electric machine, engine and method of building an electric machine

专利摘要:
ELECTRICAL MACHINE, ENGINE AND METHOD OF BUILDING AN ELECTRICAL MACHINE. The present invention relates to an electrical machine (10) comprising a rotor (14a, b) provided with permanent magnets (24a, b) and a stator (12) provided with coils (22) wound on the stator bars (16 ) for interaction with the magnets through an air gap (26a, b) defined between them. The bars (16) and the coils (22) are closed by an annular housing of the stator (42a, b) that extends between the air gap. A chamber (52,54,56) is defined which incorporates the cooling medium to cool the coils. The stator housing comprises two conjugated capsules (42, b) that fit the stator bars and coils to the machine. Each capsule is molded from reinforced plastic and interconnected (optionally through one or more intermediate components). At least one capsule has overmolded shoes of the stator bar that form part of said radial wall, and optionally one or more of the following components: cylindrical chamfer supports extending along the part of the cylindrical outer wall; connection studs that communicate electrically with the camera externally; stator coils; entrance and exit doors of (...).
公开号:BR112013003690B1
申请号:R112013003690-7
申请日:2011-08-16
公开日:2021-03-09
发明作者:Tim Woolmer；Chris Gardner；Jon Barker
申请人:Yasa Limited；
IPC主号:

专利说明:

