U.S. patent application number 14/338534 was filed with the patent office on 2014-11-13 for winding arrangement for an electrical machine.
This patent application is currently assigned to HYBRIDAUTO PTY LTD. The applicant listed for this patent is Matthew GREAVES, Ben GUYMER, Bernie WALSH. Invention is credited to Matthew GREAVES, Ben GUYMER, Bernie WALSH.
Application Number | 20140333169 14/338534 |
Document ID | / |
Family ID | 39807718 |
Filed Date | 2014-11-13 |
United States Patent
Application |
20140333169 |
Kind Code |
A1 |
GREAVES; Matthew ; et
al. |
November 13, 2014 |
WINDING ARRANGEMENT FOR AN ELECTRICAL MACHINE
Abstract
A design for and method of winding an electric motor, generator
or other electrical machine using multiple strands of wire
preformed into a wave shape with a plurality of legs connected by
shaped end turns. This results in efficient packing and improved
machine performance in terms of both efficiency and power density
without the need for flux concentrators. The conductors or windings
may be preformed so as to be a self supporting structure, aiding
assembly and eliminating the need for an iron core.
Inventors: |
GREAVES; Matthew; (Corinda,
AU) ; GUYMER; Ben; (Draper, AU) ; WALSH;
Bernie; (Cooparoo, AU) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
GREAVES; Matthew
GUYMER; Ben
WALSH; Bernie |
Corinda
Draper
Cooparoo |
|
AU
AU
AU |
|
|
Assignee: |
HYBRIDAUTO PTY LTD
Queensland
AU
|
Family ID: |
39807718 |
Appl. No.: |
14/338534 |
Filed: |
July 23, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12593630 |
Oct 6, 2009 |
8823238 |
|
|
PCT/AU08/00451 |
Apr 1, 2008 |
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14338534 |
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Current U.S.
Class: |
310/207 ;
242/430 |
Current CPC
Class: |
H02K 15/0478 20130101;
Y10T 29/49009 20150115; H02K 3/04 20130101; H02K 3/47 20130101 |
Class at
Publication: |
310/207 ;
242/430 |
International
Class: |
H02K 3/04 20060101
H02K003/04 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 2, 2007 |
AU |
2007901786 |
Claims
1. A preformed conductor for use in the manufacture of a winding
for an electrical machine, the conductor comprising multiple
strands of wire and an outer insulating layer, the conductor having
a self supporting wave shape comprising a plurality of legs
connected by end turns, wherein at least a portion of a least one
end turn follows a curved path.
2. A preformed conductor as claimed in claim 1, wherein the cross
section of the end turn at at least one point on the curved path,
viewed normal to the curved path, is thicker in a radial direction
than an axial direction, the radial and axial directions being with
respect to the instantaneous centre of curvature of the curved path
at the point.
3. A preformed conductor as claimed in claim 1, wherein the curved
path is three dimensional.
4. A preformed conductor as claimed in claim 3, wherein the curved
path is helical.
5. A preformed conductor as claimed in claim 1, wherein the cross
sectional shape of at least one of the legs is approximately
rectangular.
6. A preformed conductor as claimed in claim 1, wherein the
multiple strands of wire of the conductor comprises at least two
sub-bundles of twisted wire strands, each sub-bundle having an
outer insulating layer.
7. A preformed conductor as claimed in claim 1, wherein the
conductor has a substantially constant cross sectional area.
8. A method of manufacturing a wave winding for an ironless core
electrical machine, the winding comprising at least one conductor
arranged into a wave pattern, each conductor comprising multiple
strands of wire and an outer insulating layer, the method
comprising preforming each conductor such that it has a self
supporting wave shape, the wave shape comprising a plurality of
legs connected by end turns that progresses around the winding,
characterised in that the method further comprises weaving each
preformed conductor together to form the wave pattern.
9. A method of manufacturing a winding as claimed in claim 8,
wherein the wave pattern is bonded to form a rigid structure.
10. A method of manufacturing a winding as claimed in claim 8,
wherein each conductor is made from a length of flexible
multi-strand wire, and the conductor is preformed into the self
supporting wave shape by pressing the flexible multi-strand wire.
Description
TECHNICAL FIELD
[0001] The present invention relates to windings for electrical
machines, and in particular to a wave winding arrangement and a
method of manufacture thereof.
BACKGROUND
[0002] Electrical machines can be categorised as motors or
generators. The construction of electrical motors and generators is
similar with many electrical machines being able to operate as both
a motor and a generator.
