[go: up one dir, main page]

WO2012032399A2 - Matériau composite électromagnétique (emcm) - Google Patents

Matériau composite électromagnétique (emcm) Download PDF

Info

Publication number
WO2012032399A2
WO2012032399A2 PCT/IB2011/002092 IB2011002092W WO2012032399A2 WO 2012032399 A2 WO2012032399 A2 WO 2012032399A2 IB 2011002092 W IB2011002092 W IB 2011002092W WO 2012032399 A2 WO2012032399 A2 WO 2012032399A2
Authority
WO
WIPO (PCT)
Prior art keywords
conductive fibers
drive unit
composite
fibers
composite drive
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/IB2011/002092
Other languages
English (en)
Other versions
WO2012032399A3 (fr
Inventor
Martin Gudem
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Norwegian University of Science and Technology NTNU
Original Assignee
Norwegian University of Science and Technology NTNU
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Norwegian University of Science and Technology NTNU filed Critical Norwegian University of Science and Technology NTNU
Publication of WO2012032399A2 publication Critical patent/WO2012032399A2/fr
Anticipated expiration legal-status Critical
Publication of WO2012032399A3 publication Critical patent/WO2012032399A3/fr
Ceased legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/02—Windings characterised by the conductor material
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction

Definitions

  • the present invention is related to electromagnetic composite materials
  • the present invention is related to electromagnetic composite materials (EMCM) that can be used as part of a composite drive unit.
  • EMCM electromagnetic composite materials
  • the present invention is directed to a composite drive unit, comprising: a composite material including conductive fibers as an integrated part of the composite material, wherein the conductive fibers can be organized in different patterns, and wherein each of the conductive fibers is terminated to an electrical conductor.
  • the composite drive unit further comprises a stator; and a moving part, wherein said stator and/or said moving part includes said conductive fibers embedded in a matrix material, said conductive fibers being connected to a source of electricity to generate a magnetic field.
  • the composite drive unit is constructed as an electric motor.
  • the composite drive unit further comprises a coil, which is an integral structural component, wherein the coil functions as reinforcement fiber in a composite material, and wherein the fibers may be ferromagnetic or ferrimagnetic.
  • the ferromagnetic or ferrimagnetic fibers may also be integrated in the material, so as to guide the magnetic flux, and may also be used as electromagnetic conductors.
  • the composite drive unit is constructed as an electromagnetic generator.
  • the composite drive unit is constructed as a wheel motor, windmill or tidewater generator, a high-speed motor or generator, or a transformer.
  • the present invention is also directed to a material for a composite drive unit, comprising: a plurality of conductive fibers arranged in a predetermined pattern, said plurality of conductive fibers being embedded in a matrix material, wherein said plurality of the conductive fibers are connectable to a source of electricity to generate a magnetic field for operating the composite drive unit.
  • the present invention is also directed to a method of making a composite material for a composite drive unit, comprising the steps of: arranging a plurality of conductive fibers in a predetermined pattern; embedding said plurality of conductive fibers in a matrix material to make a composite material; and etching edges of the composite material, wherein said plurality of conductive fibers are connectable to a source of electricity to generate a magnetic field for operating the composite drive unit.
  • the method of making a material for a composite drive unit further comprises the steps of: combining the plurality of conductive fibers with structural fibers; and winding the plurality of conductive fibers and the structural fibers on a mandrel, wherein said step of embedding the plurality of conductive fibers in a matrix material includes adding the matrix material during the winding process.
  • the method of making a material for a composite drive unit further comprises the steps of: weaving the plurality of conductive fibers into plies with structural fibers; and assembling the plies, wherein said step of embedding the plurality of conductive fibers in a matrix material includes adding the matrix material during the weaving and assembling steps.
  • the method of making a material for a composite drive unit further comprises the steps of: providing a base having a chamfered surface, a plurality of pins and a central peg; and winding structural fibers around the pins and the central peg, wherein the structural fibers are maintained in close contact with the base.