[0001] The present invention relates to a permanent magnet electric machine comprising a stator and a rotor seated for rotation in the stator, and a method of building such a machine. The stator is supplied with coils wound on stator bars and the rotor is supplied with permanent magnets to cooperate with the coils through an air gap between the rotor and the stator. The machine can be either an engine or a generator and is, in many embodiments, an axial flow machine. In particular, the present invention relates to a segmented and yoke-free armor machine, hereinafter referred to as a "Y machine", and a method of constructing the machine. BACKGROUND
[0002] Woolmer and McCulloch [1] describe the topology of a Y machine, showing its advantages of reduced iron in the stator allowing an improvement in the torque density. It comprises a series of coils wrapped around bars spaced circumferentially around the stator, ideally and axially disposed (that is, parallel to the geometric axis of rotation of the rotor). The rotor has two stages that comprise discs provided with permanent magnets that are facing either end of each stator coil. The magnetic path at any stage of operation is: through a first coil to a first magnet in a first stage of the rotor; through a rotor counter rail to a second adjacent magnet in the first stage; through a second stator coil adjacent to the first coil; for a first magnet in the second rotor stage aligned with the second magnet in the first stage; through the counter rail of the second stage to a second magnet in the second stage and aligned with the first magnet in the first stage; and completing the circuit through the first coil.
[0003] One difficulty with electrical machines is usually to provide adequate cooling. This is a particular problem with a Y machine that has a high torque density that significant heat is generated in the coils at high torques and is often a limiting factor in the torques that can be employed, at least for extended periods of time. .
[0004] The magnetic connection between the coils and the permanent magnets depends on a strong magnetic field that is developed through the coils, or by the magnets in the case of a generator or by the coils themselves in the case of a motor and the permeability of the magnetic circuit must be as low as possible to allow maximum flow density through the coils. For this purpose, a core or bar with high permeability is provided around which the coils are wound. However, the bar is preferably laminated or otherwise arranged to reduce the incidence of eddy currents in the bar. Also, the bars are preferably provided with shoes to spread the flow in the air space and reduce the density of the flow in it - the air space is of high reluctance and by increasing its area it reduces this reluctance, and that means less material from permanent magnet can be used. It is desirable to reduce the amount of such material to a minimum.
[0005] WO-A-2006/066740 discloses a Y machine comprising a housing provided with a cylindrical sleeve that fits the stator coils internally, the sleeve being hollow, whereby the cooling medium circulates. However, the coils are embedded in a thermally conductive material to transport heat to the stator housing. A rotor is rotatably seated in the housing. The stator bars appear to be laminated, as they are in GB-A-2379093 which also reveals a Y machine, such as WO-A-03/094327.
[0006] US-A-6720688 discloses a Y machine in which the rotor acts as a mobile vane pump to circulate the fluid in a chamber defined by a stator housing through which a rotor rod, supported on the bearings in the housing and loading the rotor, it extends. The fluid cools the stator coils. US-A-2005/0035676 discloses another Y machine, particularly adapted for the gearless drive of a vehicle wheel.
[0007] US-A-2007/0046124 discloses a Y machine in which the rotor has two circumferentially ordered rows of alternating segments of permanent magnets and ferromagnetic pole parts.
[0008] Copending international patent applications, publication numbers WO-A-2010/092400 ("A1"), WO-A-2010/092403 ("A2") and WO-A-2010/092402 ("A3 "), reveal, respectively, various aspects of cooling, flow management and modular layout of Y machines. All the contents of each order are incorporated into the present by reference.
[0009] A1 reveals an electric machine comprising a rotor equipped with permanent magnets and a stator equipped with coils wound on the stator bars for interaction with the magnets through an air space defined between them, in which the bars and coils they are surrounded by a stator housing that extends between the air space and defines a chamber that incorporates the cooling medium to cool the coils.
[0010] The stator housing can comprise two annular places and two cylindrical walls, the annular plates including recesses for locating the bars in the chamber. Preferably, the material of the stator housing is non-magnetic and non-conductive. However, in the case of annular plates and separate cylindrical walls, said cylindrical walls are preferably aluminum and said annular plates are plastic material. Alternatively, said annular plates can be integral with said cylindrical walls, whose cylindrical walls are, in this case, divided around their circumference and connected together along the inner and outer circumferential seams. The division can be central by defining two capsules. The capsules can be substantially identical, possibly being "mirrored" images so that they fit together, making it easier to weld the seam around the joints in the rooms. The capsules can be plastic.
[0011] The annular plates can be tuned at the ends of the bar to minimize the space between the bars and magnets on the rotor. The cylindrical walls can be an internal and external wall, said external wall being provided with means for assembling the machine and said internal walls comprise means for assembling bearings for the rotor.
[0012] In A2, an electric axial flow machine comprises a rotor equipped with permanent magnets circumferentially spaced in the first and second stages of the rotor and a stator disposed between said stages and which has the coils wound on the stator bars of the stator for the magnetic interaction with the magnets through a defined air space between the rotor and the stator, in which the bars have a shoe at each end of each bar that connects the magnetic flux through the bars with said magnets at each stage, and wherein the stator is a casting of at least two annular components, each of which comprises a ring of connected shoes and one of which includes some or all of the bars or parts of them and the other of which comprises any remaining bars or parts of them, said coils are arranged on the bars before the annular components are connected together to complete the construction of said stator. The annular components can be identical, and can each comprise half of each bar, and be provided with interfaces adapted to facilitate the connection.
[0013] Also revealed and described in A2 is an electric machine that comprises a rotor equipped with permanent magnets and a stator equipped with coils wound on the stator bars for interaction with the magnets through a defined air space between them, in which the bars have shoes that connect the magnetic flux through the bars with said magnets, and where the bars and shoes are formed separately from each other and at least a part of each is formed by molding particles of sweet iron so that the particles have a short dimension that is arranged transversely to a plane of reluctance, and the bars and shoes are assembled so that said plane of reluctance of the bar is parallel to a longitudinal geometric axis of the bar and said plane of reluctance of the shoe is transversal to said longitudinal geometric axis.
[0014] The alignment of the short dimension of the transversal particles to the said reluctance planes results in each reluctance plane having a minimum reluctance. The particles of at least the bars can have a single longitudinal dimension and said particles can also be aligned so that their longitudinal dimension is parallel to a direction of reluctance in said plane of reluctance, the said direction of reluctance of the bars being parallel. to said longitudinal geometric axis of the bar. If the shoe particles have a single longitudinal dimension, preferably said reluctance direction is radial with respect to said longitudinal geometric axis when the bars and shoes are assembled.
[0015] In A3, the rotor stages can each comprise an annular disk, whose outer edges fit into said permanent magnets and whose inner edges are connected together involving said bearings. The rotor stages are plate-shaped to increase its stiffness in a radial plane (ie, a plane perpendicular to the geometric axis of rotation of the rotor and also, preferably, perpendicular to the stator bars). Each said inner edge may comprise a cylindrical flange with an interface for mutual interengaging. A spacer can be provided between the cylindrical flanges to adjust the preload on the bearing. The cylindrical flanges can include chamfers arranged parallel to said rotor geometry axis to receive fasteners to fix said rotor stages together.
[0016] The present invention is related to aspects of the stator coil capsule housing, whereby the manufacture of the machine is facilitated.
[0017] US-A-2006/0043821 reveals the overmolding of machine components. This is done in two stages. First of all, the stator bars are overmolded with a coil-shaped sleeve that has flanges on which they are wound, then the coils that are temporarily assembled using a locating ring or a series of connectors. The assembled bars and coils are inserted in a mold in which the entire stator is formed as an annular plate by means of injection molding. A similar arrangement is disclosed in WO-A-01/06623. BRIEF SUMMARY OF THE INVENTION
[0018] According to the present invention, an electric machine is provided which comprises a rotor equipped with permanent magnets and a stator equipped with coils wound on the stator bars for interaction with the magnets through a defined air space between them , with the rotor being supported for rotation with respect to the stator around a geometric axis of rotation, the bars and coils being surrounded by an annular stator housing and the stator housing comprising two conjugated capsules that assemble the stator bars and coils on the machine, each stator bar having shoes on each end and each capsule has cylindrical wall parts in the inner and outer radii and a radial wall joins the inner and outer cylindrical wall parts , whereby the two capsules are joined between the facing edges of said internal and external cylindrical wall parts to form said stator housing, and in which the here between them define a chamber through which the cooling medium circulates around the coils to cool them, characterized by the fact that
[0019] each bar is formed of at least two bar parts interconnected in a transverse slit through the section of the bar and in which
[0020] each capsule is molded by injection of reinforced plastic, being over-molded around the shoes of a part of the stator bar to retain and position the said parts of the bar on the radial wall, whereby said shoes form part of the said radial wall.
[0021] In accordance with the present invention, there is also provided a method of constructing a machine as defined above which comprises the steps of:
[0022] assemble the bar parts of the stator bars in a capsule mold provided with spaces for them,
[0023] close the mold and inject reinforced plastic material melted into the mold,
[0024] solidify the plastic material and open the mold to release a then-formed capsule, and