[0003] Permanent magnet electrical machines have a winding that
moves relative to the magnets. There are many different
configurations of permanent magnet electrical machines. The winding
may be part of the stator of the machine with the magnets attached
to the rotor, or the winding may be part of the rotor with the
magnets attached to the stator. Permanent magnet electrical
machines may be brushed or brushless.
[0004] The geometry of an electrical machine can be categorised by
the direction of the flux that the winding is exposed to. Axial
flux machines have a disc shaped winding exposed to a magnetic flux
that flows substantially parallel to the axis of rotation of the
machine. The axial flux may be provided by two disc shaped sets of
magnets with the winding positioned in the gap between the magnet
sets. One of the sets of magnets may be replaced with iron only, to
provide a return path for the magnetic field. In some applications
there may be only one set of magnets without any iron on the other
side of the winding. Radial flux machines have a cylindrically
shaped winding exposed to a radially directed magnetic flux, which
may be provided by two cylindrical sets of magnets, one cylindrical
set of magnets and an iron cylinder to provide a return path for
the magnetic field, or one cylindrical set of magnets alone.
Similarly, conical flux machines have a conically shaped winding
with magnets providing flux normal to the surface of the conical
shaped winding. Linear electrical machines have a flat rectangular
shaped winding that moves linearly relative to one or two
rectangular sets of magnets that provide flux normal to the
rectangular shaped winding.
[0005] The winding of a traditional electrical machine has
conductors wound onto a laminated iron core. The iron core is
primarily used to reduce the reluctance of the magnetic circuit,
but it serves a secondary purpose of providing a supporting
structure and thermal path for heat generated in the winding.
[0006] Ironless machines have windings without any ferromagnetic
material. When optimised, an ironless machine can have extremely
low spinning losses, no cogging torque, high peak torque and
minimal torque ripple. Ironless machines find applications in servo
drives, hard disk drives and have significant potential for use in
vehicle drives or other applications that require low spinning
losses and high transient torque. With the introduction of high
energy rare earth permanent magnets, the ability to produce high
performance ironless machines became a reality.
[0007] In order to obtain the maximum performance from an ironless
machine, it is necessary to maximise the amount of conducting
material, typically copper, in the winding. This is referred to as
the "fill factor". An electric machine has an active volume that is
dedicated to be filled by the active portions of the winding
conductors. In an axial flux ironless machine with two sets of
magnets, this active volume is the volume between the faces of the
two sets of magnets. The fill factor is defined as the proportion
of the active volume taken up by conducting material.
[0008] In ironless machines, the conductors in the winding are
exposed to the full magnetic field and so to avoid excessive eddy
currents in the winding the conductors are typically made from fine
strands of insulated copper wire. However, reducing the copper wire
diameter to reduce eddy currents also makes it difficult to
manufacture a winding with a high fill factor because of the
thickness of the insulation on the wire and the gaps between the
wire strands. Machines with poor fill factor require large magnetic
content to achieve acceptable performance, and machines with poor
fill factor typically suffer from poor thermal conductivity due to
the excessive quantity of resin required to construct the
winding.
[0009] "Litz wire" is a conductor made from a bundle or bundles of
strands of fine copper wire. The wire strands have a thin film of
insulation, and the entire bundle is surrounded by an insulating
layer made from textile yarn, tape or other materials. Litz wire
has several configurations, known as "types". Type-1 Litz wire is
comprised of a single bundle of strands of copper wire twisted
together within the outer insulating layer. Type-2 Litz wire is
comprised of multiple sub-bundles of strands of copper wire. The
strands of each sub-bundle are twisted together, like Type-1 Litz
wire, and the sub-bundles themselves are then twisted together
within the outer insulating layer. Type-2 Litz wire does not have
any additional insulating layers surrounding the sub-bundles.
Type-3 Litz wire is also comprised of multiple sub-bundles of
strands of copper wire twisted together within the outer insulating
layer but unlike Type-2 Litz wire, each sub-bundle has its own
outer insulating layer. The sub-bundles of Type-3 Litz wire may
comprise a single twist of strands, like Type-1 Litz wire, or
multiple twists of strands like Type-2 Litz wire. As supplied, Litz
wire is flexible.
