Method for making electrical windings for electrical machines and winding obtained by said method

• US 20100181860A1
• Filed: 01/19/2009
• Published: 07/22/2010
• Est. Priority Date: 01/19/2009
• Status: Active Grant

• Current Assignee: Sergey Pulnikov
• Original Assignee: Sergey Pulnikov
• Inventors: Pulnikov, Sergey
• Granted Patent: US 7,913,375 B2
• Time in Patent Office: Days
• US Class Current: 310/195
• CPC Class Codes: H02K 1/02 characterised by the magnetic material
• CPC Class Codes: H02K 1/148 Sectional cores H02K1/141 takes precedence
• CPC Class Codes: H02K 1/16 Stator cores with slots for windings
• CPC Class Codes: H02K 15/02 of stator or rotor bodies
• CPC Class Codes: H02K 15/0442 Loop windings manufacturing of windings consisting of overlapped loops H02K15/0464
• CPC Class Codes: H02K 15/12 Impregnating, heating or drying of windings, stators, rotors or machines
• CPC Class Codes: H02K 2213/03 Machines characterised by numerical values, ranges, mathematical expressions or similar information
• CPC Class Codes: H02K 3/12 arranged in slots
• CPC Class Codes: H02K 3/18 Windings for salient poles
• CPC Class Codes: H02K 3/28 Layout of windings or of connections between windings windings for pole-changing H02K17/06, H02K17/14, H02K19/12, H02K19/32
• CPC Class Codes: H02K 3/47 Air-gap windings, i.e. iron-free windings
• CPC Class Codes: H02K 3/493 magnetic
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine

Abstract

This invention presents a novel method for designing and manufacturing electrical windings for electrical machines. The presented manufacturing technique gives possibilities for an increased filling factor compared to conventional technique and improved heat transfer through application of thermally conductive compounds. Proposed winding schemes avoid intersection between different winding layers in the end-winding region. This helps automating winding production, simplifies insulation between winding layers and, if this is necessary, simplifies insertion of the winding. Both these factors affect the cost and reliability of the winding. This method is applicable for a broad range of electrical machines and allows easy automation of the winding process.

Claims

1. A winding of electrical machine with m phases and n winding layers, comprising following properties:

a. coils of one phase may be connected parallel or in series in such a way that currents flowing through these coils would create a magnetic field either having 2p poles or 4p poles, where p=1,2,3, . . . ;

b. the total number of coils equals 2pm, where p is the number of pole pairs, m is the number of phases;

c. the number of coils in a winding layer is an integer number and equals

2. The winding according to claim 1 wherein the number of slots per pole per phase q is equal to any fractional number.

3. A method of manufacturing a premade insertable winding in accordance with claim 1 and 2 for slotless stator comprising steps of:

a. Manufacturing a metal mandrel generally of a cylindrical shape with a step for the low end-winding and optionally a slight taper in the direction of extraction;

b. Installation of an internal support made of insulating material;

c. Installation of rings with turning pins on said mandrel;

d. Installation of side rings on said mandrel;

e. Treating said mandrel side rings with release agent in order to facilitate extraction of the winding;

f. Pouring thermally conducting compound on the mandrel comprising polymer and powder of non-conducting material;

g. Fixation and insulation of the first end wire for each new coil;

h. Manufacturing coils using insulated metal wire in accordance with a winding scheme described in claim 1;

i. Fixation and insulation of the second end wire for a completed coil;

j. Repeating steps f.-i. for each new coil;

k. Manufacturing and/or installing interlayer insulation upon each completed winding layer;

l. Winding a compacting bandage on each end-winding region upon completing the winding layer;

m. Repeating steps f.-l. for each new winding layer;

n. Compacting and compressing the winding using a combination of the outer shell and side rings;

o. Curing the winding;

p. Removing side rings and extracting the winding from the mandrel;

q. Installing the winding into the stator core.

4. The method in accordance with claim 3 wherein turning pins are integrated into the mandrel.

5. The method in accordance with claim 3 wherein interlayer insulation is impregnated with the same polymer as in the thermally conducting compound.

6. The method in accordance with claim 3 wherein outer shells are incorporated into side rings.

7. The method in accordance with claim 6 wherein side rings are made of material with smaller thermal expansion compared to the mandrel.

