COILS FOR ELECTRICAL MACHINES

Abstract

A coil for an electrical machine having a stator with salient poles is disclosed. The coil has first and second coil sides joined by a respective coil end at each end to define a space for accepting a salient pole. Each coil side has an inner side facing the space and an opposed outer side. The coil comprises a plurality of turns of a conductor arranged in layers of turns with a first layer disposed on the inner side of the first coil side and outer side of the second coil side and a second layer disposed on the inner side of the second coil side and outer side of the first coil side. Arrangement of layers of turns of the conductor provides a thermal conduction path for the conductor with reduced thermal impedance, which facilitates transfer of heat into the stator from portions of the conductor oriented away from the stator surface.

Claims

1. A coil for an electrical machine having a stator with salient poles, the coil comprising: first and second coil sides joined by a respective coil end at each end to define a space for accepting a salient pole, each coil side having an inner side facing the space and an opposed outer side; and wherein the coil comprises a plurality of turns of a conductor arranged in layers of turns with a first layer disposed on the inner side of the first coil side and the outer side of the second coil side and a second layer disposed on the inner side of the second coil side and the outer side of the first coil side.

2. A coil according to claim 1, wherein an arrangement of the plurality of turns in the first side is rotated about an axis along the first coil side and relative to an arrangement of the plurality of turns in the second side.

3. A coil according to claim 2, wherein the axis is centred on the first coil side.

4. A coil according to claim 2, wherein an average distance from the space along each turn is substantially constant across the plurality of turns.

5. A coil according to claim 2, wherein the arrangement of the plurality of turns in the first side is rotated about the axis and relative to the arrangement of the plurality of turns in the second side by an angle between 160 and 200 degrees.

6. A coil according to claim 5, wherein the axis is centred on the first coil side.

7. A coil according to claim 5, wherein an average distance from the space along each turn is substantially constant across the plurality of turns.

8. A coil according to claim 1, wherein the conductor is one or more of a wire, a bundle of wires, a twisted bundle of wires, a rope of wires or a braid of wires.

9. A coil according to claim 1, wherein a respective distance between each turn and the space is substantially constant over a portion of each coil side.

10. A coil according to claim 1, wherein an average distance from the space along each turn is substantially constant across the plurality of turns.

11. A coil according to claim 1, wherein the coil is disposed around a respective one of the salient poles of the electrical machine.

12. A coil according to claim 1, further comprising the electrical machine having the stator with salient poles

13. A method of forming the coil according to claim 1, the method comprising: winding the conductor on a former to form the coil having first and second coil sides joined at each end by the respective coil end; removing the coil from the former; and rotating the first coil side relative to the second coil side.

14. A method according to claim 13, wherein the turns of the first and second layer of the formed coil are sequential turns on the former.

15. A method according to claim 14, wherein the first coil side is rotated through an angle relative to the second coil side about an axis along the first coil side.

16. A method according to claim 15, wherein the angle is between 160 and 200 degrees.

17. A method according to claim 13, wherein the turns of the first and second layer of the formed coil are corresponding turns in the layers on the former.

18. A method according to claim 17, wherein each coil side is rotated through an angle relative to the other about an axis along a respective one of the coil sides.

19. A method according to claim 18, wherein the angle is between 80 and 100 degrees.

20. A method according to claim 17, wherein the first coil side is translated relative to the second coil side so that the first and second coil sides face each other.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Specific embodiments are now described, by way of example only, with reference to the accompanying drawings of which:

[0033] FIG. 1 shows a perspective view of a portion of a twisted rope conductor of the prior art for use in a stator winding for an electrical machine.

[0034] FIG. 2 shows a partial cross-section of a typical stator for a switched reluctance machine.

[0035] FIGS. 3a and 3b illustrate perspective schematic views of a multi-layer stator coil for an electrical machine in accordance with one or more embodiments of the disclosure.

[0036] FIG. 4 illustrates a schematic cross-section through a stator coil of FIGS. 3a and 3b.

[0037] FIG. 5 illustrates a partial cross-section of a stator with a stator coil mounted on a stator pole of the stator, the coil comprising three layers and eight turns per layer in accordance with an embodiment of the disclosure.

[0038] FIGS. 6a and 6b schematically illustrate two methods of forming the disclosed coils in accordance with one or more embodiments of the disclosure.