[0010] Windings for ironless machines using conductors made from
Type-1 or Type-2 Litz wire are known, but use of Type-3 Litz wire
is not known. The paper titled "Design of an in-wheel motor for a
solar-powered electric vehicle" by V. S. Ramsden, B. C. Mecrow and
H. C. Lovatt, published in the IEE Proceedings, "Electric Power
Applications", 1998, 145, No 5, 402-408, discloses an ironless
direct drive wheel motor with a winding made from Type-2 Litz wire.
International Patent Publication WO 2004/010561 A1 (Hamilton
Sundstrand) also discloses the use of Litz wire to make a winding
for an electric machine, and shows an example using Type-2 Litz
wire.
[0011] Many methods of manufacturing windings for ironless machines
have been proposed or used. U.S. Pat. No. 5,744,896 (Kessinger et
al) discloses a method of manufacturing a winding for an ironless
machine in which the winding is made up of a large number of
individually wound coils of wire strands. The coils are assembled
in a mould and wired together. The disadvantages of this method are
that each coil must be individually electrically connected and
small variations between each coil affect the overall performance
of the machine.
[0012] An alternative to individually wound coils is to arrange the
conductors of the winding into a wave pattern. The conductors of a
wave pattern winding are wave shaped, meaning that each conductor
progresses around the winding, periodically crossing the magnetic
field, without looping back on itself. Each wave shaped conductor
has a plurality of legs that are the active part of the conductor
directly exposed to the magnetic field and end turns that connect
the legs. It is desirable to minimise the length of the end turns
in order to minimise resistance losses in the machine, and to
minimise the weight and size of the winding. Compact end turns can
be difficult to achieve in a multiphase wave pattern winding
because the end turns overlap each other.
[0013] Some wave pattern windings have two layers, with the legs of
each conductor alternating between the two layers. U.S. Pat. No.
5,319,844 (Huang et al) discloses a radial air gap motor having a
two layer wave pattern winding. However, this motor has flux
concentrators positioned in the gaps between the legs of the wave
shaped conductors, rather than being a purely ironless motor.
[0014] The winding of the motor disclosed in the above referenced
paper "Design of an in-wheel motor for a solar-powered electric
vehicle" is manufactured by arranging Litz wire into a two layer
wave pattern then bonding the Litz wire with resin in a mould to
form a rigid structure. The wave pattern is formed by winding the
Litz wire directly in the mould, or winding the Litz wire onto a
temporary former, such as a board with pegs, then transferring the
wave pattern into the mould. Whilst this method of manufacturing a
winding is well suited to light weight solar-powered vehicles, a
winding having a higher copper fill factor than this prior art
method provides is desirable for higher power applications.
[0015] U.S. Pat. No. 6,649,844 (Kusumtoto et al) discloses a method
of preforming a wave shaped conductor from a bundle of strands of
copper wire. The end turns of the wave shaped conductors disclosed
in this patent are straight and lie in the plane of the wave shape,
resulting in a square wave shaped conductor. These square wave
shaped conductors are arranged into a wave pattern with large gaps
between adjacent conductor legs. This method of forming a wave
pattern winding is directed to electric machines having an iron
core to fill the large gaps between the conductor legs of the
winding. However, this method is not well suited to manufacturing
ironless wave pattern windings because the square wave shaped
conductors result in an inefficient packing of the end turns once
the gap between the legs of the conductors is reduced, as is
necessary for an efficient ironless winding arrangement.
[0016] It is an object of the present invention to provide an
improved winding arrangement for an electric machine.
SUMMARY OF INVENTION
[0017] In a first aspect, the present invention consists of a
winding for an electrical machine, comprising at least one
conductor, the conductor comprising multiple strands of wire and an
outer insulating layer, and having a wave shape comprising a
plurality of legs connected by end turns, with at least a portion
of at least one end turn following a curved path, characterised in
that the cross section of the end turn at least one point on the
curved path, viewed normal to the curved path, is thicker in a
radial direction than an axial direction, the radial and axial
directions being with respect to the instantaneous centre of
curvature of the curved path at the point.
[0018] In a second aspect, the present invention consists of a
preformed conductor for use in the manufacture of a winding for an
electrical machine, the conductor comprising multiple strands of
wire and an outer insulating layer, the conductor having a self
supporting wave shape comprising a plurality of legs connected by
end turns, characterised in that at least a portion of a least one
end turn follows a curved path.