8. The method in accordance with claim 3 wherein thermally conducting compound contains powder of soft magnetic material, the mandrel contains a layer of radially magnetized permanent magnets and side rings, the outer shell and the mandrel are made of soft magnetic material.

9. The method in accordance with claim 3 wherein turning pins are integrated into the internal support.

10. The method in accordance with claim 3 wherein said internal support contains teeth.

11. The method in accordance with claim 10 wherein the mandrel has a cylindrical shape and does not have a step in the operating area.

12. The method in accordance with claim 3 wherein the stator core is integrated into the outer shell.

13. The method in accordance with claim 11 wherein round/square or foil wire is utilized for manufacturing the winding comprising the steps of:

a. Securing the first end wire;

b. Attaching a ribbon of soft magnetic material to said foil wire in such a way that the winding could be performed in parallel with the wire and with said soft magnetic ribbon.

14. The method in accordance with claim 3 wherein wires with bondable coating are used comprising the steps of:

a. Using expandable metal mandrel;

b. Integrating turning pins into said expandable mandrel;

c. Using thermoplastic or other fast-curing fiber reinforced prepreg for manufacturing an internal support and interlayer insulation layers;

d. Preheating the bondable wire prior to reaching the mandrel with the winding;

e. Preheating said prepreg prior to reaching the mandrel with the winding.

23. A method of manufacturing a premade insertable winding in accordance with claim 1 and 2 for stators with slots comprising steps of:

a. Manufacturing a metal mandrel generally of a cylindrical shape with a step for the low end-winding and optionally a slight taper in the direction of extraction and slots for installation of teeth;

b. Installing a ring with turning pins on the top end-winding region of said mandrel and providing a gap for a compacting bandage between teeth and turning pins;

c. Installing retractable metal teeth on the mandrel in corresponding slots wherein teeth should hang over the low end-winding region of the mandrel the teeth should have rounded edges sufficient for avoiding any damage to insulation of the wire;

d. Installing side rings on said mandrel;

e. Treating teeth, mandrel and side rings by release agent in order to facilitate extraction of the winding;

f. Introducing a layer of insulation is introduced on the mandrel by pouring thermally conductive compound on the turning mandrel;

the mandrel has to turn horizontally making a few turns in one direction and then a few turns in another direction in order to keep compound on the mandrel and have a uniform insulation layer on the operating region of the mandrel and teeth;

after that curing must be performed while the mandrel keeps turning;

g. Pouring thermally conducting compound on the mandrel comprising polymer and powder of non-conducting material;

h. Fixation and insulation of the first end wire for each new coil;

i. Manufacturing coils using insulated metal wire in accordance with a winding scheme described in claim 1 and 2 with the wire going under the teeth in the low end-winding region;

j. Fixation and insulation of the second end wire for a completed coil;

k. Repeating steps g.-j. for each new coil;

l. Manufacturing and/or installing interlayer insulation upon each completed winding layer;

m. Winding a compacting bandage on the top end-winding region between teeth and turning pins upon completing each new winding layer;

n. Repeating steps g.-m. for each new winding layer;

o. Compacting and compressing the winding using a combination of the outer shell and side rings;

p. Curing the winding;

q. Removing side rings and extracting the winding from the mandrel;

r. Removing teeth from the winding;

s. Installing the winding into the stator.

24. The method in accordance with claim 23 wherein a premade insulation layer is installed on the mandrel with teeth.

25. The method in accordance with claim 23 wherein wires with bondable coating are used and bonding is applied after the winding is completed.

26. The method in accordance with claim 23 wherein

a. A certain amount of magnetic compound consisting of a mixture of a polymer and powder of soft magnetic material is poured between teeth before the winding;

b. Tangentially magnetized permanent magnets are embedded into the said teeth and both the mandrel and teeth are made of not-magnetic material;

c. This magnetic compound is cured while the mandrel is slowly turning.

27. The method in accordance with claim 23 wherein pieces of soft magnetic material are laid between teeth before beginning of the winding.

28. The method in accordance with claim 23 wherein the interlayer insulation is provided by according strengthening of wire insulation for turns coming in direct contact with another coil.