[0025] assemble the stator by connecting the two concentric faces of the two caps together and simultaneously joining said bar parts in said slot,
[0026] being that the mold, in this way, serves as a guide to position the stator bars on the machine.
[0027] More broadly, the invention provides a method of building an electrical machine of the type comprising a rotor fitted with permanent magnets and a stator fitted with coils wound on the stator bars for interaction with the magnets across a defined air space among them, in which the bars and coils are surrounded by an annular stator housing, the method comprising the steps of:
[0028] providing a first mold;
[0029] arrange the first shoes of the stator bars in the first mold;
[0030] close the first mold and inject the melted reinforced plastic material into the first mold;
[0031] opening the first mold after cooling and ejecting a first capsule in which said first shoes are retained in the plastic molded material of the first capsule;
[0032] providing a second mold;
[0033] arrange the second shoes of the stator bars in the second mold;
[0034] close the second mold and inject the melted reinforced plastic material into the second mold;
[0035] opening the second mold after cooling and ejecting a second capsule in which said second shoes are retained in the plastic molded material of the second capsule;
[0036] in which the first and second capsules are each formed with parts of the cylindrical wall in the inner and outer radii and a radial wall joins the parts of the inner and outer cylindrical wall;
[0037] mount the stator coils on the stator bars;
[0038] connect together facing edges of said internal and external cylindrical wall parts of the first and second capsule housings to form said stator housing, whereby the respective first and second stator shoes of each capsule housing they are combined together, securing the stator coils between them; and
[0039] mount the stator housing with the rotor.
[0040] It should be understood that connecting the conjugated facing edges of said internal and external cylindrical wall parts and the conjugated capsules includes in its scope the junction through the agency of other components.
[0041] Specifically, however, an electric machine can comprise a rotor equipped with permanent magnets and a stator equipped with coils wound on the stator bars for interaction with the magnets through a defined air space between them, the rotor being is supported for rotation with respect to the stator around a geometric axis of rotation where the bars and coils are surrounded by an annular stator housing and where the stator housing fits the stator bars and coils in the machine, and said stator housing has the cylindrical wall parts in the inner and outer radii and a radial wall joins the inner and outer cylindrical wall parts that define an annular chamber through which the cooling medium can circulate around the coils to cool them, characterized by the fact that
[0042] each bar is formed of at least two bar parts interconnected in a transverse slit through the section of the bar and in which
[0043] each radial wall is injection molded from reinforced plastic, being overmolded around the shoes of a part of the stator bar bar to retain and position said bar parts on the radial wall by means of said shoes form part of said radial wall.
[0044] The part of the external cylindrical wall can be aluminum, forming a housing for the machine, and the part of the internal cylindrical wall can be steel, forming a mounting ring for a bearing that rests the rotor on the stator.
[0045] Each radial wall can extend through the air space and is tuned where the shoes on each bar are retained to minimize the space between the bars and the magnets on the rotor.
[0046] When overmolding the stator shoes on the capsule, their position on the machine can be fixed, the mold serving as a guide to retain the stator shoes in the correct position with respect to each other and the capsule serves to maintain this juxtaposition during assembly. In addition, the stator shoes that are molded into the capsules, which are ultimately connected together to form the stator, provide a rigid stator construction, allowing the air space between the stator shoes and the rotor magnets to be minimized, whereby the efficiency of the machine is enhanced.
[0047] In accordance with other aspects of the present invention, electrical machines are provided that incorporate some or all of the foregoing aspects (where they are not mutually exclusive), such combinations being evident to the skilled person. While the following description of specific modalities may include or exclude the different aspects mentioned above, this is not understood to be significant. BRIEF DESCRIPTION OF THE DRAWINGS
[0048] The modalities of the invention are further described, hereinafter, with reference to the attached drawings, in which:
[0049] Figure 1 is a schematic view of a winding lathe introduced without yoke and segmented to which the present invention refers primarily (but not exclusively);
[0050] Figure 2 is a perspective view of the arrangements in Figure 1;
[0051] Figure 3 is an exploded perspective view of a stator housing and a machine stator according to an aspect of the present invention;
[0052] Figures 4a, b, c and c are, respectively, an exploded perspective view of a stator bar and shoes of an electric machine mode, an end view of another mode of the bar, a view of the end of an additional bar modality, and a perspective view of a composite stator bar and resulting flow paths;
[0053] Figures 5a, b and c are, respectively, a plan view of an embodiment of a machine according to an aspect of the present invention; a section on line A-A in figure 5a, and an exploded perspective view of the same machine;
[0054] Figures 6a and b are, respectively, a detailed view of the stator housing cutout of the figures 5a to c, seen in the direction of the arrow X in figure 5c, and a section on the line AA-AA in figure 6a;
[0055] Figures 7a and b, 8a and b, 9a and b and 10a and b, are each, respectively, an exploded perspective view and the detailed side section of three arrangements according to different modalities of the present invention; and
[0056] Figure 11a reveals a detailed side section through a motor according to the invention that shows the dispositions of the electrical connection;
[0057] Figure 11b shows a cabling option;
[0058] Figures 12 a and b respectively show an exploded view of an engine also according to an additional embodiment of the present invention, and a side section through it. DETAILED DESCRIPTION
[0059] A winding lathe introduced without yoke and segmented 10 is illustrated schematically in figure 1. Machine 10 comprises a stator 12 and two rotors 14a, b. Stator 12 is a collection of separate stator bars 16 spaced circumferentially about a geometric axis of rotation 20 of rotors 14a, b. Each bar 16 has its own geometric axis 16a which is arranged parallel to the geometric axis of rotation 20. However, this is not absolutely essential. In an axial flow machine, the axis 16a is, in fact, parallel to the axis of rotation 20. However, it can be arranged at any angle with it, even radially with respect to the axis of rotation 20. The discussion The following is in respect of an axial flow machine, this should not be understood as limiting in any sense and, where the context allows, the invention applies equally to the other inclinations of the stator bars 16.
[0060] Each end of each stator bar is provided with a shoe 18a, b which serves a physical purpose of confining a stack of coils 22, the stack 22 of which is preferably insulated wire with a square section (or possibly rectangular section) for that a high filling factor can be achieved. The coils 22 are connected to an electrical circuit (not shown) that (in the case of a motor) energizes the coils so that the poles of the resulting magnetic fields generated by the current flowing in the coils are opposite the adjacent stator coils 22.
[0061] The two rotors 14a, b carry permanent magnets 24a, b which are turned with the stator coil 22 between them. In fact, in the axial flow machine, the rotors and their magnets are radially arranged, but when the stator bars are tilted, then they are the same. The two air spaces 26a, b are arranged between the respective pairs of shoe and magnet 18a / 24a, 18b / 24b. There is a uniform number of coils and magnets spaced around the geometric axis of rotation 20 and, preferably, there is a different number of coils and magnets so that the coils, not all of them, register with the corresponding pair of magnets and in the same position of rotation of the rotor with respect to the stator. This serves to reduce rough rolling.
[0062] In an engine (to which the present invention primarily relates) the aforementioned electrical circuit is arranged to energize the coils 22 so that their polarity alternates and serves to make the coils, at different times, align with different pairs of magnets, resulting in the torque that is applied between the rotor and the stator. Rotors 14a, b are generally connected together (for example, by a rod, not shown) and rotate together about geometric axis 20 with respect to stator 12, which is generally fixed (for example, in a housing, not shown) . An advantage provided by the arrangement is illustrated in figure 1 in which the magnetic circuit 30 is provided by two adjacent stator bars 16 and two pairs of magnets 24a, b. Thus, no yoke is required for stator 12, although a rail 32a, b is required for each rotor that connects the flow between the rear of each magnet 24a, b facing away from the respective coils 22.
[0063] Thus, in the case of a motor, by means of the appropriate energization of the coils 22, the rotor 14 can be propelled to rotate around the geometric axis 20. Logically, in the situation of a generator, the rotation of the rotor 14a, b induces currents in the coils of stator 12 according to the alternating magnetic flux induced in the bars of stator 16 as the rotors 14a, b rotate.
[0064] However, in any case, heat is generated in the coils 22 and the efficiency of the machine is reduced, and its capacity is limited, if this heat is not removed. Accordingly, the present invention suggests wrapping the stator coils 16 in a housing that extends through the air space 26a, b and that defines a chamber provided with a cooling medium.
[0065] Returning to figure 3, a stator 12a is shown in which the stator coils are located between the plastic caps 42a, b. These capsules have external cylindrical walls 44, internal cylindrical walls 46, and radially arranged annular walls 48. The annular walls 48 include internal pockets 50 for receiving the shoes 18a, b of the stator bars 16 and serve to locate the stator coil assemblies 16, 22, 18a, b when the capsule housings 42a, b of stator 12a are assembled together. The stator housing 42a, b defines the spaces 52 internally of the coils 22 and also externally at 54 around the outside of the coils 22. Furthermore, there are spaces 56 between the coils. The 52,54,56 spaces are interconnected defining a cooling chamber.
[0066] Although not shown in figure 3, when assembled, the stator housing 42a, b is provided with doors that allow the cooling medium (preferably, electrically non-conductive liquid) to be pumped into the spaces 52,54,56 to circulate around the coils and cool them. In fact, being preferably made of a plastic material such as polycarbonate or other material with a low heat conduction capacity, the heat generated by the coils and conducted to the shoes 18a, b is retained in the housing and is not transmitted to the magnets 24a, b, which are particularly susceptible to heat.