DETAILED DESCRIPTION

[0039] FIGS. 3a, 3b, and 4 to 6 show coils with different cross-sectional profiles but the same reference numerals are used to denote the same features of the coils throughout.

[0040] A coil 50 for a switched reluctance machine (not shown) is formed from a continuous conductor 51. The conductor 51 can comprise a single strand of copper wire or can comprise a twisted rope as described above. The coil 50 comprises a first coil side 53 and a second coil side 54 joined by first and second coil ends 55, 56. The coil 50 is configured to be placed around, and be mounted on, a salient pole 52 of a stator 57 of a switched reluctance machine (not shown). Each salient pole 52 of the stator 57 comprises first and second pole sides 62 which are parallel to each other.

[0041] The coil 50 is of a multi-layered construction with each layer 61 comprising a plurality of turns. In the example in FIG. 5, the coil 50 comprises three full layers 61, each layer 61 comprising eight turns of the conductor 51. The coil 50 can be considered to have a rectangular cross-sectional profile comprising 3 layers of eight turns/layers, giving twenty-four turns in total. In this embodiment, each layer 61 is complete.

[0042] The first and second coil sides 53, 54 have respective longitudinal axes X, X extending the length of the coil sides 53, 54.

[0043] In some embodiments, the conductor 51 is first wound around a former (not shown) to form a coil with a number of layers 61, each layer 61 comprising a multiplicity of turns of the conductor 51. One of the coil sides 53, 54 is then rotated through 180, around its respective longitudinal axis X, X, with respect to the other coil side 54, 53. The rotation can be applied in either a clockwise or counter-clockwise direction. This forms the coil 50 which is illustrated schematically in two views in FIG. 3.

[0044] The rotation of the first or second coil side 53, 54 about its respective longitudinal axis X, X changes the position of any turn relative to the pole side from one coil side to another, for example from an inner aspect of the one coil side to an outer aspect of the other coil side. Reference to known coils illustrated in FIG. 2 shows that, for any coil, one coil side is a mirror of the other coil side about the centre line of the pole, so any turn in the coil takes up a mirror position in conventional coils. As will be apparent from the description below, there is no such mirror symmetry in the disclosed coils, such as that illustrated in FIG. 3, as will now be discussed with reference to FIGS. 4 and 5.

[0045] FIG. 4 is a schematic cross-section of the coil 50 and illustrates the way in which the conductor twists at the coil end 55. The curved arrow in FIG. 4 indicates how the first coil side 53 is rotated about its longitudinal axis X with respect to the second coil side 54. In FIG. 4, a turn of the conductor 51 is identified by the reference Y in the first coil side 53. The conductor 51 follows a path in which it twists around at the coil end 55 so that the turn of the conductor 51 that was positioned at Y in the first coil side 53 is located at position Y in the second coil side 54. It can be seen that a portion of the turn in the second coil side 54 (at Y) is adjacent the space inside the coil that accepts a salient pole, while a portion of the turn in the first coil side 53 (at Y) is adjacent an opposed, outer face of the coil.

[0046] FIG. 5 illustrates schematically a coil 50 mounted on a salient pole 52 of a stator 57 of an electrical machine, for example a switched reluctance machine. The salient pole 52 has a slot liner, which is not shown for the sake of clarity. The two coil sides 53, 54 are rotated 180 with respect to each other as discussed above. When the first coil side 53 is rotated around the longitudinal axis X with respect to the second coil side 54, and the coil is then placed around the salient pole 52 of the stator 57, an inner layer of the second coil side 54 oriented adjacent a second side of the salient pole is transposed to form an outer layer of the first coil side 53 which is displaced from the first side of the salient pole 52.

[0047] It will be understood that the transposition can vary depending upon which coil side 53, 54 is rotated and whether the rotation is clockwise or counter-clockwise. However, in any event an inner layer 61 of one coil side that is disposed adjacent one side 62 of the salient pole 52 is transposed to form an outer layer 61 of the other coil side, which is spaced away from the other side 62 of the salient pole 52. Thus, the position of a turn of the conductor 51 in an inner layer 61 of the first coil side 53 (indicated at A in FIG. 5) adjacent to the stator surface 58 translates to a position in an outer layer 61 of the second coil side, spaced away from the stator surface 58 (as indicated at point A in FIG. 5).