[0019] In a third aspect, the present invention consists of a
method of manufacturing a winding for an electrical machine, the
winding comprising at least two conductors arranged into a wave
pattern, each conductor comprising multiple strands of wire and an
outer insulating layer, the method comprising preforming the
conductors such that they each have a self supporting wave shape,
the wave shape comprising a plurality of legs connected by end
turns, characterised in that the method further comprises weaving
the preformed conductors together to form the wave pattern.
[0020] In a fourth aspect, the present invention consists of a
method of manufacturing an ironless winding for an electrical
machine, comprising arranging at least one conductor, having
multiple strands of wire and an outer insulating layer, into a wave
pattern then bonding the wave pattern to form a rigid structure,
characterised in that, prior to arranging the wave pattern, each
conductor is preformed, from a flexible state, such that each
preformed conductor has a self supporting wave shape.
[0021] Some further variations of the invention are defined in the
Claims.
BRIEF DESCRIPTION OF DRAWINGS
[0022] FIG. 1 is a cross sectional view of an axial flux electric
motor, having an ironless stator winding, in accordance with the
present invention, manufactured by a method in accordance with the
present invention.
[0023] FIG. 2 shows the winding of the motor shown in FIG. 1;
[0024] FIG. 3 is a sectioned view of the winding shown in FIG.
2;
[0025] FIG. 4 schematically shows the wave pattern of the winding
shown in FIG. 2;
[0026] FIG. 5 schematically shows a pair of wave shaped conductors
of the winding shown in FIG. 2;
[0027] FIG. 6 schematically shows a single wave shaped conductor of
the winding shown in FIG. 2;
[0028] FIG. 7 shows a single wave shaped conductor of the winding
shown in FIG. 2;
[0029] FIG. 8 is an enlarged view of part of the wave shaped
conductor shown in FIG. 7;
[0030] FIG. 9 is a sectional view of a length of Type-3 Litz
wire;
[0031] FIGS. 10 and 11 show two halves of a die set used to preform
the conductors of the winding shown in FIG. 2;
[0032] FIG. 12 shows the die set of FIGS. 10 and 11 mounted in a
press;
[0033] FIGS. 13 and 14 show how Litz wire is incrementally fed
through the die set of
[0034] FIGS. 10 and 11 to preform the wave shaped conductor shown
in FIG. 7;
[0035] FIG. 15 shows the wave shaped conductor of FIG. 7 laid out
straight;
[0036] FIG. 16 shows the wave shaped conductors being weaved
together to form the winding shown in FIG. 2;
[0037] FIG. 17 is a cross sectional view of a second embodiment of
an axial flux electric motor, having a tapered ironless stator
winding, in accordance with the present invention, manufactured by
a method in accordance with the present invention;
[0038] FIG. 18 is a partial side view of the winding of the motor
shown in FIG. 17;
[0039] FIG. 19 is a schematic side view of the winding shown in
FIG. 2;
[0040] FIG. 20 is a side view of one outer end turn of the wave
shaped conductor shown in FIG. 8, viewed along XX-XX of FIG. 8;
[0041] FIG. 21 schematically shows a wave pattern winding
arrangement in accordance with the present invention in which the
legs of the conductors are skewed to the radial direction; and
[0042] FIG. 22 is a cross sectional view of a radial flux electric
motor, having an ironless stator winding, in accordance with the
present invention, manufactured by a method in accordance with the
present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE INVENTION
[0043] The present invention will be described in detail primarily
as applied to axial flux motors but the method of manufacturing the
winding described, and the resulting winding arrangement, is
equally applicable to other configurations of electrical machines,
such as radial or conical flux machines, generators, and linear
machines, regardless of whether the winding forms the stator or the
rotor, or the machine has brushes or is brushless.
[0044] Referring to FIG. 1, axial flux electric motor 1 comprises a
disc shaped ironless stator 2 positioned between two disc shaped
sets of permanent magnets 4 that are mounted on backing plates 5.
Backing plates 5 are attached to a hub 6 that is supported for
rotation around stub axle 9 by bearings 10. Magnets 4, backing
plates 5 and hub 6 make up the rotor 3 of motor 1. The stub axle 9
is attached to the motor housing 8, and the stator 2 is attached to
the housing 8 by a clamp plate 7. Motor 1 can be used as a direct
drive wheel motor for a vehicle by attaching the motor housing 8 to
the suspension of the vehicle, and mounting a wheel onto the motor
hub 6.
