Abstract
The subject matter of the invention is the method of construction of a linear motor winding, consisting of phase paths, characterised in that a solid flat bar is cyclically bent at a selected binding radius R.sub.1, the active part and the end parts constitute a uniform plane of the phase path, which has got elongated end fragments: the beginning of the section and the end of the section or the phase path is cut of metal sheet, as shown in the figure and then, along the line, separating the end part from the active part, it is bent at the bending radius R.sub.2, where the bend angle α.sub.1 is within the range between 0° and 180°.
Claims
1. The method of construction of a linear motor winding, consisting of phase paths, characterised in that a solid flat bar is cyclically bent at a selected binding radius, an active part and an end part make a uniform plane of the phase path, which has got elongated end fragments: a beginning of a section and an end of the section or the phase path is cut of a metal sheet, and then, it is bent along the line, separating the end part from the active part the phase path is bent at the bending radius, where the bend angle α1 is within the range between 0° and 180°.
2. The method of claim 1, characterised in that a solid flat bar or sheet is made of a diamagnetic or paramagnetic material.
3. The method of claim 1, characterised in that the phase paths are laid down parallel and in a non-conflicting way, making a section.
4. The method of claim 3, characterised in that the winding of a linear winding is sectioned and consists of many identical sections.
5. The method of claim 3, characterised in that subsequent sections are connected by means of screws and then placed in clamping plugs, welded or connected via a system of contactors.
6. The method of claim 1, characterised in that the phase path is cut from a metal sheet with laser beam, water or plasma.
7. The method of claim 1, characterised in that the winding is made as either single- or double-layer winding.
8. The method of claim 1, characterised in that the active part and the end parts are covered with an insulation layer, either by lacquer coating or by pouring a thermoplastic material on it in a prepared mould.
9. The method of claim 1, characterised in that the sections are fastened to a base with screws, spring clips or latches.
Description
[0023] This invention has been discussed in detail in examples and demonstrated in figures, where
[0024] FIG. 1 shows semi-finished (intermediate) products, out of which, the winding is further made, according to the description of the invention: a flat bar 1 and a metal sheet 5. Also demonstrated is an example pattern of cutting of several phase paths 2 from a metal sheet.
[0025] FIG. 2 shows a single phase path 2, consisting of active parts 2a, end parts 2b and of the beginning of section 2c and of the end of section 2d. Also marked is the pole pitch r, the bending radius R.sub.1 and the phase path length L.
[0026] FIG. 3 shows a phase path 2 in isometric projection FIG. 4 shows the cross-sections of bent phase paths in the following three versions: Phase A, Phase B, Phase C. The active part and the end parts have different heights for each version. The bending radii (R.sub.2) and the bend angle (α.sub.1) are also marked.
[0027] FIG. 5 shows a bent phase path in isometric projection.
[0028] FIG. 6 shows 3 phase paths 2 in each version, combined in one section of the winding 3a in the single-sided system. The following elements are indicated: the terminals of the beginning of the section 3e and of the end of the section 3f.
[0029] FIG. 7 shows a three-phase winding in the double-sided system. In addition, the fastening screws are shown.
[0030] FIG. 8 shows a three-phase winding, presented in FIG. 7 after its pouring with a thermoplastic material 3d.
[0031] FIG. 9 shows the cross-section of the structure presented in FIG. 8. The separator 3c is marked; it is used in the double-sided system and protects against short circuit of the right and left side of the winding.
[0032] FIG. 10 shows a three-phase winding in the double-sided system, similarly as in FIG. 9, however, at different bend angles α.sub.1 than in FIG. 9.
[0033] FIG. 11 shows a three-phase winding from the picture of FIG. 10 in isometric projection.
[0034] FIG. 12 shows a fastening method—by means of spring clips 3h—of a winding poured with a thermoplastic material 3d.
[0035] FIG. 13 shows a fastening method with spring clips 3i of the winding, poured with a thermoplastic material 3d.
[0036] FIG. 14 shows the connection of adjacent sections 3 by means of welding 4a of the phase path endings.
[0037] FIG. 15 shows the connection of adjacent sections 3 by means of fastening with screws of the connector 4b to the ends of the phase paths.
[0038] FIG. 16. shows a connecting socket 4c, enabling a three-phase winding 3a to be placed in it.
[0039] FIG. 17 shows a schematic system of track sectioning with contactors 6a, connecting the subsequent sections 6b with the three-phase mains 6d. The signal cable 6c is also marked, informing about the current vehicle position and about the switching sequence of particular sections.