[0048] Similarly, the position of the turn of the conductor 51 in the second coil side 54 indicated at B in FIG. 5, adjacent the stator surface 58, translates in the first coil side 53 to a position distant the stator surface 58 at B in FIG. 5. All the turns have moved their position as they transition from one coil side to the othere.g. turn F is now in position F. As can be seen from FIG. 5, those portions of the conductor 51 that are located internally of the coil 50, such as those indicated at F and F do not change their position within the coil relative to the stator surface as significantly. In FIG. 5, the positions of the conductor 51 at F and F are the same displacement from the salient pole 52 but are disposed slightly nearer and further away from the surface of the back-iron 63.

[0049] The change of position of each turn takes place in the respective coil ends 55, 56 and there is no change in position of any turn within in the respective coil side 53, 54. Thus any turn in one of the first or second coil sides 53, 54 remains in substantially the same position within each coil side with respect to the stator surface 58 whilst running along the respective side 62 of the salient pole.

[0050] The rotation of one coil side 53, 54 with respect to the other has the effect of changing the position of the conductor 51 at different points within the coil 50. The conductor 51 follows a path which takes it through different positions within the coil cross section, changing the separation, or distance, of portions of the conductor 51 from the stator surface 58 along the length of the conductor 51. Specifically, turns of the conductor may have a portion (for example at A or B) adjacent the stator surface 58 and a portion spaced away from the stator surface 58 (for example at A or B). Thus, heat from a spaced away portion of the conductor can be dissipated into the stator through an adjacent portion close to the stator surface 58, for example an adjacent portion of the same turn. As a result, heat may be conducted to the stator 57 more easily.

[0051] In other words, as the conductor 51 is continuous, the section of the conductor 51 at A is thermally coupled to the section of the conductor 51 at A. The section at A is oriented so that it is adjacent to or in close proximity to the inner stator surface and therefore more easily able to conduct heat to the stator 57 than the section at A. Thus heat from the section at A can dissipate via the section of the conductor 51 at A to the stator 57. The rotation of the conductor 51 in the first coil side 53 relative to the second coil side 54 (around axis X) provides a thermal conduction path with reduced thermal impedance, which enables more efficient transfer of heat into the stator 57 from the coil. In some embodiments, when the coil is placed around the respective salient pole 52, the average distance of every turn from the inner stator surface 58 is constant. As a result, the average thermal dissipation path is substantially the same for each turn of the conductor 51 and the temperature differential described for the prior art is virtually eliminated.

[0052] The relative rotation of 180 between the first and second coil sides 53, 54 can be achieved in a number of different ways. As described above, the coil can be wound in layers on a coil former which essentially has the same dimensions as the pole 52, one coil side is rotated 180 relative to the other to form the coil, and the coil then placed on the pole, with the pole effectively replacing the coil former. In these embodiments, the layers of the arrangement of turns in the final coil correspond to sequential (i.e. adjacent in an axial direction) turns of the coil on the former.

[0053] Other methods are schematically illustrated in FIGS. 6a and 6b, as will now be described.

[0054] In both examples, the coil 50 is wound on the former 64 at 90 to the required coil profile for the pole 52. In other words, the layers of the final coil are now formed by corresponding turns in the layers on the former, for example turns in the same axial position on the former. So, for example, using the 83 profile of the coil illustrated in FIGS. 4 and 5, rather than winding the coil on the former 64 in that 83 profile, the coil 50 can be wound on the former with a 38 profile. FIGS. 6a and 6b show the coil 50 being wound with that alternative profile. One or both coil sides are manipulated so that corresponding turns in adjacent layers on the former become adjacent along an axial direction in the final coil. Thus, in these embodiments, the layers of the arrangement of turns in the final coil correspond to corresponding turns in the layers on the former. In FIGS. 6a and 6b, positions of some turns in the coil 50 are indicated by references C, C; D, D; and E, E. Thus, C and C are the same turn, D and D the same turn and so on.

[0055] In FIG. 6a, the coil 50 can be formed by translating one side, for example through an L-shaped 90 movement, as indicated by the arrow to bring the coil sides into a facing alignment again. For example, the coil 50 is manipulated with a lateral movement, in which the coil sides 53, 54 are laterally displaced from each other, and then the coil side is moved in a direction orthogonal to the direction of the lateral displacement to bring the coils sides 53, 54 into a position facing each other. The coil 50 can then be mounted on a salient pole 52 (indicated by dashed lines in FIG. 6a).

