Axial-flux electric machine with winding rotor and method for the production thereof
09912203 ยท 2018-03-06
Assignee
Inventors
Cpc classification
H02K1/24
ELECTRICITY
Y10T29/49014
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
H02K1/28
ELECTRICITY
H02K15/12
ELECTRICITY
H02K1/24
ELECTRICITY
Abstract
An axial-flux electric machine with a winding rotor comprises a stator section and a rotor section, both developing around and axis. The rotor section comprises a rotor, which, in turn, comprises a toroidal rotor core made of a ferromagnetic material and a plurality of windings and of teeth, which are angularly distributed on the rotor core in an alternated configuration. The teeth have, on at least one lateral surface of theirs, a shaped profile defining at least one holding surface, which is such as to cooperate with a resin matrix, which is suited to steadily lock the teeth on the rotor core.
Claims
1. An axial-flux electric machine (M) with a winding rotor comprising a stator section (PS) and a rotor section (PR), which both develop around a rotation axis (X) of the electric machine (M), the rotor section (PR) comprising a rotor (1), which, in turn, comprises: a rotor core (2) with a toroidal shape, which develops around the axis (X) and has at least one receiving surface (5) with an annular shape; a plurality of teeth (4), which are arranged in contact with said receiving surface (5) and extend away from the receiving surface (5) along said axis (X), each one of said teeth (4) having a first tangential surface (4c) facing the axis (X) and a second tangential surface (4d) opposite to said first tangential surface (4c); a plurality of windings (3), which are angularly distributed around said axis (X) and cooperate with said rotor core (2) and said teeth (4) so as to concatenate a magnetic flux flowing through the rotor core (2) and the teeth (4), characterised in that at least one of said teeth (4) has, on at least one of said tangential surfaces (4c, 4d), a shaped profile defining at least one holding surface (12), which faces away from the toroidal rotor core (2), and in that said rotor (1) has a resin matrix that binds together said toroidal rotor core (2) and said teeth (4), wherein the resin matrix engages together said holding surface (12) and said toroidal rotor core (2) to lock the tooth (4) on the toroidal rotor core (2).
2. A machine (M) according to claim 1, characterised in that, in said rotor (1), said holding surface (12) is defined by a step (13) of said shaped profile (13) and is substantially parallel to said receiving surface (5) of the toroidal rotor core (2).
3. A machine (M) according to claim 1, wherein said holding surface (12) is defined at least on said first tangential surface (4c) of at least one tooth (4).
4. A machine (M) according to claim 1, wherein said at least one holding surface (12) is defined by each one of said teeth (4).
5. A machine (M) according to claim 1, wherein said holding surface (12) is defined at least on said second tangential surface (4d) of said at least one tooth (4), and wherein the rotor (1) comprises an outer casing (11), which shaped so as to embrace said second tangential surfaces (4d) of the teeth (4) and has at least one locking portion, which can be engaged with said holding surface (12) so as to keep the tooth (4) pressed against said toroidal rotor core (2).
6. A machine (M) according to claim 5, wherein said at least one holding surface (12) is defined by each one of said teeth (4), and wherein the locking portion of the casing (11) extends in a circumferential manner along an entire angular length developing around the axis (X) and can be engaged with said holding surfaces (12) of the teeth (4) so as to keep the teeth (4) pressed against said toroidal rotor core (2).
7. A machine (M) according to claim 1, wherein said teeth (4) are angularly distributed around said axis (X) so as to define, between two successive teeth (4), a respective slot (14), and wherein each one of said windings (3) is at least partially housed inside one of said slots (14) and fitted onto the toroidal rotor core (2).
8. A machine (M) according to claim 1, wherein each one of said windings (3) is fitted onto a respective tooth (4).
9. A machine (M) according to claim 1, wherein each tooth (4) has, furthermore, a base wall (4a) resting on the receiving surface (5) of the toroidal rotor core (2) and a top wall (4b) opposite to said base wall (4a), wherein said top wall (4b) has an outer flat surface (10), which is parallel to said receiving surface (5) of the toroidal rotor core (2) and laterally abuts on the corresponding top walls (4b) of the adjacent teeth (4).