[0045] The stator 2 is comprised of a wave pattern winding 13
bonded together by encapsulating it in a resin 14 to form a rigid
structure. Referring to FIG. 2, winding 13 is made up of six wave
shaped conductors 15a, 15b, 15c, 15d, 15e and 15f. Motor 1 is a
3-phase motor with the conductors 15a-f arranged as three pairs 15a
and 15b, 15c and 15d, and 15e and 15f. Each pair of conductors is
connected in series or parallel such that each pair of conductors
is electrically in phase. Each conductor 15a-f makes one turn of
the winding 13 such that all the conductors 15a-f enter and exit
the winding 13 at approximately the same location on the outer
circumference of the winding 13.
[0046] As shown in FIG. 3, winding 13 has two layers 16a and 16b.
FIG. 4 schematically shows how the wave pattern of winding 13 is
arranged. Each conductor 15a-f is shown as a solid line when it is
in the front layer 16a, and a dashed line when it is in the back
layer 16b. FIG. 5 schematically shows a single pair of conductors
15a-b. Each conductor 15a-f has the same shape and FIG. 6
schematically shows the shape of a single conductor 15a. Conductor
15a has a wave shape, in that it never loops back on itself as it
progresses around the winding 13, with radially extending legs 17
connected by end turns 18a and 18b. As conductor 15a progresses
around winding 13, its legs 17 alternate between the two layers 16a
and 16b. To clearly show how the wave pattern is arranged, in FIGS.
4 and 5 the legs 17 of each pair of conductors 15a-b, 15c-d and 15
e-f are schematically shown as slightly circumferentially offset
from each other. In the actual winding 13, the legs 17 of each pair
of conductors 15a-b, 15c-d and 15 e-f are circumferentially aligned
with each other.
[0047] FIG. 19 schematically shows a partial side view of winding
13. Referring to FIGS. 4, 5, 6 and 19, as each conductor 15a-f
progresses clockwise around the winding 13, the outer end turns 18a
always progress from the front layer 16a to the back layer 16b, and
the inner end turns 18b always progress from the back layer 16b to
the front layer 16a. As such all of the outer end turns 18a are
skewed in the same direction with respect to the axis of the motor
and never cross over each other. Likewise, all the inner end turns
18b are skewed in the same direction, opposite to that of the outer
end turns 18a.
[0048] FIGS. 7 and 8 show an actual wave shaped conductor 15a of
winding 13. The remaining conductors 15b-f are the same shape as
conductor 15a. Referring to FIG. 8, the legs 17 of conductor 15a
have a rectangular cross section as indicated by the broken outline
23. The corners of the rectangular section are shown as being sharp
for clarity of description. In practice the corners may be rounded
with the cross sectional shape of legs 17 then being approximately
rectangular. The use of a rectangular cross sectional shape of legs
17 results in winding 13 having a significantly higher fill factor,
than if the winding was made with legs having a substantially
circular cross section.
[0049] Referring to FIG. 8, each outer end turn 18a of conductor
15a is curved such that it follows a three dimensional curved path
as indicated by broken line 19a. The curved path 19a is helical
about axis 24a. FIG. 20 is a side view of one outer end turn 18a of
conductor 15a, which shows that axis 24a is approximately parallel
to, and mid way between layers 16a and 16b. Referring again to FIG.
8, similarly, each inner end turn 18b is curved such that it
follows a three dimensional curved path as indicated by broken line
19b. The curved path 19b is helical about axis 24b. Axis 24b is
also approximately parallel to, and mid way between layers 16a and
16b.
[0050] The end turns 18a and 18b are flattened as will be described
by reference to the cross sectional shape at a single point on each
end turn, as follows. Broken outline 22a shows the cross section of
an outer end turn 18a at a single point 46a on the curved path 19a,
viewed normal to the curved path 19a. Point 47a is the
instantaneous centre of curvature of path 19a at point 46a.
Reference numeral 21a indicates the thickness of cross section 22a
in a radial direction with respect to the instantaneous centre of
curvature 47a, and reference numeral 20a indicates the thickness in
an axial direction with respect to centre 47a. The radial direction
is defined by a line through points 46a and 47a, and the axial
direction is defined as being perpendicular to the radial direction
and to the tangent direction of path 19a at point 46a. Cross
section 22a is approximately elliptical in shape such that its
radial thickness 21a is thicker than its axial thickness 20a.
