranging intermediate parts of the respective phase wires in alternating positions in the top or in the bottom layer in the active area. Intermediate parts of the phase wire will be the parts between the ends thereof.
  • the phase wires are arranged in determined positions in the winding by the use of a support structure holding the phase wires in place.
  • the support structure comprises warps into which the phase wires woven providing a winding in the form of an electromagnetic mat.
  • the winding has a circular shape and wherein the two ends thereof are connected.
  • a circular shape will be applicable in rotary machines.
  • the winding is directly formed with a circular shape.
  • the winding is directly formed within the circumference of an electric machine by being connected to the stator or rotor back iron.
  • the winding is first made with a flat shape, e.g. as a flat electromagnetic mat, which is then bent to a circular shape and next connection the ends of the winding/electromagnetic mat.
  • the winding/electromagnetic mat can be made and left flat.
  • the winding is consolidated/structurally enforced by moulding it in a curable liquid potting material, such as epoxy or resin.
  • a curable liquid potting material such as epoxy or resin.
  • the phase wires may be of any conductive type, such as, but not limited to, Litz-wires, solid wires, etc.
  • the winding comprises two or more phases.
  • the most common number of phases being three.
  • the present invention reduces the number of wire ends from twelve to six (compared to the closest prior art).
  • a method of production of a double-layer ironless winding of an electric machine comprises continuously extending the phase wires at one end.
  • the method further comprises, when going in longitudinal or circumferential direction from the one end to the other end of the winding, changing transversal direction of and crossing the respective phase wire ends in end-winding region of the winding and arranging intermediate parts of the respective phase wires in alternating positions in top or bottom layer in active area of the winding, and positioning all phase wire ends at the one and same end of the winding.
  • the method comprises holding the phase wires in place by fixing or integrating the phase wires in a support structure.
  • the method comprises fixing or integrating the phases wires to or in the support structure by weaving.
  • the support structure is according to one embodiment comprising warps that is used to weave the phase wires into the support structure.
  • it comprises coiling the phase wire length of each phase on two respective storages so that there is approximately the same length of phase wire coiled on each of the respective storages.
  • it comprises starting winding creation process from approximately the middle of the phase wires and the winding creation process is performed by moving the respective storages across the winding in transversal direction.
  • it comprises bending the winding to a circular shape and connecting the ends.
  • it comprises consolidating the winding by moulding it in a curable liquid potting material, such as epoxy or resin.
  • Fig. 1 is a principle drawing of an electromagnetic mat according to prior art
  • Fig. 2a-b are cross-sectional drawings of a double-layer coreless winding according to prior art
  • Fig. 3a-b are principle drawings of a coreless stator of axial-flux electric machine and its winding diagram according to prior art
  • Fig. 4 is a reconstruction of the design according to prior art
  • Fig. 5 is a principle drawing of a structure of a winding according to the present invention, showing end-windings for one phase only,
  • Fig. 6 is a principle drawing of the structure of a winding according to the present invention, showing end-windings of all phases,
  • Fig. 7a-d are principle drawings of the production method of a winding according to the present invention.
  • Fig. 8 is a principle drawing of an alternative design and alternative way to produce the winding according to the present invention.
  • Figure 1 is a principle drawing of an electromagnetic mat according to prior art US2020244149A1. As can be seen in Fig. 1 the end-windings of the neighbouring phases cross each other resulting in thicker end-windings compared to the thickness of the electromagnetic mat in the active area.
  • Figures 2a-b are cross-sectional drawings of a double-layer coreless winding of a slotless electric machine according to prior art GB1526614A. As can be seen from Fig. 2a-b the end-windings are quite long and thicker than the winding part in the active area.
  • FIGs 3a-b are principle drawings of a coreless stator of an axial- flux electric machine and its winding diagram according to prior art US2010117481A1.
  • the ironless winding comprises multiple strands of wire preformed into a wave shape with a plurality of legs connected by shaped end turns. As can be seen from Fig. 3a-b the total number of wire ends is twelve. From the winding diagram one can further see that six wire ends belong to the left-hand side of the winding and six wire ends belong to the right-hand side of the winding.
  • FIG 4 showing a representation of a flat winding 10 structure (like an electromagnetic mat) of the same design and structure as the winding presented in Figure 3b.
  • the phase wires 21-26 of different phases A, B, C, respectively, are represented by lines of different thickness.
  • the phase wires 21-26 in the first (top) layer are represented by solid lines and the phase wires 21-26 of the second (bottom) layer are represented by dashed lines.
  • phase wire 21-26 ends will be on both sides of the winding 10, grouped into a first group 41 at the left-hand side of the winding 10 and a second group 42 at the right-hand side of the winding 10. It is apparent that the winding 10 is made of six phase wires 21-26 belonging to the three phases, where:
  • FIG 5 is a principle drawing of the structure of a double-layer multiphase ironless winding 10 according to one embodiment of the present invention. Note that end-windings 70 are only shown for the first phase (phase wire 21).
  • the winding comprises three phases.
  • the three phases take positions one after another in a sequence A-B-C-A-B-C-... (phase wire 21-22-23-21-22-23-).
  • the present invention does not start the forming of the winding 10 from the ends of the phase wires 21-23, but from the middle of the phase wires 21-23.
  • the straight part of the phase wire 21 (on the left-hand side) comprises the starting part (intermediate part) of the winding 10.
  • Forming direction for the phase wire 21 is according to the present invention shown by arrows 30.
  • the present invention enables that parts of the same phase wire 21-23 (of the same phase) can be arranged in either a top or bottom layer in active part 80 (shown in Fig. 6) of the winding 10.
  • the first three straight parts of the phase wires 21-23 belong to the bottom layer and the last three straight parts of the phase wires 21-23 (right-hand side of the winding) belong to the top layer.
  • the winding 10 is bent to exhibit a circular shape, wherein the two single-layer parts is arranged on top of each other forming the double-layer structure.
  • the phase wire 21 of the first phase has both ends 21a-b at a second end 102 of the winding 10, wherein the phase wire 21 is continuously extending at a first end 101 of the winding.
  • the two phase wire ends 21a-b when going in longitudinal or circumferential direction from the one end 102 to the other end 101 of the winding 10, i.e. from right to the left in Fig. 5, change transversal direction and are crossing each other in end winding 70 region (shown in Fig. 6) of the winding 10.
  • the intermediate parts of the phase wire 21 are arranged in alternative positions in the top or the bottom layer and the phase wire 21 ends 21a-b "meet" each other in the first end 101 of the winding 10.
  • Figure 6 is a principle drawing of a structure of a winding 10 according to the present invention, showing end-windings 70 of all phases, phase wire ends 21a-b, 22a-b, 23a-b of all phases, as well as defining what is the active area 80 of the winding 10.
  • a three phase winding 10 is formed, since three is the most common number of phases.
  • Phase wire 21, 22, 23 length of each phase is coiled on two respective storages, e.g. storages 51A and 51B for phase wire 21, storages 52A and 52B for phase wire 22, storages 53A and 53B for phase wire 23.
  • the amount of phase wire 21, 22, 23 on the two respective storages 51A-B, 52A-B, 53A-B, should be approximately equal, so that the part of the phase wire 21, 22, 23, respectively, between the two respective storages 51A-B, 52A-B, 53A-B is approximately the middle part of the total wire length.
  • the winding creation process starts from the middle of the respective phase wires 21-23, and not from one of the ends as in the prior art solutions.
  • Fig. 7a-c further show the use of an embodiment of a support structure 60 used for holding the phase wires 21-23 in place in the winding 10.
  • the support structure 60 comprises warps 61 into which the wires 21-23 are woven, but any other suitable support structure can be used in the production method according to the present invention.
  • the respective storages 51A-B, 52A-B, 53A-B are repeatedly transferred from one side of the support structure 60 to the other side (swapping) to form loops like the ones shown in Figure 7b.
  • two layers of the winding 10 can be formed, wherein phase wire ends 21a-b, 22a-b, 23a-b from the same wire 21-23 can be laid on top of each other thus making the two levels/layers.
  • the process sequence would be first to integrate the first three phase wire 21-23 of the three phases into the support structure 60 next to each other, then make the first loop with the phase wire 21 of the first phase by moving/swapping the storages 51A and 51B, then make the second loop with the phase wire 22 of the second phase by moving/swapping the storages 52A and 52B, then make the third loop with the phase wire 23 of the third phase by moving/swapping the storages 53A and 53B.
  • Figure 7c The result of this sequence of steps is shown in Figure 7c.
  • FIG. 7d The schematic representation of the cross-section of the part of the winding 10 shown in Figure 7c is given in Figure 7d.
  • the first three phase wires 21-23 of the three phases are in the same single layer and the next three phase wires 21-23 are in two layers where the phase wires 21-23 of the same phase are located on top of each other.
  • the process continues until the required length of the winding 10 is reached.
  • the last three conductors 21-23 will also be in a single layer.
  • the two single-layer parts will be put on top of each other forming the double-layer structure, so that the whole ironless winding 10 has two layers everywhere along the circumference.
  • the production process (method) as described above can be manual or automated.
  • the support structure 60 can be of any kind, not only warps 61 like in the presented example.
  • FIG. 8 showing a schematic representation of the cross-section of the ironless winding 10 according to the present invention, where, if seen along the length of the winding 10, the phases A, B, C repeat more than one time, namely two times: for a three-phase system the sequence of phases can be A-A-B-B-C-C-A-A-...
  • the present invention is applicable for electric machines with any direction of the magnetic flux, e.g. for axial-flux or radial-flux machines.
  • the present invention is applied in linear or planar electric machines.
  • the present invention is applied for any number of phases.
  • the present invention is applied for any electric application and not only to the main windings 10 of the electric machines.
  • phase wires of phase A (wire lengths of phase A)