  • the present invention is also directed to a method of making a composite material for a composite drive unit further comprises the steps of: inserting pins into a foam base covered with a non-stick material; winding a plurality of conductive fibers in predetermined patterns using the pins to hold the plurality of conductive fibers in place; and embedding said plurality of conductive fibers in a matrix material to make a composite material, wherein said plurality of conductive fibers are connectable to a source of electricity to generate a magnetic field for operating the composite drive unit.
  • the method of making a composite material for a composite drive unit further comprises the steps of: covering the embedded conductive fibers with a sheet of non-stick material; pressing a foam block onto the non-stick material, so that the pins protrude through a top of the non-stick material and into the foam block, resulting in compression on the embedded conductive fibers; curing the embedded conductive fibers while under compression; and removing the foam-blocks, nonstick materials, and pins to form the composite material.
  • the EMCM Electromagnetic Composite Material
  • the EMCM uses conductive fibers as an integrated part of a long-fiber composite.
  • the conductive fibers can be organized in different patterns, and each conductive fiber is terminated to an electrical conductor, so as to make the EMCM exhibit electromagnetic properties.
  • the material has the potential of offering increased design flexibility and improved performance in electromagnetic devices, such as motors, generators, resonators, solenoids, etc.
  • Motors and generators using the EMCM can be designed with basis in existing coreless machinery.
  • Coreless machines exclude the use of ferromagnetic cores as a means of directing the magnetic flux.
  • Benefits associated with this technology include more lightweight design solutions.
  • enclosing the conductive fibers inside a nonmagnetic structure will reduce or eliminate unintended buckling of rotor and/or stator components, which can be experienced in axial flux permanent magnets (AFPM) and similar structures. This property is particularly important for designing large-scale machines.
  • AFPM axial flux permanent magnets
  • Ferrimagnetic and/or Ferromagnetic fibers may also be integrated in the material, so as to guide the magnetic flux. These fibers can be terminated, thereby serving as electrical conductors as well as flux-carriers.
  • the composite material may include structural fibers, which serve solely as reinforcement to the overall structure (e.g. glass fiber, carbon fiber, etc.).
  • structural fibers which serve solely as reinforcement to the overall structure (e.g. glass fiber, carbon fiber, etc.).
  • Figure 1 is a schematic view illustrating the composition of a long fiber composite
  • Figure 2 is a schematic view illustrating conductive material integrated into a sandwich structure
  • Figure 3 is a schematic view illustrating a different orientation of the structural and conductive fibers
  • Figure 4 is a schematic view illustrating a magnetic field resulting from imposing an electric current in the conductive fibers
  • Figure 5 is a schematic view illustrating a piece of EMCM where the conductive fibers are made from a ferrimagnetic or ferromagnetic material
  • Figure 6 is a schematic view illustrating the same piece of EMCM as in Figure
  • Figure 7 is a photograph illustrating a manual prototype before epoxy resin is added
  • Figure 8 is a photograph illustrating a manual prototype after curing
  • Figure 9 is a photograph illustrating a foam base, release liner, pattern markup, and guiding pins
  • Figure 10 is a photograph illustrating plies of reinforcement fibers and a winding tool
  • Figure 11 is a photograph illustrating matrix material added
  • Figure 12 is a photograph illustrating the part being cured under compression
  • Figure 13 is a photograph illustrating the part after compression
  • Figure 14 is a photograph illustrating the trimmed part after removal of the release liners and guiding-pins
  • Figure 15 is a photograph illustrating the center peg and chamfered sides keeping fibers close to base
  • Figures 16a, 16b and 16c are schematic views illustrating an AFPM based on
  • Figure 16a illustrates the entire construction
  • Figure 16b illustrates the stator
  • Figure 16c illustrates the rotor
  • Figure 17 is a schematic view illustrating conductive fibers arranged on a 3- phase configuration, and the resulting magnetic field.
  • the EMCM is developed with a basis in long-fiber composites.
  • Long-fiber composites gain their strength from structural fibers (e.g. glass or carbon fibers), held together by a matrix material (e.g. epoxy).
  • Figure 1 illustrates the make-up of a typical long- fiber composite.