29. The method in accordance with claim 23 wherein the interlayer insulation is provided by installing a net over the mandrel with winding with openings for teeth.

30. The method in accordance with claim 23 wherein the interlayer insulation is provided by spraying a fast-curable polymer of a completed winding layer.

31. A method of manufacturing a premade insertable winding in accordance with claim 1 and 2 for stators with split cores comprising steps of:

a. Manufacturing a cylindrical metal mandrel optionally having a slight taper in the direction of extraction of the winding and additional elements for centering and fixation of a teeth core;

b. Installing a teeth core on the mandrel with axial slots for further installation of compacting bandages;

c. Introducing slot insulation into the slots either;

d. Installing side rings on said mandrel;

e. Treating teeth, mandrel and side rings by release agent in order to facilitate extraction of the winding;

f. Introducing a layer of insulation in the slots either by inserting a whole premade insulation structure or by installing individual premade shells on each tooth of the teeth core;

g. Pouring thermally conducting compound on the mandrel comprising polymer and powder of non-conducting material;

h. Fixation and insulation of the first end wire for each new coil;

i. Manufacturing coils using insulated metal wire in accordance with a winding scheme described in claim 1 and 2;

j. Fixation and insulation of the second end wire for a completed coil;

k. Repeating steps g.-j. for each new coil;

l. Manufacturing and/or installing interlayer insulation upon each completed winding layer;

m. Winding compacting bandage through axial slots in the teeth core and on end-winding regions upon completing each new winding layer;

n. Repeating steps g.-m. for each new winding layer;

o. Compacting and compressing the winding using a combination of the outer shell and side rings;

p. Curing the winding;

q. Removing side rings and extracting the winding with the teeth core from the mandrel;

r. Installing the winding into the stator.

32. The method in accordance with claim 31 wherein the stator yoke is integrated into the outer shell.

33. The method in accordance with claim 31 wherein wires with bondable coating are used and bonding is applied after the winding is completed.

15. A method of manufacturing a tape concentric winding comprising steps of:

a. Manufacturing a central tooth;

b. Manufacturing side plates matching said central tooth and installing the said side plates on the central tooth;

c. Making a temporary winding of insulated metal wire connected to the main storage of said wire with the length approximately corresponding to the half length of the tape winding that is supposed to be made;

d. Locating wire connecting the main storage of the wire and said temporary winding between said side plates;

e. Performing circular movement in the opposite directions by the wire supplied from said temporary winding and by the wire supplied from the main storage;

f. Repeating steps c.-e. for subsequent coils;

g. Filling the winding with a polymer;

h. Curing the winding;

i. Removing side plates;

j. Removing the coil;

k. Repeating steps c.-j. for subsequent coils;

16. The method in accordance with claim 15 wherein pieces of soft magnetic material are inserted between side plates and introduced into a coil during winding.

17. The method in accordance with claim 15 wherein teeth are inserted between side plates during winding of the coil in order to achieve slots in the winding.

18. The method in accordance with claim 17 wherein slot insulation is inserted together with teeth.

19. The method in accordance with claim 15 wherein interlayer insulation is inserted next to the side plates.

20. The method in accordance with claim 15 wherein wires with bondable coating are used and bonding is applied either after the winding is completed or after the final shape is achieved.

21. The method in accordance with claim 15 wherein foil wire is used and winding is performed only in one direction comprising the steps of:

a. Securing the first end-winding;

b. Attaching a ribbon of soft magnetic material to said foil wire in such a way that the winding could be performed in parallel with the wire and with said soft magnetic ribbon.

22. The method in accordance with claim 15 wherein tape windings are folded into the stator in case of external stator or onto the stator in case of internal stator.

34. A method of manufacturing a split stator core comprising the steps of:

a. Manufacturing a teeth core wherein teeth are joined together and have a slope at the top edge;

b. Manufacturing a stator yoke core with teeth on the inner surface with a slope corresponding to the slope on teeth in the said teeth core;

c. Inserting said teeth core into said stator yoke with subsequent rotating of any of said cores in the direction of slopes on teeth in said teeth core until the teeth core and the stator yoke are completely engaged.