10. A machine (M) according to claim 1, wherein each tooth (4) has, furthermore, a base wall (4a) resting on the receiving surface (5) of the toroidal rotor core (2) and a top wall (4b) opposite to said base wall (4a), wherein said top wall (4b) as an outer flat surface (10), which is parallel to said receiving surface (5) of the toroidal rotor core (2) and is laterally spaced apart from the corresponding top walls (4b) of the adjacent teeth (4), so to as to define a respective gap, said rotor (1) comprising, furthermore, at least one fixing ring made of a ferromagnetic material, which is rigidly connected to the top walls (4b) of the teeth (4) so as to establish an electric and magnetic continuity among the teeth (4).
11. A machine (M) according to claim 1, wherein said toroidal rotor core (2) has a first and a second receiving surfaces (5) with an annular shape, which are opposite to one another and substantially perpendicular to said axis (X), and wherein said plurality of teeth (4) are divided into a first series of teeth (4) applied to said first receiving surface (5) and extending away from the first receiving surface (5) along said axis (X) and a second series of teeth (4) applied to said second receiving surface (5) and extending away from the second receiving surface (5) along said axis (X), at least one tooth (4) of each series having said holding surface (12).
12. A method to produce an axial-flux electric machine (M) comprising the following steps: manufacturing a stator section (PS); manufacturing a rotor section (PR); arranging the rotor section (PR) and the stator section (PS) in a predetermined relative position along a rotation axis (X) of the electric machine (M); the step of manufacturing the rotor section (PR) comprising the step of manufacturing a rotor (1), which, in turn, comprises the sub-steps of: providing a rotor core (2) made of a ferromagnetic material, which develops around a circular line and has at least one receiving surface (5) lying on said circular line; providing a plurality of teeth (4) made of a ferromagnetic material, each tooth (4) having a base wall (4a), which can be engaged with said receiving surface (5), a top wall (4b), which is opposite to the base wall (4a), and at least two tangential walls (4c, 4d), which are opposite to one another and are delimited by said base wall (4a) and top wall (4b), and wherein at least one of said teeth (4) has, on at least one of said tangential surfaces (4c, 4d), a shaped profile defining at least one holding surface (12) facing away from the base wall (4a); providing a plurality of windings (3); applying the teeth (4) to the rotor core (2) so that the base wall (4a) of each tooth (4) is arranged so as to simply rest on said receiving surface (5); applying the windings (3) to the rotor core (2) so that the windings (3) cooperate with the rotor core (2) and with the teeth (4) in order to concatenate with a magnetic flux flowing through the rotor core (2) and the teeth (4); after the teeth (4) have been applied to the rotor core (2), impregnating the rotor core (2) and the teeth (4) with a resin matrix, so that the resin sticks to the holding surface (12), thus locking the teeth (4) to the rotor core (2).
13. A method according to claim 12, wherein between the sub-step of applying the teeth (4) to the rotor core (2) and the sub-step of impregnating the rotor core (2) and the teeth (4) with a resin matrix there is interposed the sub-step of securing the teeth (4) to the rotor core (2) by inserting the rotor core (2) and the teeth (4) applied thereto into a die.
14. A method according to claim 12, wherein the sub-step of providing a rotor core (2) made of a ferromagnetic material is performed by providing two half-rings (2a, 2b) made of a ferromagnetic material, and wherein said sub-step of applying the windings (3) to the rotor core (2) is performed by fitting said windings (2) onto the respective half-ring (2a, 2b), said sub-step of applying the windings (3) to the rotor core (2) is performed before the step of applying the teeth (4) to the half-rings (2a, 2b); said method comprising, furthermore, the sub-step of joining said half-rings (2a, 2b) so as to obtain the entire toroidal rotor core (2).