[0067] A preferred arrangement involves building the machine as described above (or as described below) and then, when completed, fill in the spaces 52,54,56 with a configurable liquid resin or lacquer that moistens all the internal surfaces of those spaces , including the coils 22. Once the resin has had the opportunity to penetrate every space, it is drained from the machine leaving only a covering of the resin surface inside the chamber defined by the spaces 52,54,56. Consequently, the resin cures to form an electrically insulating layer that separates the spaces 52,54,56 from the coils 22. In this way, water can be used as the cooling medium. Suitable lacquers are within the knowledge of a person skilled in the art.
[0068] It is known that the coil cores for electrical machines are often made of steel laminations. Steel is an excellent conductor of a magnetic field - it has a low magnetic reluctance and provides a low reluctance path and has low hysteresis loss. However, a problem with most ferromagnetic materials is that they are also generally electrical conductors. Therefore, the altered flow through an electrical conductor creates eddy currents. These are minimized by employing laminations that are separated by an insulator, with the insulation being parallel to the desired flow direction so that transverse electrical currents are minimized. However, a new technique is successfully found, employing insulating coated sweet iron particles and molded into a desired shape (soft magnetic compounds - SMC), which are bonded together by resinous insulation. A high pressure compaction process is used to shape the component into a complex shape, capable of producing three-dimensional magnetic flux patterns with an excellent shape factor and which allows a high filling factor winding to be employed, wound straight into the tooth. of the SMC.
[0069] In fact, in an electric machine mode, the problem of minimizing the reluctance of the stator bar material and the shoe in the direction of the magnetic flow is referred to in the arrangement of figures 4a to d. Thus, although the SMC material is very suitable, it should be noted that, although the coated iron particles have the ability to reduce eddy currents and generally have a low magnetic reluctance in all directions, they do not have the better, that is, the minimum possible reluctance, which is still in the domain of the laminations, at least in the plane or in the direction of the laminations.
[0070] In this respect, it is suggested to use such particles in the construction of the stator bar 16 and the shoes 18, but to arrange them so that they have a preferential, or at least flat, low reluctance direction, which is preferably inferior to that normally supplied by such particles. In the case of the bar 16, this preferred direction is, in planes, parallel to the geometric axis 16a. In the case of shoes 18, a minimum reluctance is desirably arranged in planes perpendicular to the longitudinal geometric axis 16a. This can be provided in a variety of ways, although separate construction of the bar 16 and shoes 18, as shown in figure 4a, and subsequent assembly is essential.
[0071] Thus, the bar 16 of figure 4a is manufactured from coated iron particles that control insulation and rounds. These particles are first flattened to form disc-like components before being placed in a mold and finally pressed together. The mold is arranged so that the direction of pressing the particles, and their initial distribution before pressing, is such that the largest dimensions of the particles are in a plane that is parallel to the geometric axis 16a. This, most conveniently, should be achieved, although only partially, by starting with the essentially round particles in the mold and pressing them together in a direction perpendicular to the geometric axis 16a. For example, pressing upward in the direction of Arrow A not only flattens the particles in a plane orthogonal to direction A, but also tends to spread them in the direction of Arrows B.
[0072] Ideally, however, the particles are elongated and are arranged in the mold with their long geometric axis parallel to the geometric axis 16a. This can be achieved by employing a magnetic field to align the particles. On this occasion, the minimum flow line for the component is not only in planes parallel to the geometric axis 16a, but in fact in this specific direction.
[0073] On the other hand, the shoes 18 are preferably manufactured by pressing round particles in a direction parallel to the geometric axis 16a so that, during the compaction process, they spread laterally in the plane perpendicular to the geometric axis 16a. When the shoes 18 and the bar 16 are assembled together, the magnetic flux can therefore travel with minimal reluctance through the bar 16 in the direction of the longitudinal geometric axis 16a and out of the bars 16 both in the direction of the geometric axis 16 through the end 16d of the bars to enter air spaces 26a, b directly, but also orthogonally on the peripheries of the shoe 18c, as can be seen from the arrows of the magnetic flux indicated in figure 4d.
[0074] In a preferred arrangement, the stator bars 16 also comprise a lamination roller, which can improve the directional inclination of the minimum reluctance. Thus, in figure 4b, a roller 90 of steel coated with insulation is arranged in a mold (not shown) with its geometric axis parallel to the geometric axis (last) 16a of the bar 16b to be formed. The mold is then filled with particles that are pressed and compacted around the laminating roller so that a plane of minimum particle reluctance is parallel to the geometric axis 16a. They surround roller 90 and provide the bar with its desired trapezoidal section.
[0075] An alternative construction in figure 4c has a trapezoid-shaped core 92 of pressed iron particles that have at least one plane of minimal reluctance parallel to the geometric axis 16a. A laminating roller 94 is then wrapped around core 92 and results in a stator bar 16c having the desired external sectional shape.
[0076] Both bars 16b, c of figures 4b and c, each, have preferred directions of minimum reluctance parallel to the geometric axis 16a. The collars 18c, formed from the pressed sweet iron particles, have minimal reluctance planes perpendicular to the geometric axis 16a. When assembled, the bar and collars result in a stator core that has an extremely low reluctance and is directionally optimized. Alternatively, instead of collars 18c, the end plates (or shoe elements - not shown) could be employed against which the ends of the bar elements 16 are joined to the top to complete the construction. The shoe elements and the ends of the bar elements could have corresponding conjugate features (not shown in figures 4a-d) that align with each other. Even so, such end plates could be constructed with a central region provided with an axial direction of minimal reluctance and a collar such as collar 18c with a radial direction of minimal reluctance.
[0077] An embodiment of the invention is described with reference to figures 5a, b and c, which illustrate a particular construction of the engine 100. Again, although an engine is described, it must be understood that the principles also apply directly to a generator. The motor 100 is, in fact, a single piece of the motor and two or more of them can be screwed together, as described below. Each motor has a tubular stator housing 102a, b provided with radially planar end faces 104a, b between the internal (108a, b) and external (106a, b) side walls. The radially outer cylindrical walls 106a, b each have an outer circumferential flange extension 110a, b that defines the radially planar end faces 112a, b of the motor. In fact, the stator housings 102a, b constitute the motor housing itself. Several housings 102 can be screwed together, end to end by screws and nuts (not shown) that pass through the chamfers 113 (see figure 5c) arranged around housings 102a, b. In fact, motor 100 can be fitted to a vehicle, for example, which uses chamfers 113 as plug-in flanges.
[0078] Despite being screwed together and being a composite motor 100, each piece of motor 100 can be independent of the other, as described below, and can be driven at its own speed and torque, as required by a management system engine, which is not described later in the present. However, as also explained further below, the pieces of motor 102 could be connected to a single output unit, thereby doubling the available output torque. In fact, there is no limit to the number of pieces of the engine that can be stacked together.
[0079] The housings 102a, b define a stator housing when joined, through their internal end faces 113a, b and 115a, b of the inner and radially outer cylindrical walls 106a, b 108a, b respectively. An annular chamber 53 is thus closed and contains, locates and fixes a plurality of stator coils 122 fitted to the stator bars 116 which have shoes 118a, b. In fact, as described below, the shoes of at least the stator bars are overmoulded in the material of the stator housings 102a, b. The coils 122 are spaced circumferentially around the geometric axis of the rotor 120a, as described in figure 5c and there are 24 of them in this motor (see also figure 10). Each stator coil shoe 118a, b is received in a bag 150 of chamber 53. Housings 102a, b are molded from non-electrically conductive and non-magnetic material, preferably glass or other fiber-reinforced polymer such as nylon. The housings are in the form of a capsule.
[0080] In figure 5b, the bars of stator 116 can be seen to be built in two halves with integral shoes 118a, b in half of each bar which is divided into a central line 117. Capsules 102a, b are molded in one mold (not shown) and, prior to molding, the shoes 118a, b of the stator bars are located in the spaces in the mold so that when the plastic is injected into the mold, the shoes 118a, b are fixed in the respective bags 150. One Once the capsules are shaped, the coils are slid over each bar, the cabling of which is handled as described below.
[0081] Finally, the outer race 165 of a bearing 164 is located on step 120 of the inner cylindrical wall 108a, b. When capsules 102a, b are joined, the additional adhesive bonds to faces 117 of bars 116 together and the outer race of the bearing is captured. In fact, the entire bearing 164 is most likely pre-assembled and captured by steps 120, the bearing having an inner race 167. The bearing can be supplied with its pre-loaded roller elements (as shown in figure 5b), but the inner race could be divided (as shown in figure 5c) whereby tightening the inner race performs the necessary preload. In fact, steps 120 can be replaced by a solid metal ring (not shown) overmolded in the cap on which the outer race of bearing 165 is seated.
[0082] Rotors 114a, b are connected together through internal flanges 166a, b. These are tubular and are provided with spaced chamfers 168 to receive nuts and bolts (not shown) that connect the two rotors 114a, b together. Thus, rotors 114a, b are, for all purposes, a unique and integral structure. Extending from the cylindrical flanges 166a, b are the plate-shaped tabs 172a, b ending in an annular section 174a, b into which the magnets 124a, b are fitted. In fact, extensions 174a, b are preferably provided with pouches 176 to receive the magnets and locate them firmly. Inner flanges 166a, b have interlocking tabs 169 and tighten inner race 167 of bearing 164 when assembled.