EMBODIMENT 1
[0040] The phase path 2 (FIG. 2) is made by bending of the flat bar 1 at a selected binding radius R.sub.1 or by cutting from a metal sheet 5. The cutting is done with laser beam, water, plasma or by die shearing. The shape of this element 2 is cyclically repeated with each subsequent pole pitch τ. At this stage, the active part 2a and the end parts 2b make a uniform plane, where the phase path has any length L. The production limitations include, for example, the dimensions of available material or the working area of the bending or cutting machine tool. The single phase path has elongated end fragments: the beginning of section 2c and the end of section 2d. They enable the mutual connection of subsequent sections. Then, such an element is bent along the line which separates the end part from the active part. The phase path is bent at the bending radius R.sub.2, as shown in FIG. 4. If the bending radius exceeds 0 m, then the active part and the end parts cease to form a common plane and the angle α.sub.1 appears in the range from 0 to 180°. Each of the phase paths is bent at various heights, what enables to lay them out in a non-conflicting way into a three-phase winding 3a, what is shown in FIG. 6. Each phase path is bent at a different bending angle α.sub.1 or it has a different height of the active part. It allows all the construction variants to be laid out in a non-conflicting way into a three-phase winding 3a, as in FIG. 6. One example of the application of such a winding is a double-sided, synchronous, linear motor, the windings of which can be composed of two three-phase windings, laid out side-by-side, as in FIG. 7, with a thin separator 3c in between. The angle α.sub.1 may be the same for each phase, as shown in FIG. 6, where it is 90°, it may, however, also be variable, as in FIG. 10, where the angle α.sub.1 is 0°, 30° and 60°, respectively. Such a laid out winding is covered with an insulation layer, either by lacquer coating or pouring with a thermoplastic material 3d in a preset mould. The thermoplastic material is used to pour onto end parts and the active part, however, pouring does not include the terminals from the beginning of the section 3e or the terminals from the end of section 3f, as shown in FIG. 8. At this stage, a self supporting structure of the single winding section 3 is formed, the structure being fastened to the base. The fastening is made by means of screws 3b (FIG. 9), spring latches 3i (FIG. 13) or spring clips 3h (FIG. 12). The complete winding of a linear motor is made by connection with subsequent sections. The connections between subsequent sections are made by means of contactors 4b, fastened with screws (FIG. 15) to the terminals from the end of one section and to the terminals from the end of a subsequent section or by welding of the terminals from two adjacent sections 4a (FIG. 14) or by placing the terminals from the end and from the beginning of the adjacent section in a connection socket 4c (FIG. 16). One of the ways to connect sections is the use of a contactor system 6a (FIG. 17), enabling an infinitely variable sectioning of a track during a vehicle passage, and thus allowing for reduction of the length of a powered section. The subsequent sections 6b are activated only when the vehicle runs either on them or on their adjacent sections. This information is delivered to the contactors by the signal cable 6c. The contactors switch on subsequent phases, connecting them with the three-phase mains 6d. In this way, the losses, associated with the energy transfer in the track, will be reduced
EMBODIMENT 2
[0041] This exemplary embodiment shows a winding, the phase path of which is presented in FIG. 2 and FIG. 5 and which has the following dimensions:
The phase path length L=920 mm,
The pole pitch τ=10 mm,
The height of the active part=15 mm,
The height of the end part=6 mm,
The radius R.sub.1=6 mm,
The radius R.sub.2=6 mm,
The bend angle α.sub.1=90°.
[0042] The proposed solution enables to reduce the production costs of a linear motor winding in case, when it is laid out on a route of many kilometres. The method according to the invention consists in using easily available materials, such as flat bars and metal sheets. Another specific feature, resulting in a lower production cost, are the simple and fast procedures of material processing, i.e. sheet cutting or flat bar bending. These two mentioned features mean that a winding, made in such a way, is cheaper than an analogous one, made of conductors or cut from a sheet to be then welded or press welded. Due the process of pouring a thermoplastic material onto the winding, a self-supporting structure is obtained, which is easy in transport, handling and assembly.
[0043] Another advantage of the proposed solution is its universality. First of all, taking into account the type of the used drive system. The winding of a linear motor in various geometric configurations is intended for application both in induction and synchronous motors, where it supports a mover mounted on a vehicle. It is possible to construct a motor in a single-sided and double-sided system. Various selection values of the angle α.sub.1 enable to control the height of the entire stator, what influences the shape of the vehicle chassis.
[0044] The use of a solid, coreless winding enables to reduce the production costs and eliminate the negative effects, observed in linear machines, such as the cogging force. The form, in which the winding is proposed, i.e. ready-made sections of a predefined length, allows for a fast and cheap assembly on a previously prepared base.
[0045] The solution, according to this invention, is used as an element of an electric linear motor driving the vehicle. The solution is used in high-speed transport applications, at environments with atmospheric or decreased air pressure.