15. A method according to claim 12, wherein the sub-step of providing a rotor core (2) is performed by providing a single rotor core (2) with a toroidal shape made of a ferromagnetic material, and wherein the sub-steps of applying the teeth (4) to the rotor core (2) and applying the windings (3) to the rotor core (2) are performed by fitting each winding (3) onto a respective tooth (4) and by subsequently applying the tooth (4) to the rotor core (2) by laying the base wall (4a) of the tooth (4) onto the receiving surface (5) of the rotor core (2).
16. A method according to claim 12, wherein the sub-step of applying the teeth (4) to the rotor core (2) is preceded by the sub-step of mutually connecting at least a sub-set of said teeth (4) by fixing the top wall (4b) of said teeth (4) to a fixing ring made of a ferromagnetic material.
17. A method according to claim 12, wherein the step of manufacturing the rotor (1) comprises the sub-step of coupling a casing (11) with an annular shape to the outside of the toroidal rotor core (2), the teeth (4) and the windings (3), said casing (11) having at least one locking portion, which can be engaged with said holding surface (12) of said at least one tooth (4) so as to keep the tooth (4) pressed against said toroidal rotor core (2).
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The invention is described in detail below with the help of the drawings, which show a merely explanatory and non-limiting embodiment thereof.
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DETAILED DESCRIPTION OF THE INVENTION
(10) With reference to
(11) For the purpose of the present invention, the term electric machine can indifferently define both an electric motor and an electric generator.
(12) The electric machine M comprises a stator section PS and a rotor section PR, both developing around a rotation axis X of the electric machine M.
(13) The stator section comprises at least one stator S, S, which is provided with a relative core NS, NS and with active elements AS, AS. The active elements AS, AS can be permanent magnets or electric windings, depending on the needs. The stator core NS, NS develops with an annular shape around the axis X. The rotor section PR comprises a rotor 1, which also develops with an annular shape around the axis X.
(14) With reference to
(15) The rotor 1 substantially consists of a toroidal rotor core 2 (more visible in
(16) On the rotor core 2 there are arranged the windings 3, which, more precisely, are fitted onto the rotor core 2. In other words, each winding 3 is obtained by creating a plurality of parallel turns in a metal conductor, so as to define a final structure with an annular shape. Furthermore, each winding 3 has an insulating support 7, around which the loops are arranged and which defines a central opening 6, which is substantially complementary to the cross section of the toroidal rotor core 2. In order to allow the windingswhich were previously preparedto be fitted, the toroidal rotor core 2 is divided into two preferably identical half-rings 2a, 2b, each developing on a circular line around a respective axis X1, X2 for a partial development of said line. The two half-rings 2a, 2b allow the toroidal rotor core 2 to be put back together after the windings 3 have been inserted. Each winding 3 has, furthermore, a pair of connection terminals 8, so that, when the rotor 1 is ready, the windings 3 can be connected in a desired manner to a terminal board (for example, to supply power to a load rotating with the rotor 1) or to a series of sliding contacts or brushes or the like, depending on the needs.
(17) The windings 3, therefore, are fitted onto the rotor core 2 so that the loops are linked with the circular development line of the rotor core 2, thus they are linked with the magnetic flux flowing through the core 2 (and through the teeth 4, as explained more in detail below). In other words, the windings 3 have loops that are arranged according to a substantially radial direction, namely substantially passing through the axis X of the toroidal rotor core 2. The windings 3 are placed on the rotor core 2 according to an equally spaced apart arrangement around the axis X and define, between one another, respective seats 9 for the insertion of the teeth 4. The teeth 4 are alternated with the windings 3 and are applied to the receiving surfaces 5 of the rotor core 2.
(18) More in detail, as shown in
(19) The teeth 4 are manufactured, for example, through sintering or they are obtained form laminate materials. In any case, the teeth 4 have ferromagnetic properties. The top wall 4b has an outer flat surface 10, which is parallel to the receiving surface 5 of the rotor core 2 and is suited to face the gap defined in cooperation with the stator S, S. The teeth 4 are arranged on the receiving surface 5 of the rotor core 2, so as to cause the base wall 4a to rest on it, and extend away from the receiving surface 5 along the axis X. In particular, the aforesaid plurality of teeth 4 is divided into a first and a second series of teeth, which are applied to a first receiving surface 5 and to the other receiving surface 5, respectively, and extend away from the respective receiving surface 5 along the axis X.