[0083] Between magnets 124a, b and capsules 142a, b are air gap 126a, b. As will be well understood in engine technology, the air space should be as small as possible in order to reduce the reluctance of the magnetic circuit. However, the arrangement of the engine described with reference to figures 5a, b and c allows a very narrow air space to be designed due to the few manufacturing tolerances that must be accommodated in the assembly of the engine 100a, b. Due to the fact that bearing 164 represents a (relatively) significant source of lost movement, the rotors are potentially adapted to apply a pre-tension on the bearings, the pre-tension of which can be limited by a spacer arranged between them. Logically, the axial dimension of the spacer can be designed to ensure a tight fit. However, with the exception of the bearing, there are relatively fewer other components whose tolerances advance and require a large air space. Logically, such a component is the stator 112 itself, for which the dimensions of the cylindrical walls 106a, b, 108a, b are critical in ensuring the smallest air gap 126a, b possible, despite the presence of a wall (104a) formed by the capsule that is included in it. Furthermore, it is evident that any stresses on the rotor will result in the stresses in the stator housing 112 that must be accommodated. However, the series of stator bars and shoes running through chamber 53 provides significant reinforcement in chamber 53 to make housing 112 extremely secure in an axial direction.
[0084] Furthermore, the concept of fitting rotor 114 directly to stator 112 has two additional beneficial effects. The first is connected with the general principle of motor design that demands that magnets 124 and coils 122 be arranged as far away as possible from the rotational axis 120a so that the magnetostrictive force acting between the coils and magnets rotates in torque. maximum around the geometric axis of rotation. This means, however, that if the fixation of the rotor with respect to the stator is the distance that is not much less than the radius of the magnets / coils, the rotor must be very rigid over this distance. When fitting the rotor directly to the stator, this distance is reduced and therefore the rotor does not have to be as rigid. Alternatively, the air space may be less. Second, by connecting the rotor using a plate-shaped annular space 172 that turns into a tubular body 166, an additional 30 'return path (see figure 8) for the magnetic flux is created. At least, this is the case if the rotor is made from ferromagnetic material. This additional flow path is advantageous because it reduces the flow requirement to be confined in a circumferential direction on the flanges 174 between the magnets, but also allows for an alternative return path for each magnet-coil-magnet circuit. The general reluctance of the magnetic circuit is thus reduced.
[0085] It should be noted that the axial force applied to each rotor due to the magnets is significant, and it increases as the air space reduces and can be in the order of 7,500N per rotor. As a result of this, the axial support of the rotors is extremely important and therefore the bearing (s) between the stator and the rotor must (m) provide a strong and stable reaction to this force. If the rotors are preferably located on either side of the stator, there is a net axial force of zero, but to achieve this narrow construction tolerances and a firm bearing assembly are required. However, by mounting the rotor directly inside the stator as described in the present, this accuracy is achievable within reasonable cost. The steps 120 against which the bearings sit and are located, axially, are critical in this regard.
[0086] Logically, the joint between each cylindrical wall 106a, b, 108a, b is equally critical. Capsules 102a, b can be identical, mirror images of each other or different. In the modalities described below, they are different, for reasons to be explained. Thus, the capsule 102a is provided with grooves 109 (see figure 6b) on the end faces 111 of the inner and outer cylindrical walls 106a, 108a. The corresponding edges (not shown) are provided on the corresponding end faces of the other walls 106b, 108b of the capsule 102b, whereby a labyrinthine connection region (which is radially accurate and provides a long leakage path, as well as a large connection area) is provided. The adhesive connection is also a potential connection mechanism, at least as a temporary measure during the total construction of the motor 100 (since the screws connecting the chamfers 113 also hold the capsules together). The sealing rings (not shown) can be arranged in the grooves 109. However, it is the faces 111 that determine the axial dimension of the stator 112.
[0087] Capsule 102a is provided with a chamfer for port 154, provided with an inlet port 156 for the cooling medium and an outlet port 160. Within the chamber 53 barriers or blocks 158a, b are formed to support the coils 122 and to divide chamber 53 into two annular passages so that the fluid entering port 156 circulates around the motor which interleaves between the various coils 122 before it can leave port 160, returning the cooling medium to a pump and the heat sink (neither shown) where it came from.
[0088] The preferred arrangement has blocks 158a, b that are on either side of the coil between inlet 156 and outlet 160 (as shown in figure 6a), and other blocks (not all visible) are periodically arranged around the machine alternately on the inside and outside of the coils (say, every four coils). Through this arrangement, the flow enters the inlet 156 and begins around the outside of the machine, but is directed by a first block 158c to pass inside the chamber 53, between different intervening coils 122. From there, the flow continues to circulate around the machine, but is forced by an internal block (blocks not visible, but conveniently 180 degrees opposed 158a, b) to flow the flow back to the outside of the chamber. Further around the machine, another external block (block not visible, but 180 degrees opposite 158c) forces the transition back to the inside before block 158b forces the fluid to transition back to the outside and finally, exit the machine via exit 160. In this diagram, there are four transitions. However, any even number of transitions is possible.
[0089] As mentioned above, two motors 100 can be interconnected by screws that pass through two stacks of housings of the capsule 112, through the aligned chamfers 113. In such a case, the motors could be independent with the rotors 114 not being connected between itself. However, they could clearly be, by arranging an appropriate spacer (not shown) between them, and extending the screws through the respective chamfers 168 so that they pass through both rotors. In fact, there is nothing to prevent additional engines from being added in series, so that three or more engines can be employed in tandem.
[0090] The (end) sides of the compound motor can be closed by linings (not shown). In the absence of such linings, the width of the machine 100 is defined by the capsules 102a, b, in particular, by the outer flanges 110a, b which house the rotor stages 114a, b.
[0091] The output (not shown) of motor 100 can comprise any suitable component and can be a rod. However, typically, in an automotive application, it can be a standard drive hub that has a tripod cup for receiving a rod (not shown) that has a trilobulated yoke. However, it is an aspect of direct mounting of the rotor to the stator that varying the output configurations without any disturbance to the motor design is possible. Thus, the rodless topology allows for a wide variety of output configurations, which include:
[0092] Automotive "constant speed" (CV) gasket housing;
[0093] Striated rod (either male or female); and
[0094] Flat drive plate with any hole pattern.
[0095] It can be seen that when mounting the rotor directly on the stator at a distance from the axis of rotation, a substantial hollow space is created within the rotor. Depending on the application, this provides an opportunity to arrange a gearbox, particularly a planetary gearbox, inside the engine. To a certain extent, in many circumstances with a machine of the present design, a gearbox is not necessary because the electronics required to manage the coils can enable the machine to operate at a substantially constant maximum torque (subject substantially only to cooling limitations) over a wide range of speeds, for example, torques of 500Nm per engine piece, at speeds in excess of 3000rpm, are feasible. However, this option is distinctly available.
[0096] This provision also has the advantage of facilitating the interconnection of machines in tandem, because there is no requirement to disturb the support arrangement of the rotor in the housing as would normally be the case where the rotor is supported on the bearings fixed in the housing. Clearly, there is some scope for debating as to where a stator starts and an accommodation where it is fixed ends. In fact, the invention provides, in terms of engine, the following non-exclusive list of options:
[0097] A single piece of 500Nm with a splined output;
[0098] Two 500Nm pieces independently controlled, each with its own CV-type output for automotive applications;
[0099] Four pieces joined as two pairs (1000Nm per pair), each pair with a CV output, again, potentially for automotive applications (high performance);
[00100] Four pieces fixed rigidly together giving 2,000Nm;
[00101] A specific embodiment of the present invention is now described below:
[00102] As is evident from the above, the stator housing of the motor 100 is not merely a housing for the stator, but it is also the housing for the entire motor, subjected to any closing linings. In this way, it requires structural rigidity that is provided when employing carbon fiber-reinforced glass or plastic such as nailon, or more specifically, a polyphthalamide (PPA). The present invention establishes that certain elements are overmolded by the stator housing during the construction of the motor, for several reasons as discussed below.
[00103] Referring to figure 6a, b, the shoes 118 are not merely positioned in the bag 150, but are actually molded in the bag 150. For this purpose, the bag may have a small recess to retain the shoe in the bag after the molding and to facilitate handling. However, it is hardly required due to the fact that the shoe can be coated with an initiator to facilitate the adhesion of the plastic to the face and sides of the shoe. Second, the sides 153 of the bag tightly tighten the shoe because of the differential shrinkage between the shoe and the plastic during cooling. Overmoulding of shoe 118a, b is preferred at any time because it facilitates the formation of thinning of end face 104a. That is, the face of the shoe 118a, b can be provided with a trunk 151a of the grooves that can help the flow of the plastic material and ensure uniform and complete coverage over the tuned area. Clearly, such a trunk would be possible to form on either side of the mold itself, if the shoe was not being overmolded; but in this case, the trunk, if it were on the outside face 104a, would lead to an effective thickening of the wall preventing the magnets from being arranged near face 104a. This would require the trunk to be subsequently attached to the face to restore fineness. If the trunk were on the inside of bag 150, then it would be compatible and would fit precisely with a corresponding trunk on the face of the shoe. It clearly couldn't be a tight fit. However, when using the shoe face itself as the mold, not only is the registration between the trunk 151 and the grooves 151a to be guaranteed, but, of course, it is adjusted between them, it is complete and adds to the safety of the location and the shoe retention in pocket 150. The groove trunk 151a shown in figure 6b assumes a mold filling in the direction of the arrows, that is, radially and externally of the geometric axis of rotation 120a.