[0051] Similarly, broken outline 22b shows the cross section of an
inner end turn 18b at a single point 46b on the curved path 19b,
viewed normal to the curved path 19b. Point 47b is the
instantaneous centre of curvature of path 19b at point 46b.
Reference numeral 21b indicates the thickness of cross section 22b
in a radial direction with respect to the instantaneous centre of
curvature 47b, and reference numeral 20b indicates the thickness in
an axial direction with respect to centre 47b. The radial direction
is defined by a line through points 46b and 47b, and the axial
direction is defined as being perpendicular to the radial direction
and to the tangent direction of path 19b at point 46b. Cross
section 22b is approximately elliptical in shape such that its
radial thickness 21b is thicker than its axial thickness 20b.
[0052] The shape of the end turns 18a and 18b results in a compact
end turn arrangement with relatively short end turns compared with
other wave pattern windings. The helical path combined with the
flattening of the end turns allows the end turns to closely nest
together. Each end turn 18a, 18b must circumferentially overlap its
adjacent end turns 18a, 18b for a significant proportion of its
length, and the relatively small axial thickness 20a, 20b of the
end turns 18a, 18b minimises the overall axial thickness of winding
13 at the end turns.
[0053] The wave shaped conductors 15a-f are made from Type-3 Litz
wire. FIG. 9 is a sectional view of a length of Type-3 Litz wire
25. Litz wire 25 has many copper wire strands 26 and an outer
insulating layer 27 made from textile yarn, tape, or other suitable
material. The wire strands 26 are arranged as multiple sub-bundles
28 twisted together, with each sub-bundle 28 having its own outer
insulating layer 29. Each sub-bundle 28 is made up of multiple
smaller sub-bundles 30 twisted together, with each smaller
sub-bundle 30 being made up of multiple wire strands 26 twisted
together. The wire strands 26 typically have a thin insulating
coating, but it is necessary for the sub-bundles 28 to have outer
insulating layers 29 to ensure they are electrically separated, as
the thin insulating coating is easily broken. Litz wire is
flexible, even though it may not fully spring back if bent sharply.
Litz wire is usually supplied as a roll. As an example, the copper
wire strands may have a diameter of 0.3 to 0.4 mm.
[0054] FIGS. 10 and 11 show two halves 33, 34 of a die set used to
preform the wave shaped conductors 15a-f from Type-3 Litz wire 25.
One half 33 of the die set has a punch 35 and the other half 34 has
a cavity 36. When the die sets halves 33 and 34 are placed together
there is a gap between the punch 35 and the cavity 36 that has the
shape of four legs 17, two inner end turns 18b, and one outer end
turn 18a of a conductor 15a-f.
[0055] FIG. 12 shows the die halves 33, 34 mounted in a simple
press 39 that has a cylinder 40 to open and close the die set.
FIGS. 13 and 14 show how Litz wire 25 is incrementally fed through
the die halves 33, 34 to preform the wave shaped conductor 15a.
Referring to FIG. 13, a portion of the Litz wire 25 is bent and
placed in the die cavity 36. The die halves 33, 34 are then closed
and pressurised together by cylinder 40 such that the original
substantially circular cross section of the portion of the Litz
wire 25 in the cavity 36 is deformed and compacted to preform a
portion of the wave shaped conductor 15a. Referring to FIG. 14, the
Litz wire 25 is then incremented through the die cavity 36 to
preform the next portion of the wave shaped conductor 15a. Even
though the die cavity 36 extends for approximately two wavelengths
of the wave shaped conductor 15a, the Litz wire 25 is only
incremented by one wavelength between pressings to ensure correct
spacing of the wave shape.
[0056] As a result of pressing the Litz wire 25 as it is preformed
into a wave shape, the wave shape of conductor 15a is substantially
self supporting in that it will maintain its wave shape without
needing to be supported, as it is handled. The die cavity 36 and
punch 34 are shaped to curve the conductor 15a as it is preformed,
with a radius equal to that of the final winding 13. However, the
self supporting preformed wave shaped conductor 15a is still
flexible to an extent that it can be laid out straight as shown in
FIG. 15.
[0057] To avoid the Litz wire 25 springing back after pressing,
significant compaction pressure is required to permanently compact
and deform the Litz wire 25 into the shape of the rectangular
sectioned legs 17 and the arcuate end turns 18a and 18b. However,
the compaction pressure should not be excessive or the Litz wire 25
may be damaged. As an example, a compaction pressure of the order
of 10 MPa may be used.
