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CN-115516745-B - Method and device for producing a multiphase electromagnetic pad for forming a current carrying component of a power conversion system

CN115516745BCN 115516745 BCN115516745 BCN 115516745BCN-115516745-B

Abstract

The invention provides a method and a device for producing a multiphase electromagnetic mat (10) for forming a current carrying component of a power conversion system, wherein the electromagnetic mat (10) comprises a structural fiber section (20), the structural fiber section (20) being divided into at least two groups (21, 22), and a wound fiber section (71A, 71B), the wound fiber section (71A, 71B) being divided into several groups corresponding to the number of phases and the number of parallel conductors of one phase, wherein the wound fiber section (71A, 71B) is held in place by the groups (21, 22) of structural fiber sections (20).

Inventors

  • O. A. Ostmore
  • H. BERGER
  • J. Selness

Assignees

  • 阿尔瓦工业股份公司

Dates

Publication Date
20260508
Application Date
20210507
Priority Date
20200508

Claims (18)

  1. 1. A method of producing a multi-phase electromagnetic pad (10) for forming a current carrying component of a power conversion system, wherein the electromagnetic pad (10) comprises: Structural fiber segment (20), and A plurality of wound fiber segments (71A, 71B), wherein the wound fiber segments (71A, 71B) form a wound fiber (70), the wound fiber (70) having a winding pattern for forming one or more windings of the power conversion system, and wherein the wound fiber segments (71A, 71B) are divided into a plurality of groups, Characterized in that the method comprises: -dividing the structural fibre segments (20) into at least two groups (21, 22), namely a first group (21), a second group (22), -a..an, an nth group, and-dividing the wound fibre segments (71A, 71B) into a number of groups corresponding to the number of phases and the number of parallel branches per phase, and-winding the wound fibre segments (71A, 71B) on a plurality of reservoirs (81A) accommodated in at least two movable boxes (31, 32), wherein at least one movable box (31, 32) is located on each side of the electromagnetic pad (10) as seen in the plane of the electromagnetic pad (10) to be produced, Wherein the method comprises a winding process comprising at least the steps of: -moving the first group (21) of structural fiber segments (20) in a first direction substantially perpendicular to the plane of the electromagnetic pad (10) to be produced, and moving the second group (22) of structural fiber segments (20) in a second direction so that both groups (21, 22) of structural fiber segments (20) are at an angle to the plane of the electromagnetic pad (10) to be produced, the second direction being the opposite direction to the first direction, Inserting a selected number of said wound fibre segments (71A, 71B) into openings formed between said first set (21) and said second set (22) of structural fibre segments (20) such that said wound fibre segments (71A, 71B) extend across said structural fibre segments (20), -Holding the wound fiber segments (71A, 71B) in place by moving the two groups (21, 22) of the structural fiber segments (20) such that the two groups (21, 22) exchange positions at least once, or by using at least one other group of the structural fiber segments (20) such that the at least one other group exchanges positions at least once, thereby enabling the formation of various patterns of overlapping structural fibers and the wound fibers (70).
  2. 2. A method according to claim 1, wherein the method comprises holding the wound fibre segments (71A, 71B) in place by changing the direction of the two groups (21, 22) of structural fibre segments (20) at least twice in a rotational movement and thereby forming a twist (23) of the structural fibre segments (20).
  3. 3. The method according to claim 1, wherein the method comprises transferring at least one reservoir (81A) to which the wound fibre segments (71A, 71B) belong from the movable cassette (31, 32) on one side of the electromagnetic pad (10) to another movable cassette (31, 32) on the other side of the electromagnetic pad (10) upon insertion of a selected number of the wound fibre segments (71A, 71B) into an opening formed between the two groups (21, 22) of structural fibre segments (20).
  4. 4. A method according to claim 3, wherein the method further comprises a predefined movement of the movable box (31, 32) in order to cause the reservoir (81A) of the wound fibre segment (71A, 71B) to be next inserted into a most convenient position with respect to the openings formed by the two groups (21, 22) of structural fibre segments (20).
  5. 5. A method according to claim 1, wherein the method comprises pushing the inserted wound fibre segments (71A, 71B) towards the head of the electromagnetic pad (10) after insertion, and then holding it in place.
  6. 6. The method according to claim 1, wherein the method comprises winding the electromagnetic pad (10) directly on a stator or rotor part of an electric machine.
  7. 7. The method according to claim 1, wherein the method comprises changing the winding design during production, thereby enabling production of various electromagnetic gaskets (10) or a plurality of identical electromagnetic gaskets (10) in one continuous process.
  8. 8. A method according to claim 1, wherein the method comprises controlling and adjusting the tension on the inserted wound fibre segments (71A, 71B).
  9. 9. The method of claim 1, wherein the method comprises producing a portion of the electromagnetic pad (10) from an auxiliary fiber.
  10. 10. A production device for a multiphase electromagnetic pad (10) forming a current carrying component of a power conversion system, wherein the electromagnetic pad (10) comprises: Structural fiber segment (20), and A plurality of wound fiber segments (71A, 71B), wherein the wound fiber segments (71A, 71B) form a wound fiber (70), the wound fiber (70) having a winding pattern for forming one or more windings of the power conversion system, Characterized in that the device comprises at least: -a reservoir (81A) for storing at least two groups (21, 22) of said wound fiber sections (71A, 71B) accommodated in at least two movable cassettes (31, 32) by means of holders (51A, 51B), wherein, seen in the plane of the electromagnetic pad (10) to be produced, at least one movable cassette (31, 32) is located on each side of the electromagnetic pad (10), -An assembly (85) for moving the two groups (21, 22) of structural fiber segments (20) in a reciprocating manner in different directions, and -At least one transfer mechanism for transferring the reservoir (81A) from a movable cassette (31, 32) on one side of the electromagnetic pad (10) to a movable cassette (31, 32) on the other side of the electromagnetic pad (10).
  11. 11. The device according to claim 10, wherein the assembly (85) is further arranged for rotational movement of the structural fiber segment (20).
  12. 12. The device according to claim 10, wherein the device comprises means for controlling and adjusting the tension of the inserted wound fiber segments (71A, 71B) upon insertion.
  13. 13. The device according to claim 10, wherein the device comprises means for synchronizing the movement of at least the movable boxes (31, 32) and means (85) for moving the at least two groups (21, 22) of structural fiber segments (20).
  14. 14. The device according to claim 10, wherein the device comprises an assembly (90) for pushing the inserted wound fiber segments (71A, 71B) towards the head of the electromagnetic pad (10).
  15. 15. The device according to claim 10, wherein the holder (51A, 51B) for the reservoir (81A) in the movable cartridge (31, 32) is in the form of an opening or recess.
  16. 16. The apparatus of claim 10, wherein the delivery mechanism comprises one or more actuators.
  17. 17. The device according to claim 10, wherein the transfer mechanism comprises means for fastening the reservoir (81A) to the movable cassette (31, 32) and releasing it from the movable cassette (31, 32).
  18. 18. The device according to claim 10, wherein the removable cartridge (31, 32) is removable and replaceable.

