Process for producing an electromagnetic subassembly for a magnetic levitation railway

• US 6,584,671 B2
• Filed: 05/06/1999
• Issued: 07/01/2003
• Est. Priority Date: 02/12/1996
• Status: Expired due to Term

• Current Assignee: Thyssen Transrapid System GmbH (Thyssenkrupp AG)
• Original Assignee: Thyssen Transrapid System GmbH (Thyssenkrupp AG)
• Inventors: Hahn, Wolfgang, Miller, Luitpold
• Primary Examiner(s): Tugbang, A. Dexter
• Application Number:
  US09/125,092
• Publication Number:
  US 20010002507A1
• Time in Patent Office: 1,517 Days
• Field of Search: 295/96, 295/98, 296/09, 310/42, 310/43, 264/272.19, 264/272.2, 264/261, 156/305, 156/330
• US Class Current: 29/596
• CPC Class Codes: B60L 13/03 Electric propulsion by linear motors
• CPC Class Codes: B60L 2200/26 Rail vehicles
• CPC Class Codes: E01B 25/32 Stators, guide rails or slide rails
• CPC Class Codes: H01F 41/0213 Manufacturing of magnetic circuits made from strip(s) or ribbon(s) magnetic cores made by winding a ribbon H01F27/25
• CPC Class Codes: H02K 15/024 with slots
• CPC Class Codes: H02K 41/02 Linear motors; Sectional motors
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/49012 Rotor
• CPC Class Codes: Y10T 29/49078 Laminated

Abstract

The method provides an electromagnetic assembly in the form of a magnet pole or of a stator packet of an extended stator linear motor for a magnetic levitation train. The assembly includes a sheet stack (8) made of ferromagnetic material and at least one additional component (12,13,14). The sheet stack (8) is assembled from raw magnetic steel sheets and is positioned in a shaping tool. Thereafter by feeding a hardenable mixture into the tool and hardening or hardening out the mixture, the sheets are surrounded with the mixture and connected to each other in a single working step to form the finished sheet stack. In the same working step, the sheet stack (8) is connected to the additional component (12,13,14) and the assembly as a whole is provided with its final electrical, magnetic, mechanical and/or geometric properties.

Claims

1. A method of manufacturing an electromagnetic assembly in form of a stator packet of a long stator motor for a magnetic levitation train, said assembly including a sheet stack consisting of ferromagnetic material, and at least an additional component, said method comprising the steps of:

providing a plurality of raw magnetic steel sheets;

providing first apertures on upper sides of said sheets;

providing second apertures on undersides of said sheets;

stacking said sheets for providing said stack so that at least one first groove is formed in said stack by said first apertures and at least one second groove is formed in said stack by said second apertures, said second groove being intended to accommodate an elastically deformable electrical conductor and having a groove wall and a cross-section selected according to desired electromagnetic properties of said stack;

inserting a cross-piece into the at least one first groove, said crosspiece sewing as an aid for mounting said electromagnetic assembly;

forming said assembly from said stack and said component;

positioning said assembly in a cavity defined by wall portions of a shaping tool; and

then finishing said assembly by means of a pressure-gelation method, said pressure gelation method comprising the steps of providing a thermally hardenable mixture which comprises a duroplastic epoxy resin component and a hardener component;

introducing said mixture into said cavity such that said mixture is introduced into cavities between said sheets so as to connect said sheets as well as surrounds said sheets, said stack and said assembly as a whole on all sides;

heating said shaping tool;

hardening or hardening out said mixture at least as long until removal of said assembly from said shaping tool, whereby in one single working step said sheets are connected together, said stack is connected with said at least one component, said wall of said at least one second groove is provided during introduction of said mixture into said cavity with a lining comprised of said mixture such that a mechanically effective groove results having an effective groove wall with a cross-section selected according to said conductor, said assembly is provided with final electrical, magnetic and/or mechanical properties and said assembly is completely surrounded with an anti-corrosion layer having a thickness which is selected by a spacing between said sheet stack and wall portions of said shaping tool.

2. The method according to claim 1, wherein the effective groove wall has a final cross-section selected so that the effective groove wall opens outwards by means of a slot having a narrowest point of smaller width than the corresponding to an external diameter of said conductor.

3. The method as defined in claim 1, wherein said mixture has electrical insulating properties such that a mutual electrical insulation is produced between said sheets.