[0058] The process of incrementally feeding the Litz wire 25
through the die set 33, 34 may be automated. In other not shown
embodiments of the invention, a die set may be used that is large
enough to preform the entire length of a wave shaped conductor in
one pressing. Alternatively, the wave shaped conductors may be
preformed by using rollers or a machine similar to a CNC spring
bending machine to press the Litz wire.
[0059] To manufacture the complete winding 13, the six identical
wave shaped conductors 15a-f are individually preformed as
described above. The conductors 15a-f are then progressively woven
together as shown in FIG. 16. This is made possible by the
conductors 15a-f retaining a degree of flexibility after they are
preformed. Optionally, one or more threads may also be woven into
the winding 13 to assist with tying the winding 13 together.
[0060] The winding 13 is then placed in a mould (not shown). A
vacuum is applied to the mould and resin 14 is pressurised into the
winding 13 to encapsulate it and bond it together, thereby forming
the stator 2. The mould may have several pegs that protrude into
the gaps between the conductor legs 17 to ensure that the
conductors 15a-f are properly circumferentially aligned.
Optionally, the winding 13 may be pressed after it is placed in the
mould to further compact it.
[0061] Winding 13 has a high fill factor compared with other known
windings made from Litz wire, such as the motor disclosed in the
above referenced paper "Design of an in-wheel motor for a
solar-powered electric vehicle", primarily due to the rectangular
cross section of the legs 17 of the wave shaped conductors 15a-f,
and the compaction of the Litz wire 25 as it is pressed in the die
set 33, 34. The fill factor of a winding manufactured as described
above will typically be in the range of 40% to 70%.
[0062] Windings in accordance with the present invention may be
made from multi-strand conductors other than Litz wire. However, an
advantage of using conductors made from Litz wire compared with
using a conductor with multiple wire strands that are not twisted
together, is that the twisted arrangement of the Litz wire means
that each wire strand is near the surface of the conductor at
various points along its length, allowing it to conduct heat to the
surface of the conductor at those points. The overall thermal
performance of the winding is therefore improved.
[0063] An advantage of using conductors made from Type-3 Litz wire
25 rather than Type-1 or Type-2 Litz wire is that the insulated
sub-bundles 28 can be connected in series. This means that a single
turn of Type-3 Litz wire 25 around the winding can provide multiple
electrical turns, and therefore it is not necessary to have
multiple physical turns of a conductor to provide multiple
electrical turns, which makes the winding easier to manufacture.
Furthermore, it is possible to actively switch the connection of
the sub-bundles 29 between series and parallel.
[0064] FIG. 17 shows a second embodiment of an axial flux electric
motor 1a in accordance with the present invention. Motor 1a is the
same as motor 1 shown in FIG. 1 except that the stator 2a and its
winding 13a are tapered such that the active portion of the winding
13a in the axial gap between magnets 4a becomes thinner as the
radius increases. The magnet sets 4a have a corresponding conical
shape such that the same small gap is maintained between the
magnets 4a and the stator 2a as the radius varies.
[0065] Referring to FIG. 18, the legs 17a of each wave shaped
conductor 15aa-af of winding 13a are tapered in the plane of the
wave shape of conductors 15aa-af such that they become thinner as
the radius decreases. This is illustrated by the thickness
indicated by reference numeral 42 being less than the thickness
indicated by reference numeral 43.
[0066] Reference numeral 44 indicates the gaps between adjacent
legs 17a. The taper of the legs 17a in the plane of the wave shaped
conductors 15aa-15af minimises the gaps 44 between the legs 17a. As
shown in FIG. 18, the gap 44 does not vary with the radial distance
from the centre of the winding 13a, and in practice the adjacent
legs 17a may contact each other such that there is no gap. In
contrast, if the legs have a constant thickness, such as legs 17 of
motor 1 described above, then the gap between the legs will
increase as radial distance from the centre of the winding
increases. This minimisation of the gaps 44 between the legs 17a
provided by the tapering further improves the fill factor.
[0067] Like the motor shown in FIG. 1, the wave shaped conductors
15aa-af of motor 1a are made from Type-3 Litz wire 25. The
substantially constant cross sectional area of Litz wire 25 results
in the Legs 17a also tapering in a direction transverse to the wave
shape such that they become thinner as the radius increases, thus
resulting in the tapering of the stator 2a and winding 13a shown in
FIG. 17.