(20) Preferably, the rotor 1 comprises, furthermore, an outer casing 11 with an annular shape, which is shaped so as to embrace the outer periphery of the rotor core 2 and of the teeth 4, in particular the second tangential surfaces 4d of the teeth 4, so as to compact the overall structure of the rotor 1.
(21) Advantageously, at least one of the teeth 4, preferably a sub-set of the aforesaid plurality of teeth 4 and, more preferably, each one of the teeth 4, has, on at least one of the tangential surfaces 4c, 4d, a shaped profile defining at least one holding surface 12, which is substantially parallel to the receiving surface 5 of the toroidal rotor core 2 and faces away from the toroidal rotor core 2, when the teeth 4 is applied to the core 2. Preferably, the holding surface 12 is defined by a step, which is preferably right, namely consisting of two perpendicular surfaces, in particular a first surface parallel to the tangential surface 4c, 4d and a second surface parallel to the receiving surface 5. In an embodiment shown in
(22) Preferably, the holding surface 12 is defined both on the first and on the second tangential surface 4a, 4b, in accordance with
(23) Advantageously, at least one rotor core 2 and the teeth 4 and, preferably, even the casing 11 are impregnated by means of a resin matrix 15, which stabilizes the different components of the stator 1 in a stable position. The resin, by sticking to the holding surfaces 12, steadily locks the teeth 4 relative to the rotor core 2. This allows the teeth 4 to be initially applied to the rotor core 2 by simply laying the base wall 4a of the teeth 4 on the receiving surface 5, without using adhesive substances that might jeopardize the overall reluctance of the rotor magnetic circuit. Preferably, the resin is applied by means of injection or through casting into a mould.
(24) Preferably, the casing 11 has at least one locking portion (not shown), which can be engaged with the holding surfaces 12 obtained on the second tangential surface 4d of the teeth 4. Preferably, in this configuration, the locking portion extends in a circumferential manner along an entire angular length developing around the axis X and can be engaged with the holding surfaces 12 of the teeth 4 so as to keep the teeth 4 pressed against the receiving portion 5 of the toroidal rotor core 2. In case the holding surfaces 12 are available on the second tangential surface 4d of the teeth 4 and are defined by projections 13 (
(25) The resin usually is an epoxy resin with insulating features, preferably with mechanical and/or heat conductivity properties.
(26) As already mentioned above, the windings 3 are placed on the rotor core 2 according to an equally spaced apart arrangement around the axis X and define, between one another, respective seats 9 for the insertion of the teeth 4. As shown in
(27) As shown in
(28) Preferably, when the teeth 4 are applied to the rotor core 2, the top wall 4b laterally abuts on the corresponding top walls 4b of the adjacent teeth 4. In other words, the top walls 4b of the teeth 4 have lateral edges 4e that converge towards the axis X (thus giving to the outer flat surface a substantially trapezoidal shape) and are suited to come into contact with corresponding lateral edges 4e of the adjacent teeth 4.
(29) Preferably, after having applied the casing 11, the latter presses the teeth 4 towards the axis X, thus causing the mutual locking of the top walls 4b of the teeth 4. In this locked configuration, the slots 14 are closed (on the lower side by the rotor core 2, laterally and on the upper side by the teeth 4) and, therefore, they permit a dispersed flux that does not leave the rotor and, thus, does not interact with the stator to generate a mechanical power. This configuration turns out to be especially useful to carry out the defluxing of the electric machine.
(30) In a different embodiment (shown in
(31) In a different embodiment shown in
(32) Now, we will describe a method for the production of an axial-flux electric machine M according to the present invention.