[00104] To help the melted plastic flow easily and not solidify too soon, the mold can be preheated, as can the shoes. The precise temperatures selected will depend on the plastic used, but in the case of polyphthalamide, for example, the mold can be at a temperature of 150 ° C, while the shoes can be at 180 ° C.
[00105] Referring to figures 7a and b, the tuned wall of the capsule pouch 202 can be removed all at once and replaced by a window 250 in which the stator shoe 218 is overmolded. The shoe has a labyrinthine edge 220, whereby good adhesion, contact and location with respect to window 150a can be performed. When capsules 202 are formed with overmoulded shoes 218, location characteristics 222 are turned inward. These can be small undulations and combine corresponding characteristics (i.e., bubbles) on the end faces 224 of the stator bars 216, whereby their relative locations in a radial plane can be precisely controlled. Also, improved bonding through adhesion between stator bar 116 and shoe 218 can be achieved, although it may be preferred to omit the adhesive in order to improve magnetic reluctance. It should be noted that bars 216 and shoes 218 can be formed from directionally preferred magnetic reluctance material, as described above in relation to figures 4a to d.
[00106] Figures 8a and b show an alternative arrangement (to that of figures 7a, b) in which an integral shoe and part of the bar 317 are over-molded and fill the window 250 of the capsule 302. The face 224 of the part of the bar 317 has the resources 222 described above, but at present, care must be taken that parts 222 interact properly. This can be achieved by making the features 222 symmetrical (in reflection) so that two identical bar parts 317 interlock appropriately.
[00107] A component optionally also overmoulded by the stator housing is chamfer reinforcements or 113x gloves (see insert in figure 5c). These trace the chamfers 113 and prevent damage to the plastic material when the screws through the chamfers 113 are tightened. However, it is also possible that such gloves can be fitted by pressure after molding, in which case, at least one end of the 113x glove must be undiluted (both ends are shown dilated in figure 5c).
[00108] In figures 9a and b, a coil 422 is overmoulded by capsule 402, an edge 410a of the coil forming the core for the edge 414 of window 450 of capsule 402. When the opposite edge 410b is joined against the corresponding face (not shown) ) of the other capsule, a through hole 430 is formed in which the integral bar elements and shoes 417 can be fitted. Any annular pouch 432 provides a seat for the edge 418 of the bar 417 that can be attached to it. Again, the face 424 of each member of the bar 417 can have the features 222. However, according to the present invention, both the bar 417 and the coil 422 are overmoulded by the cap 402.
[00109] In figures 10a and b, rings 500 are overmolded in capsules 102a ', b' (which are otherwise identical to the capsules in figure 5c) around each pocket 150 in order to reinforce the connection between the capsule and the stator bars 116. The pocket corner 502 has been found to represent a concentration of stress that is at least partially relieved by chamfering the corner with a radius R (see figure 6b). However, the reinforcement rings 500 also act against the effect of the stresses imposed.
[00110] In figures 11a, b a drive phase conductor u (from three-phase supplies u, v and w) is connected to terminal 600 by a nut 610. Terminal 600 comprises a stud with two flanges with hexagonal section 620 separated by a slot 621, the stud being overmolded in the 602 capsule with the wall material both entering the slot 621 in order to locate the stud axially (with respect to its own geometric axis) and also around the hexagonal flanges 620 in order to secure the rotating prisoner (again with respect to its own geometric axis). The winding wires 630 of the coils (not shown) can be interconnected with a clamp 640 that is also connected to the underside of the stud 600 by an additional nut 611. A bus bar 650 can also connect the terminal to the coils of the same phase anywhere on engine 100 or to a different engine. In figure 11b, four quadrants 670 of coils 622 for each phase u, v, w are shown. (In a motor with 24 coils, there are six coils in each quadrant, two for each phase of a three-phase supply). The phase conductor u is connected in series to each first coil in each quadrant at 90 degrees of mutual separation (45 degrees with 24 coils) before returning to another phase (ie u to v, v to w, w to u).
[00111] Returning to the doors 156,160 (figure 6a), these can be characteristic of the molded plastic. However, it is also feasible to overmould plates that form the seal with the conduit connections and / or fixing means in the forms of prisoners, in any of them themselves molded, or integrated with said plates (none of the above that are shown).
[00112] Finally, as mentioned above, several rings and other metallic components can be overmoulded in the capsules to help maintain the shape and integrity of plastic capsules under tension. In particular, as mentioned above, a ring can be overmoulded on the inner cylindrical walls 108a, b in order to support the bearing 164.
[00113] Overmolding components involve creating spaces to receive such components in the mold that forms the capsule housing. The capsule housings are ideally formed by two parts of molds that open in a single direction, but clearly, the cores and recesses can be formed by additional components. However, the assembly of the motor described above is substantially facilitated by adjusting the shoes 118a, b in the appropriate spaces in the mold before the mold is closed. The closing of the mold can only be achieved with the shoes properly positioned and, consequently, when the injection occurs and the mold is opened after solidification, all the shoes are positioned and retained in the capsules. Since the shoes are retained in position, then, it facilitates the additional assembly of the motor. For example, if the coils are not themselves overmolded in the capsules themselves, then they can easily be positioned on the bars that can be located on the shoes using features 222 (figure 7a, b). Alternatively, the bars can be integral with the shoes (figure 8a, b), in which case the coils are simply slid over them, or in the mold if they were also overmolded or later, during assembly. The coils can be pre-wound in the hollow cores, for example, injection-molded gloves mounted in temporary solid forms for the winding.
[00114] While the modalities of the invention described with reference to figures 5 to 11 involve the molded capsules that constitute the housing for the machine, as well as for the stator, the embodiment of figures 12 to b involves the housing of the machine 1000 as a whole it comprises an aluminum or other metallic glove 1001. The glove 1001 is conveniently made of cast material, with machined faces for precise dimensions. Capsules 1002 are identical and comprise a molded annular disk provided with an inner circumferential wall or flange 1008 and a small thickening 1006 in its outer circumference. In accordance with the previous embodiments, in particular the embodiment of figure 6, the stator bars 1116 each comprise a shoe element 1118 and half element of the integral bar 1117 (as per the arrangement of figure 10b). In fact, at present, each shoe element 1118 is shown with a protrusion or lower cut 1118a whereby the shoe is embedded in the overmoulded material of the capsule 1002.
[00115] In addition to providing the necessary stator housing and chamber wall, the mold (not shown) in which the 1002 capsules are molded forms a guide that positions the 1116 shoes precisely in relation to each other on the machine 1000, the capsules 1002 maintaining this position after assembly of the machine. In this embodiment, a separate coil assembly 1122 is provided comprising coils 1022 wound in pairs and mounted on a coil guide so that when cabling 1670 is completed (for example, as in figure 11b) and attached to the coils, they are all captured together in a loose circle. A connection socket 1672, with phase pins u, v and w, is attached last and, when this has been done, the coil circle is positioned in housing 1001 with socket 1672 attached to socket 1674 which is part of housing 1001. The electrical connection is made, but socket 1674 seals the inside of housing 1001 from the outside.
[00116] Then, one of the capsules 1002 is offered up to one of the two internal shoulders 1004 of the housing1001 and connected in place using a suitable adhesive between the thickened edge 1006 and the shoulder 1004. In this process, the coils are each passed above the bar elements 1117 of the stator bars 1116. A mounting ring of the bearing 1200 is then slid into the inner cylindrical wall (flange) 1008 and connected in place. A ridge 1202 of ring 1200 limits an end face of flange 1008 and locates the ring axially. Finally, the second capsule 1002 is positioned, the adhesive having been applied to the end faces 1117a of the bar elements 1117 so that each one is bonded together. The flange 1006 is also connected to the other shoulder 1004 of the housing 1001 and to the ring 1200 on which the flange 1008 slides. Ridge 1202 is then pressed between the two capsules, as can be seen more clearly in figure 12b. Bearing 1164 can now be located in ring 1200 which has a shoulder 1208 against which the outer race 1165 of the bearing rests and a groove 1210 in which a washer is provided to locate the other side of the bearing race. The inner race 1167 fits the rotor (not shown in figure 12a, b).
[00117] The provisions described above facilitate the construction of the machine as a whole.
[00118] Throughout the description and claims of this specification, the words "understands" and "contains" and variations of them mean "includes, but is not limited to", and they are not intended (and do not) exclude other means , additives, components, whole numbers or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context requires otherwise. In particular, where the indefinite article is used, the specification should be understood as contemplating the plurality, as well as the singularity, unless the context requires otherwise.
[00119] The resources, whole numbers, characteristics, compounds, chemical means or groups described together with a specific aspect, modality or example of the invention must be understood to be applicable to any other aspect, modality or example described in present, unless it is incompatible between them. All features disclosed in this specification (including any claims, summary and attached drawings), and / or all steps of any method or process then disclosed, may be combined in any combination, except for combinations in which at least some of such characteristics and / or stages are mutually exclusive. The invention is not restricted to the details of any previous embodiments. The invention extends to any new feature, or any new combination, of the features disclosed in this specification (including any claims, summary and attached drawings), or to any new steps, or any new combination, of the steps of any method or process then revealed.
[00120] The reader's attention is directed to all essays and documents that are currently deposited with or prior to this specification in connection with this request and which are open to public inspection with this specification, and the contents of all such essays and documents are hereby incorporated by reference. REFERENCES [1] TJ Woolmer and MD McCulloch "Analysis of the Yokeless and Segmented Armature Machine", International Electric Machines and Drives Conference (IEMDC), 3 to 5 May 2007.