[0068] The winding 13a is manufactured using the same method as
described for motor 1 above. The only difference is that the punch
35 and cavity 36 of the die set 33, 34 are shaped differently to
preform the tapered shape of legs 17a.
[0069] Whilst the present invention is primarily directed to the
manufacture of ironless windings, it is also applicable to windings
having flux concentrators. These flux concentrators are made from a
ferro-magnetic material, such as iron, and can be placed in the
gaps between the legs of the wave shaped conductors after they have
been weaved together, but before bonding the winding. Metglass may
also be used for the flux concentrators.
[0070] Whilst the embodiments of the axial flux motor described
above have windings in which the legs of the wave shaped conductors
are radially oriented with respect to the centre of the winding,
other not shown embodiments may have windings in which the
conductor legs are skewed to the radial direction. In this case,
each pair of conductor legs will tend to cross each other as viewed
in the plane of the winding, however each pair of legs can still be
considered as being circumferentially aligned together. This
alternative winding arrangement is schematically shown in FIG. 21.
FIG. 21 shows a wave pattern winding 13b, in a similar manner to
FIG. 4. The legs 17b of each conductor 15ba to 15bf are skewed to
the radial direction, and the legs 17b of each pair of conductors
15ba and 15bb, 15bc and 15bd, and 15be and 15bf cross over each
other. The performance of the winding 13b is reduced by having the
legs 17b of the conductors 15ba to 15bf skewed but this is
compensated for by the resulting reduced length of the end turns
18ba, 18bb, compared with the arrangement shown in FIG. 4.
[0071] FIG. 22 is a cross sectional view of a radial flux electric
motor 1c, comprising a cylindrical ironless stator 2c positioned
between two cylindrical sets of permanent magnets 4c that are
mounted on backing cylinders 5c. The inner backing cylinder 5c is
mounted on a hub 6c, and the outer backing cylinder 5c is mounted
on a separate carrier 49 that is bolted to the hub 6c. Magnets 4c,
backing plates 5c, hub 6c and carrier 49 make up the rotor 3c of
motor 1c. The hub 6c is supported for rotation around stub axle 9c
by bearings 10c. The stub axle 9c is attached to the motor housing
8c, and the stator 2c is attached to the housing 8c by a clamp
plate 7c. Motor 1c can be used as a direct drive wheel motor for a
vehicle by attaching the motor housing 8c to the suspension of the
vehicle, and mounting a wheel onto the motor hub 6c. The stator 2c
is comprised of a wave pattern winding 13c bonded together by
encapsulating it in a resin 14c to form a rigid structure.
[0072] The cylindrical wave pattern winding 13c is similar in
construction to the disc shaped winding 13 shown in FIG. 2. Winding
13c is comprised of six wave shaped conductors that are preformed
and woven together in the same manner as winding 13, to form a
winding pattern having two cylindrical layers. The end turn regions
50a and 50b of the stator 2c must be thicker than the active region
of the stator 2c, between the magnets 4c, to accommodate the
additional radial thickness at the end turns of the winding 13c. To
allow assembly of motor 1c, end turn region 50a is biased radially
inwards, and end turn region 50b is biased radially outwards. The
end turns of the wave shaped conductors used to make up winding 13c
are preformed into a three dimensional curved shape to suit this
biasing of the end turn regions 50a, 50b. Motor 1c is assembled by
fitting the hub 6c, with the inner set of magnets 4c attached, onto
the stub axle 9c, then sliding the stator 2c over the inner set of
magnets 4c and clamping it to the housing 8c. Then, the carrier 49,
with the outer set of magnets 4c attached, is slid over the stator
2c and bolted to the hub 6c.
[0073] In other not shown embodiments of the invention, Litz wire
with a heat bondable coating may be used so that the winding
arrangement can be bonded together prior to final encapsulation in
resin.
[0074] In other not shown embodiments of the invention, the winding
may be bonded by methods other than using a vacuum mould to
encapsulate it in a resin. For example, the winding may be bonded
and encapsulated by injection moulding. Materials other than resin
may also be used, such as thermoplastics or polyurethane.
[0075] In other not shown embodiments of the invention, two
preformed wave shaped conductors may be formed on the one
continuous length of Litz wire. This may reduce the number of
connections that need to be made at the ends of the wave shaped
conductors.
[0076] The term "comprising" as used herein is used in the
inclusive sense of "including" or "having" and not in the exclusive
sense of "consisting only of".
* * * * *