  • a plurality of structural fibers 10 is illustrated stacked up in three layers with the longitudinal axis of each fiber being oriented in the same direction.
  • a matrix material 12 occupies the volume between the fibers.
  • the fibers 10 may be oriented in layers, or plies in different directions, so as to achieve direction-specific mechanical properties.
  • EMCM uses conductive fibers 14 (e.g. thin wires), which are integrated into a sandwich structure.
  • the conductive fibers 14 may consist of copper, steel, aluminum, or any other material with satisfactory electric conductivity.
  • the conductive fiber or wire may be pre-coated with insulation (not shown), so as to prevent short-circuiting.
  • the insulation is etched off at the contact points where the conductors are connected to an electric circuit.
  • the conductive fibers may be oriented in a direction different from that of the structural fibers.
  • the sandwich construction may be based on conductive fibers 14 serving as structural elements, eliminating the need for separate structural fibers 10.
  • Figure 4 illustrates a magnetic field 18 resulting from imposing an electric current 16 in the conductive fibers 14.
  • Figure 5 illustrates a piece of EMCM where the conductive fibers are made from a ferrimagnetic or ferromagnetic material. Imposing an electric current 16 in one layer induces a magnetic field 18 in the perpendicular layers.
  • Figure 6 shows the same piece of EMCM as in Figure 5, but with an electric current 16 running through the upper and lower layer. This imposes a magnetic field 18, which is carried by the center layer.
  • the EMCM can be manufactured using processes similar to those associated with the production of other long-fiber composites. However, the manufacturing process requires high precision to avoid tearing off the conductive fibers 14 and ensuring that conductors are terminated properly. Manufacturing methods include:
  • Conductive fibers 14 are combined with structural fibers 10 and wound onto a mandrel. Matrix material 12 is added in the winding process. The edges of the resulting component are etched, and the conductive fibers are soldered to connector points.
  • Conductive fibers 14 are woven into plies with structural fibers 10. Plies are assembled and matrix material 12 is added in a lay-up process. The edges of the resulting component are etched, and the conductive fibers are soldered to connector points.
  • the second prototype was manufactured using a semi- automated process where the conductive fiber 14 was wound using a CNC-machine (Computer Numerical Control).
  • the ping-guided winding process is suitable for making flat or curved parts with fiber-orientation that changes direction while staying parallel to the part surface. The process includes the following steps:
  • a foam-base is prepared with a release liner
  • Conductive fibers 14 are wound around pins using CNC machinery
  • Fibers are applied by hand (lay-up) or by CNC machinery (winding);
  • Steps 4 and 5 are repeated to create a sandwich construction
  • the part is trimmed.
  • Figure 7 shows a prototype made using a manual pin-guided winding process before epoxy resin is added.
  • Copper wire conductive fibers 14
  • glass-fibers structural fibers 10
  • the pins 26 served as guides for both the conductive fibers 14 and the structural glass- fiber (structural fibers 10).
  • the workpiece is made up from several layers of copper wire and glass fiber stacked onto each other.
  • the pins 26 are made of metal. However, it should be understood that other materials such as plastic or glass may be more suitable. For example, pins made of thermoplastic material may be molten after the part is cured, making the removal process easier.
  • Figure 8 shows the final part after the matrix material 12 has been added and the part has been compressed and cured. This test was conducted without covering the foam base with non-stick film, and the EMCM is consequently glued onto the foam base 24.
  • Figure 9 shows the foam base 24 used in a semi-automated pin-guided winding process.
  • the foam base 24 has been covered by a release liner 28, and a pattern 30 has been sketched out using a felt pen guided by a CNC machine. Pins 26 have been placed in each corner of the pattern 30.
  • the conductive wire (conductive fibers 14) are wound around the pins 26 using a CNC machine, and plies of reinforcement fibers (structural fibers 10) are added. The process is repeated to create a desired sandwich-structure.
  • Figure 10 shows the workpiece, which is made up from multiple plies of reinforcement fibers (structural fibers 10), stacked with conductive wire (conductive fibers 14).
  • matrix material 12 is added, and the part is cured under compression (see Figure 12).
  • Figures 13 and 14 the final product is illustrated. Once the final product is trimmed, the terminal ends of the conductive fibers 14 extending out of the matrix material 12 can be connected to an electrical connector (at 27).