权利要求:
Claims (26)
[0001]
1. Electric machine (100) comprising a rotor (114a, b) with permanent magnets and a stator (112) with coils (122) wound on the bars (116) for interaction with the magnets (124) through a air space (126) defined between them, the rotor (114a, b) being supported for rotation with respect to the stator (112) around an axis of rotation (120) in which the bars (116) and the coils (122) are enclosed in it by an annular stator housing (102a, b) and in which the stator housing comprises two conjugated capsules (102a, b) that mount the stator bars (116) and the coils (122) on the machine (100), each stator bar (116) has shoes (118) at each end and each capsule (102a, b) has cylindrical wall parts (108ab) in the inner and outer radii (106a, b) and one radial wall joins the internal and external cylindrical wall parts (44, 46), whereby the two capsules are connected together between the facing edges (113a, b; 115a, b) of said pair of the internal and external cylindrical wall to form said stator housing, and in which the capsules define between them an annular chamber (53) through which the cooling medium can be circulated around the coils to cool them, characterized by the fact: each stator bar (116) is formed from at least two parts of the bar interconnected in a transverse slit (117) through the stator bar section, and in which each capsule (102a, b) is molded by injection of reinforced plastic, being over-molded around the shoes (118a, b) of a part of the stator bar bar to retain and position said parts of the bar on the radial wall whereby said shoes form part of said wall radial.
[0002]
2. Electric machine according to claim 1, characterized by the fact that the radial wall extends through the air space and is tuned where the shoes of each bar are retained by the capsules to minimize the gap between the bars and the magnets in the rotor, optionally wherein said flat radial wall on an external face thereof.
[0003]
3. Electric machine according to claim 2, Electric machine according to claim 2, characterized by the fact that a pocket is formed internally in the radial wall around the stator bar shoe during said overmoulding, the floor of such the pouch comprises said thinning, and in which a transition zone is provided between said thinning and the radial wall whereby stress concentrations are substantially avoided, optionally wherein the face of the shoe against said thinning comprises grooves by means of than it is facilitated the flow of melted plastic material for said thinning throughout its area, and more optionally in which said grooves are in a tree formation.
[0004]
4. Electric machine according to any one of the preceding claims, characterized by the fact that at least some of the parts of the stator bar each comprise a terminal shoe element and an intermediate bar element, in which it is the shoe of each stator bar that is overmolded by the radial wall during the formation of the stator housing, optionally in which each stator bar comprises three components, two shoe elements and a single bar element, and more optionally in which the element shoe has characteristics of location on its inner face both to locate the shoe element in the mold during the formation of the stator housing capsule and to locate the bar element during the assembly of the stator housing, and more optionally where said location features may comprise small undulations or bubbles on the surface of the shoe element, with bubbles or small the corresponding undulations in the mold core and bar elements.
[0005]
5. Electric machine according to claim 4, characterized by the fact that each stator bar comprises two bar parts, two shoe elements, in at least one of the said bar element, optionally in which: two bar parts are identical, each having a shoe element and a bar element; or one shoe element is no more than a shoe element while the other is a shoe element with the entire bar element integrated with it.
[0006]
6. Electric machine according to claim 4 or 5, characterized by the fact that the shoe elements and the bar element are discrete components whereby their respective reluctance can be minimized in an optimal direction.
[0007]
7. Electric machine according to any one of the preceding claims, characterized by the fact that at least one capsule has an external flange on the part of the external cylindrical wall to provide a recess for the reception of the rotor, in which the stator housing also comprises the housing for the machine.
[0008]
8. Electric machine according to any one of the preceding claims, characterized by the fact that at least one of said internal and external cylindrical wall parts of the capsules is connected together through an intermediate component, optionally in which: said intermediate component is between said external cylindrical wall parts and said intermediate component and comprises a housing for the machine; or said intermediate component is between said internal cylindrical wall parts and said intermediate component comprises a mounting ring for a bearing that engages said rotor in said stator.
[0009]
9. Electric machine according to claim 8, characterized by the fact that two said intermediate components are interposed between each pair of cylindrical wall parts of the capsules.
[0010]
Electric machine according to claim 8 or 9, characterized in that said cylindrical wall parts of the capsules combined together through said intermediate component are no more than an edge of said radial wall.
[0011]
Electric machine according to any one of claims 1 to 10, characterized in that one or both of the capsules also have overmolded in them at least one of the following components: (a) cylindrical chamfer supports extending along the part the cylindrical outer wall; (b) connection studs, to electrically communicate the stator coils externally to the stator housing; (c) stator coils; (d) refrigerant inlet and outlet ports; and (e) an outer race of a bearing or rotor ring to support said outer race.
[0012]
Electric machine according to claim 11, characterized by the fact that component a) is provided, whereby said cylindrical chamfer supports form at least one of: (i) means for interconnecting the capsules; (ii) means for mounting the stator housing on the machine; and (iii) means for mounting the machine on a support.
[0013]
13. Electric machine, according to claim 11 or 12, characterized by the fact that component b) is provided, in which said connection studs are a simple stud, threaded at each end to receive a nut, by means of that an electrical connector can be attached, both internally and externally to the chamber, to said stud, completing the required electrical connections to and from the machine, optionally where the stud has a stud shaft and comprises a pair of flanges separated by a annular groove, whereby the stator housing mold material both enters said annular groove to locate the stud axially and surrounds at least one of said flanges, whose flange or flanges are of polygonal section to prevent rotation of the stud in the stator housing around said prisoner axis.
[0014]
14. Electric machine according to any one of claims 11 to 13, characterized by the fact that component d) is provided, in which the refrigerant inlet and outlet ports additionally comprise the studs for securing the connection flanges to the doors, the said connection flanges being part of the ducts that supply the stator chamber with the cooling medium and extract it from it, optionally in which a door is in each capsule, and more optionally in which the said molded doors additionally comprise face flanges to combine the coupling with said flue connection flanges.
[0015]
Electric machine according to any one of claims 11 to 14, characterized by the fact that component e) is provided, in which the outer race or ring is overmolded in a first internal cylindrical wall of the capsule, the capsule of which is not is the same as a second conjugated capsule, the bearing being centrally located with respect to the axial direction within the stator housing by the first capsule which has a relatively long internal cylindrical wall, whereby a joint between the internal cylindrical walls of the the first and second capsules are at one end of the stator housing.
[0016]
16. Electric machine according to any one of claims 1 to 15, characterized by the fact that the capsules are attached together or to said intermediate component, using an adhesive; and / or the capsules are continuously welded together; and / or the stator bars are parallel to the axis of rotation, the machine being an axial flow machine, and the rotor is a two-stage rotor having a stage at each axial end of the stator bars, said radial walls of the capsules extend between said internal and external cylindrical wall parts substantially radially with respect to the axis of rotation; and / or the capsules are made of a plastic material that is semi-crystalline and has a glass transition temperature in excess of 60 ° C, preferably in excess of 100 ° C
[0017]
17. Electric machine, according to claim 16, characterized by the fact that each said capsule has said external flange, each one of which receives one of said rotor stages, and in which said external flanges define the width of the machine , in the absence of any coverings on it; and / or the plastic material comprises a polyimide (PI), a polyphthalamide (PPA), a polyether ether ketone (PEEK), a partially crystalline aromatic polyester based on p-hydroxybenzoic acid and related monomers, such as a liquid crystal polymer (LCP ) and a polyphenylene sulfide (PPS), in particular, a PPA.
[0018]
18. Engine comprising a machine, as defined in any of the preceding claims.
[0019]
19. Method of construction of an electric machine of the type comprising a rotor (114a, b) with permanent magnets and a stator with coils (122) wound on the stator bars (116) for interaction with the magnets through a air space defined between them, in which the bars and coils are surrounded by an annular stator housing, the method characterized by the fact that it comprises the steps of: (a) providing a first mold; (b) arrange the first shoes (118a, b) of the stator bars in the first mold; (c) close the first mold and inject the melted reinforced plastic material into the first mold; (d) opening the first mold after cooling and ejecting a first capsule (102a, b) in which said first shoes are retained in the plastic molded material of the first capsule; (e) providing a second mold; (f) arranging the second shoes (118a, b) of the stator bars in the second mold; (g) closing the second mold and injecting the melted reinforced plastic material into the second mold; (h) opening the second mold after cooling and ejecting a second capsule (102a, b) wherein said second shoes are retained in the plastic molded material of the second capsule; (i) where the first and second capsules (102a, b) are each formed with cylindrical wall parts in the inner (108a, b) and outer (106a, b) radii and a radial wall joins the parts of the internal and external cylindrical wall; (j) mount the stator coils (122) on the stator bars; (k) connecting facing edges together (113a, b; 115a, b) of said internal and external cylindrical wall parts of the first and second capsule housings to form said stator housing, whereby the respective first and second stator shoes (102a, b) of each housing of the capsule are combined together, securing the stator coils (122) between them; and (l) mounting the stator housing (102a, b) with the rotor (114a, b).
[0020]
20. Method according to claim 19, characterized in that said first and second capsules are identical when molded; and / or said stator bars comprise shoe elements and integral bar elements, the shoe elements incorporate said first and second shoes, and optionally wherein said first and second shoes are mirror images of each other and include conjugated features to locate one relative to the other when combined.
[0021]
21. Method according to claim 19 or 20, characterized in that one or both of said first and second molds include additional spaces to receive at least one of the following components: (i) cylindrical chamfer supports, to extend to the along the part of the cylindrical outer wall when molded; (ii) connection studs, to electrically communicate the stator coils externally to the stator housing when molded; (iii) refrigerant inlet and outlet ports; and (iv) an outer race of a rotor bearing or ring for mounting it.
[0022]
22. Method according to any one of claims 19 to 21, characterized in that an annular chamber is defined when said first and second capsule housings are interconnected, whose chamber is adapted to receive the cooling medium to cool said coils, and optionally in which the blocks are molded in said first and second capsules in steps c) and g), against whose blocks the coils rest when assembled in step j), whereby a flow path is defined in said chamber for the cooling medium; and / or said step k) of connecting the facing edges of said internal and external cylindrical wall parts is by means of an intermediate component, and optionally wherein said intermediate component is between said internal cylindrical wall parts and comprises a mounting ring for a bearing that supports the rotor in the stator.
[0023]
23. The method of claim 22, characterized in that said intermediate component is between said external cylindrical wall parts and comprises a housing for the machine; and / or in which, between steps j) and k), the blocks are inserted between the coils and said intermediate component whereby a flow path is defined for the cooling medium.
[0024]
24. Method according to any one of claims 19 to 23, characterized in that the method is employed to build a machine according to any of claims 1 to 17, or an engine according to claim 18.
[0025]
25. Method according to claim 24, characterized by the fact that step j) is performed between steps b) and c) and / or between steps f) and g), whereby the coils are also overmolded with the said molten plastic injected in steps c) and / or g).
[0026]
26. Method according to claim 24 or 25, characterized in that said capsules, each, axially have internal and external circumferential facing faces that are combined together in step k) and welded, bonded or screwed together to define and closing an annular chamber between them, and optionally in which the blocks are molded into said capsules in steps c) and / or g) against which the coils rest by means of which a flow path is defined for the cooling medium .