Description

Method and device for producing a multiphase electromagnetic pad for forming a current carrying component of a power conversion system The present invention relates to a method for producing a multiphase electromagnetic pad for forming a current carrying component of a power conversion system according to one aspect of the present invention. The invention also relates to a production device for a multiphase electromagnetic pad forming a current carrying component of a power conversion system according to another aspect of the invention. Background Multiphase electromagnetic pads can be used in numerous power conversion applications such as rotating electrical machines, linear and planar machines, transformers, heaters, chargers, and the like. The function of the electromagnetic pad is to carry current and generate an electromagnetic field that interacts with other components of the power conversion system. The electric machine is a large field of application for electromagnetic gaskets, since there are various series of electric machines (so-called slotless ironless electric machines), wherein the stator or rotor part may partly or entirely comprise electromagnetic gaskets shaped to form a cylinder in a rotating electric machine or to remain flat in a linear or planar electric machine. These components typically have a mat molded in some resin to form a composite component. In a slotless motor, the composite component is typically attached to a ferromagnetic core, whereas in a slotless motor (also referred to as a coreless or hollow motor), the pads molded in resin typically represent separate composite components, such as a stator or rotor. A typical method of producing windings for an ironless or slotless motor is to wind the conductor around some form/mandrel. The profile may comprise a ferromagnetic core of the motor, or may be a temporary profile that may be removed later. For example, US4691746a discloses a method for producing a flat stator of an axial flux rotary electric machine, comprising winding a conductor on a disc-shaped profile, and in CN1868010a, forming a toroidal winding of a slotless electric machine by winding the conductor on a toroidal core, and in CN103620916a and US4644209a, methods of winding on a short cylinder are proposed. Such as US4320319A, US4151964A, JPS58204751A, JPS583550A, GB2048729A, JPS54114709a and JPS5518875A, numerous patent applications disclose methods of winding conductors on an elongate shaped cylindrical profile. The winding patterns obtained by these methods are characterized by having conductors wound at an angle relative to the cylinder axis. The winding also has more than one layer. All methods are partially or fully automated, and thus corresponding machines are proposed in many publications. Only a few publications (such as JPH09271158a and WO2019074375A 1) describe electromagnetic pads of motors as flat sheets. The mat is assumed to be first made as flat sheets, where each sheet is made up of windings and can be divided into individual electromagnetic mats or segments, which can then be shaped to form the stator or rotor of the motor. Reference is made to fig. 1 which discloses the structure of an electromagnetic pad formed by the principle of JPH09271158 a. JPH09271158a fails to disclose a method of producing a plurality of continuous windings that the production pattern is arranged such that the electromagnetic pad can be used in a multi-phase motor without the additional steps of cutting and reconnecting the wiring that result in expensive and suboptimal products. A mechanism and a method for introducing wave windings from a prefabricated wave winding mat into stator sheet metal cladding slots are known from US 2018294702 A1. A mechanism for introducing wave windings from a pre-formed wave winding pad into a rotor or stator body has a receiving device for receiving and holding the rotor or stator body and a feeding device for feeding the wave winding pad to the receiving device. The receiving device also has an introduction device which can isolate the windings of the winding pad and introduce the windings into the rotor or stator body in the depth direction of the slots. WO2019074375A1 in the name of the applicant describes both the structure of an electromagnetic pad and the production method of an electromagnetic pad, and also discloses a machine for producing an electromagnetic pad. In fig. 16a to 16c, for example, in WO2019074375A1, the production of electromagnetic mats by means of double twisting (twisting) is disclosed. Reference is made to fig. 2 showing a machine of WO2019074375A1, wherein the machine comprises a circular member (90 in fig. 2) rotatable about an electromagnetic pad (fig. 2). Double twisting does not produce a single ply mat and, in addition, it presents a problem of securing the entangled fibers (30 in fig. 2) to the structural fibers (20 in fig. 2). Thus, WO2019074375A1 fails to disclose a machine for producing single layer