  • the foam base 24 used in this process has also been designed to work with fiber strands as the structural fibers 10, laid out by a CNC machine. Keeping the fibers close to the base represents a challenge when using this method, since loose fibers may interfere with the routing of conductive fibers 14.
  • Structural fibers 10 are wound around needles 34 positioned at a chamfered edge 36 below the final part surface, thereby being pulled towards the base 24.
  • a peg 32 with a tapered surface is placed at the center for the base 24. Winding the structural fibers 10 around or partly around the peg ensures good contact between base and structural fibers 10 at the center ( Figure 15).
  • Manufacturing process 2 described above uses pre- woven mats consisting of conductive fibers 14 and structural fibers 10.
  • the ends of the conductive fibers 14 in this process will either have to be separated from the reinforcement fibers before matrix material 12 is added (un-sewing the edges and separating the fiber ends will work).
  • grinding and/or dissolving the matrix material 12 covering the material edges will be necessary if the ends of the conductive fibers 14 have not been separated from the rest of the part before matrix is added.
  • Other matrix materials such as thermoplastics, may be more suitable for this process.
  • AFPM AFPM machine based on EMCM technology.
  • An AFPM uses a magnetic field parallel to the machine's axle 4 in creating torque.
  • the short distance between the opposing magnetic poles of the two stators 2 eliminates the need for a ferromagnetic core for guiding the magnetic flux.
  • the machine is made up from two stators 2 consisting of permanent magnets backed by a steel disc, which provides structural support and guides the magnetic field (see Figure 16a).
  • the rotor 1, which is made from EMCM is attached to the axle 4, which is held in place by two bearings 3.
  • the pin-guided winding process described above may be suitable for manufacturing the rotor 1.
  • the conductive fibers are wound according to the pattern illustrated in Figure
  • EMCM electrospray induced current generator
  • the electrical conductors represent an integrated part of the structural support.
  • a rotor made from EMCM will be more lightweight and support higher rotational speed compared to traditional designs where separate coils of copper are held in place by a mechanical structure.
  • Enclosing the conductive fibers inside a non-magnetic structure will also reduce or eliminate unintended buckling of rotor and/or stator components, which can be experienced in axial flux permanent magnet (AFPM) machines and similar structures. This property is particularly important for designing large-scale turbines.
  • Traditional, large- diameter rotors made from ferromagnetic material will be affected by the magnetic field in which the coils travel to produce electricity. The rotors must exhibit high bending stiffness, so as to avoid sticking to the permanent magnets.
  • EMCM is expected to eliminate this problem, supporting the development of large-diameter, high-power, and lightweight axial flux generators.
  • Parts made from EMCM are sealed units, a quality that can make them particularly suitable for harsh operating conditions, such as corrosive environments, or underwater installations.
  • the EMCM-technology may offer increased design flexibility and improved performance in electromagnetic devices, such as motors, generators, resonators, solenoids, etc.
  • Application areas that may benefit from the introduction of EMCM include:
  • the concept may offer significant weight savings, thereby reducing the unsprung mass when installed in cars, scooters, etc.
  • the concept may offer significant weight savings, easing the structural requirements for such installations. 3. Motors and/or generators for harsh operating environments
  • Parts made from EMCM are sealed units, a quality that can make them particularly suitable for harsh operating conditions, such as corrosive environments, or underwater installations.
  • a rotor made from composite material may offer higher strength, and thus permit higher angular speed for motors/generators. This may be particularly relevant for large-scale generators.
  • An AC transformer can be made by installing two or more coil-shaped circuits on a patch of material. AC current is run through the input coil, imposing a magnetic field. The changing magnetic field induces electricity in the output coil(s).
  • [0073] Can be used in setting up a steady or varying magnetic field, applicable for transmitting electricity wirelessly or support propulsion and/or elevation for mag-lev (magnetic levitation) designs.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Moulding By Coating Moulds (AREA)
  • Laminated Bodies (AREA)