[0056] In another embodiment, illustrated schematically in FIG. 6b, the coil 50 is manipulated by rotating both coil sides 53, 54 through 90 in the same angular direction around their respective longitudinal axes X, X, to achieve the same 180 relative orientation. This manipulation is done when the coil 50 is taken off the former 64. As the rotation is done, there may also be some lateral manipulation so that the coil sides 53, 54 are opposing each other for fitting around the salient pole 52.

[0057] In both these coil manipulations shown in FIG. 6, a coil is produced with a 180 relative rotational orientation between the first and second coil sides 53, 54, as described above.

[0058] The present disclosure includes the following embodiments:

[0059] A coil for an electrical machine having a stator with salient poles, the salient poles having first and second pole sides, the coil being wound from a continuous conductor and comprising one or more layers, each layer comprising a multiplicity of turns of the conductor, the coil having a first coil side, a second coil side, and first and second coil ends connecting the first and second coil sides, the first coil side having a longitudinal axis, wherein the first coil side is rotated around the longitudinal axis with respect to the second coil side such that, when placed around a salient pole of the stator, an inner layer of one of the first and second coil sides disposed adjacent the salient pole is transposed to form an outer layer of the other of the first and second coil sides, disposed on an outer aspect of the other of the first and second coil sides, away from the salient pole. In one example, the first coil side is rotated through an angle of between 160 and 200. In another example, the longitudinal axis extends centrally through the first coil side. In yet another example, the continuous conductor is a twisted bundle or rope of wires.

[0060] A method of making a coil wound from a conductor, wherein the method includes the steps of: winding the conductor on a former to faint a coil comprising one or more layers, each layer comprising a multiplicity of turns of the conductor, the coil having a first coil side, a second coil side, and first and second coil ends connecting the first and second coil sides, with a predetermined cross-sectional profile, and the first coil side having a longitudinal axis; removing the coil from the former and rotating the first coil side around the longitudinal axis such that, when placed around a salient pole of the stator an inner layer of one of the first and second coil sides disposed adjacent the salient pole is transposed to faith an outer layer of the other of the first and second coil side, disposed on an outer aspect of the other of the first and second coil side, away from the salient pole. In one example, the first coil side is rotated through an angle of between 160 and 200. In another example, the longitudinal axis extends centrally through the first coil side.

[0061] A method according to item 5, wherein the second coil side has a longitudinal axis and wherein the coil is wound on the former with a cross-sectional profile that is at an orientation of 90 to the predetermined cross-sectional profile, and the step of rotating the first coil side around the longitudinal axis is achieved by rotating the first and the second coil sides along their respective longitudinal axes such that, when placed around a salient pole of the stator an inner layer of one of the first and second coil sides oriented adjacent the second side of the salient pole, is transposed to form an outer layer of the other of the first and second coil side, disposed on an outer aspect of the other of the first and second coil sides, away from the salient pole. In one example, the rotation of each of the first and second coil sides around their respective longitudinal axes is at an angle of between 80 and 100.

[0062] A method of making the coil wound from the conductor, wherein the coil is wound on the former with a cross-sectional profile that is at an orientation of 90 to the predetermined cross-sectional profile, and instead of rotating the first coil side around the longitudinal axis, manipulating the coil with an initial lateral movement in which the coil sides are laterally displaced from each other, and then moving at least one of the first and second the coil sides in a direction orthogonal to the direction of the lateral displacement to bring the coils into a position such that, when placed around a salient pole of the stator an inner layer of one of the first and second coil sides oriented adjacent the salient pole, is transposed to form an outer layer of the other of the first and second coil side, disposed on an outer aspect of the other of the first and second coil sides, away from the salient pole.

[0063] The skilled person will appreciate that variation of the disclosed arrangements are possible without departing from the invention, particularly in the details of the shape of the coil and the bending tool. For example, FIGS. 3a and 3b and FIG. 4 schematically illustrate a six-layer coil 50 with eight turns per layer. This profile is illustrative only and a skilled person would understand that other profiles and number of turns can be formed depending upon requirements. Accordingly, the above description of several embodiments is made by way of example and not for the purposes of limitation. It will be clear to the skilled person that minor modifications can be made to the coil design and method of production described above. The present invention is intended to be limited only by the scope of the following claims.