Landscapes

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

Abstract

L'invention concerne un procédé de production d'un enroulement sans fer multiphasé à double couche (10) d'une machine électrique, le procédé comprenant le démarrage d'un processus de création d'enroulement à partir approximativement du milieu des fils de phase (21, 22, 23) et le processus de création d'enroulement est effectué en déplaçant les dispositifs de stockage respectifs (51A, 51B, 52A, 52B, 53A, 53B) à travers l'enroulement (10) dans la direction transversale. L'invention concerne également un enroulement sans fer multiphasé à double couche (10) produit par le procédé.
EP22912070.4A 2021-12-20 2022-12-20 Procédé de fabrication d'un enroulement sans fer multiphasé à double couche et enroulement ainsi obtenu Pending EP4454111A4 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
NO20211544A NO347240B1 (en) 2021-12-20 2021-12-20 Method for production of a double-layer multiphase ironless winding and winding resulting therefrom
PCT/NO2022/050321 WO2023121476A1 (fr) 2021-12-20 2022-12-20 Procédé de fabrication d'un enroulement sans fer multiphasé à double couche et enroulement ainsi obtenu

Publications (2)

Publication Number Publication Date
EP4454111A1 true EP4454111A1 (fr) 2024-10-30
EP4454111A4 EP4454111A4 (fr) 2025-12-10

Family

ID=86903267

Family Applications (1)

Application Number Title Priority Date Filing Date
EP22912070.4A Pending EP4454111A4 (fr) 2021-12-20 2022-12-20 Procédé de fabrication d'un enroulement sans fer multiphasé à double couche et enroulement ainsi obtenu

Country Status (3)

Country Link
EP (1) EP4454111A4 (fr)
NO (1) NO347240B1 (fr)
WO (1) WO2023121476A1 (fr)

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH09271158A (ja) * 1996-03-29 1997-10-14 Toyota Autom Loom Works Ltd 誘導モータ及びその製造方法
US8823238B2 (en) * 2007-04-03 2014-09-02 Hybridauto Pty Ltd Winding arrangement for an electrical machine
SG172208A1 (en) * 2008-09-23 2011-07-28 Aerovironment Inc Motor air flow cooling
US9425664B2 (en) * 2012-05-09 2016-08-23 Thingap, Llc Composite stator for electromechanical power conversion
DE102013226875A1 (de) * 2013-12-20 2015-07-09 Robert Bosch Gmbh Verfahren zur Herstellung einer mehrphasigen Wicklung für einen Stator einer elektrischen Maschine
NO343559B1 (en) * 2017-10-11 2019-04-08 Alva Ind As Method for production of stator or rotor component for electrical machine and stator or rotor component for electrical machine
NO20200543A1 (en) * 2020-05-08 2021-07-19 Alva Ind As Method and apparatus for production of a multiphase electromagnetic mat for forming current carrying components of a power conversion system

Also Published As

Publication number Publication date
EP4454111A4 (fr) 2025-12-10
NO20211544A1 (fr) 2023-06-21
WO2023121476A1 (fr) 2023-06-29
NO347240B1 (en) 2023-07-24

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