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同族专利:

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公开号 | 公开日

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EP2606561A1|2013-06-26|

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BR112013003690A2|2016-08-16|

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JP5901633B2|2016-04-13|

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US20130147291A1|2013-06-13|

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GB201013881D0|2010-10-06|

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KR20140009970A|2014-01-23|

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RU2013111995A|2014-09-27|

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GB201103504D0|2011-04-13|

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KR101859784B1|2018-05-18|

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JP2013537797A|2013-10-03|

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RU2551844C2|2015-05-27|

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CN103329410A|2013-09-25|

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GB2482928A|2012-02-22|

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EP2606561B1|2014-10-15|

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WO2012022974A1|2012-02-23|

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法律状态:
2018-12-11| B25F| Entry of change of name and/or headquarter and transfer of application, patent and certif. of addition of invention: change of name on requirement|Owner name: YASA MOTORS LIMITED (GB) Free format text: AFIMDEATENDERASALTERACOESDENOMEESEDEREQUERIDASATRAVESDAPETICAONO870180151185 DE 13/11/2018, E NECESSARIO APRESENTAR DOCUMENTO QUE COMPROVE TAL ALTERACAO EQUEOMESMOESTEJAACOMPANHADODETRADUCAOJURAMENTADA,SEFOROCASO,ERESPECTIVOAPOSTILAMENTO OU LEGALIZACAO CONSULAR. |

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2018-12-26| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2019-03-26| B25G| Requested change of headquarter approved|Owner name: YASA MOTORS LIMITED (GB) |

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2019-04-09| B25G| Requested change of headquarter approved|Owner name: YASA MOTORS LIMITED (GB) |

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2019-10-15| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2019-11-05| B25L| Entry of change of name and/or headquarter and transfer of application, patent and certificate of addition of invention: publication cancelled|Owner name: YASA MOTORS LIMITED (GB) Free format text: ANULADA A PUBLICACAO CODIGO 25.7 NA RPI NO 2518 DE 09/04/2019 POR TER SIDO INDEVIDA. |

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2020-01-28| B25D| Requested change of name of applicant approved|Owner name: YASA LIMITED (GB) |

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2020-06-09| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|

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2021-01-12| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2021-03-09| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 16/08/2011, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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GBGB1013881.6A|GB201013881D0|2010-08-19|2010-08-19|Electric machine - construction|

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PCT/GB2011/051550|WO2012022974A1|2010-08-19|2011-08-16|Electric machine - over-moulding construction|

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