Abstract

L'unité de commande composite selon l'invention comprend un matériau composite incluant des fibres conductrices 14 faisant partie intégrante du matériau composite. Les fibres conductrices 14 peuvent être organisées en différents motifs, et chacune des fibres conductrices est terminée par un conducteur électrique. Le matériau pour une unité de commande composite comprend une pluralité de fibres conductrices 14 agencées en un motif prédéfini 30. La pluralité de fibres conductrices 14 sont incorporées dans un matériau de matrice 12. La pluralité des fibres conductrices 14 peut être connectée à une source d'électricité pour générer un champ magnétique 18 servant à activer l'unité de commande composite.
PCT/IB2011/002092 2010-09-07 2011-09-07 Matériau composite électromagnétique (emcm) Ceased WO2012032399A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US38057310P 2010-09-07 2010-09-07
US61/380,573 2010-09-07

Publications (2)

Publication Number Publication Date
WO2012032399A2 true WO2012032399A2 (fr) 2012-03-15
WO2012032399A3 WO2012032399A3 (fr) 2014-01-23

Family

ID=44910264

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IB2011/002092 Ceased WO2012032399A2 (fr) 2010-09-07 2011-09-07 Matériau composite électromagnétique (emcm)

Country Status (1)

Country Link
WO (1) WO2012032399A2 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2019074375A1 (fr) 2017-10-11 2019-04-18 Alva Industries As Mat électromagnétique pour un composant de stator ou de rotor d'une machine électrique

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH10257706A (ja) * 1997-03-12 1998-09-25 Fuji Electric Co Ltd 回転機固定子コイル
US7268461B2 (en) * 2001-02-15 2007-09-11 Integral Technologies, Inc. Low cost electrical motor components manufactured from conductive loaded resin-based materials
JP2010135566A (ja) * 2008-12-04 2010-06-17 Seiko Epson Corp 電磁コイルおよび電気機械装置および電気機械装置を用いた装置

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2019074375A1 (fr) 2017-10-11 2019-04-18 Alva Industries As Mat électromagnétique pour un composant de stator ou de rotor d'une machine électrique
CN111213303A (zh) * 2017-10-11 2020-05-29 阿尔瓦工业股份公司 用于电气机器的定子或转子部件的电磁垫
US20200244149A1 (en) * 2017-10-11 2020-07-30 Alva Industries As Electromagnetic Mat for a Stator or Rotor Component of an Electric Machine
US11646645B2 (en) 2017-10-11 2023-05-09 Alva Industries As Electromagnetic mat for a stator or rotor component of an electric machine

Also Published As

Publication number Publication date
WO2012032399A3 (fr) 2014-01-23

Similar Documents

Publication Publication Date Title
US10875053B2 (en) Method for making a component for use in an electric machine
Wang et al. Development of a permanent magnet motor utilizing amorphous wound cores
CN102044916B (zh) 磁性铁芯以及其制造方法、轴隙式旋转电机、静止机
AU2008234418B2 (en) Winding arrangement for an electrical machine
US6242840B1 (en) Electrical machine including toothless flux collector made from ferromagnetic wire
EP2264860B1 (fr) Roteur pour machine électrique d'un véhicule sur rails, une telle machine et véhicule sur rails ayant une telle machine
US12495493B2 (en) Magnetic material filled printed circuit boards and printed circuit board stators
EP2660956A1 (fr) Machine électrique tournante
US10965235B2 (en) High frequency electric motor, control system, and method of manufacture
EP3076522A1 (fr) Moteur électromagnétique
US20210234450A1 (en) Continuous winding for electric motors
JPWO2012007984A1 (ja) アモルファスコア、及びそれを用いた電磁部材と回転電機、並びにその製造方法
CN110048569A (zh) 机器人用双层halbach阵列的定子无铁心伺服电机
WO2012032399A2 (fr) Matériau composite électromagnétique (emcm)
US20190280550A1 (en) Laminated stack motor
CN215990363U (zh) 轿车轮毂电机
CN110752724A (zh) 永磁电机转子制造方法、电机转子和永磁电机
Morimoto Rare earth free, traction motor for electric vehicle
JP2004201488A (ja) 同期電動機及びその製造方法
CN113595286A (zh) 轿车轮毂电机
CN214958935U (zh) 一种复合型齿部结构及具有复合型齿部结构的定子
Morimoto et al. Induction motor made of SMC
Kim et al. Theoretical analysis and experiments of axial flux pm motors with minimized cogging torque
CN113517773A (zh) 集成化悬浮推进模组
EP4531245A1 (fr) Rotor avec manchon de protection

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 11779483

Country of ref document: EP

Kind code of ref document: A2

122 Ep: pct application non-entry in european phase

Ref document number: 11779483

Country of ref document: EP

Kind code of ref document: A2