(33) The method comprising the steps of: manufacturing a stator section PS; manufacturing a rotor section PR; arranging the rotor section PR and the stator section PS in a predetermined relative position along the rotation axis X of the electric machine M. The step of manufacturing the rotor section PR comprises the step of manufacturing a rotor 1, which, in turn, comprises the sub-steps of: providing the rotor core 2 made of a ferromagnetic material, which develops along a circular line In particular, along a segment thereof in case of half-rings 2a, 2b) and has at least one receiving surface 5 lying on the circular line; providing a plurality of teeth 4 having the configuration described above and, in particular, at least one holding surface 12; providing a plurality of windings 3; applying the teeth 4 to the rotor core 2 so that the base wall 4a of each tooth 4 is arranged so as to simply rest on the receiving surface 5, in particular without the use of glueing substances interposed in the interface between the rotor core 2 and the tooth 4; applying the windings 3 to the rotor core 2 so that the windings 3 cooperate with the rotor core 2 and with the teeth 4 in order to concatenate with a magnetic flux flowing through the rotor core 2 and the teeth 4; impregnating the rotor core 2 and the teeth 4 with a resin matrix, so that the resin, by sticking to the holding surfaces 12, locks each tooth 4 to the rotor core 2.
(34) Preferably, the step of manufacturing the rotor 1 comprises, furthermore, the sub-step of applying the outer casing 11 on the outside of the toroidal rotor core 1 and to the relative windings 3 and teeth 4. The application of the casing 11 allows the relative locking portion to act upon the holding surfaces 12 of the teeth 4, thus keeping the teeth 4 locked on the rotor core 2.
(35) Prior to the sub-step of impregnating with the binding resin matrix, there is provided the sub-step of securing the teeth 4 to the rotor core 2. During this securing step, the assembly made up of the rotor core, the teeth and the casing are inserted into a die (not shown). This die is configured so as to exert a pressure upon the two opposite faces of the rotor (namely, the die presses on the teeth). Furthermore, this die is suited to receive (for example, through injection) an impregnating resin.
(36) In case of application of windings 3 to be fitted onto the rotor core 2 (embodiment of
(37) In order to permit the application of the teeth 4, the windings 3 are arranged in a position that allows them to be equally spaced apart from one another, so as to leave, between one another, suitable portions of the receiving surface 5 uncovered.
(38) After the application of the windings 3 (and, preferably, before the application of the teeth 4), the two half-rings 2a, 2b are joined to one another, so as to obtain the entire toroidal shape of the rotor core 2.
(39) In the solution with the windings 3 fitted on the teeth 4 (
(40) It is possible that, in this step, some teeth are not provided with a winding. This characterises rotors provided with teeth with windings and teeth without windings, which are alternated with one another so as to define a peculiar magnetic circuit.
(41) In an embodiment that is compatible with both solutions described above (windings 3 fitted on the rotor core 2 or windings 3 fitted on the teeth 4), the step of applying the teeth 4 to the rotor core 2 is preceded by the step of mutually connecting at least a sub-set of said teeth 4 (for example, for each half-ring 2a, 2b, all teeth 4 or part of the teeth 4 associated with it) by fixing the top wall 4b of said teeth 4 to the fixing ring made of a ferromagnetic material. Alternatively, the application of the fixing ring to the teeth 4 can take place after the teeth 4 have been arranged on the rotor core 2.
(42) The present invention addresses a rotor 1 having two series of teeth 4 arranged on opposite axial sides. This solution can be used in axial machines M provided with a central rotor 1 and with two stators S, S, which are coaxial to the rotor 1 and are arranged on the two sides of the rotor 1 (see
(43) The invention fulfils the object set forth above for the following reasons.
(44) The architecture of the rotorwith teeth that simply rest on the core and with the resin matrix that locks the teeth to the coreallows manufacturers to ensure a high sturdiness and mechanical resistance (for example, against mechanical stresses caused to the teeth by the magnetic interactions with the stator), granting, at the same time, a reduced reluctance of the resulting magnetic circuit, which is not contaminated by the presence of adhesive substances between the rotor core and the teeth.
(45) The invention described may be subject to changes and adjusted in several ways without thereby departing from the inventive scope of protection that characterises it.
(46) Moreover, all the details of the invention may be replaced by technically equivalent elements.
(47) All the materials used as well as the sizes can be chosen based on the needs of the user.