Method and Apparatus for Production of a Multiphase Electromagnetic Mat for Forming Current Carrying Components of a Power Conversion System

Abstract

A method and apparatus for production of a multiphase electromagnetic mat for forming current carrying components of a power conversion system, wherein the electromagnetic mat comprises structural fibre lengths divided into at least two groups and winding fibre lengths divided into several groups corresponding to the number of phases and the number of parallel conductors of one phase, wherein the winding fibre lengths are retained in position by the groups of structural fibre lengths.

Claims

1-18. (canceled)

19. A method for production of a multiphase electromagnetic mat (10) for forming current carrying components of a power conversion system, the electromagnetic mat (10) having structural fibre lengths (20) and a plurality of winding fibre lengths (71A, 71B), wherein the winding fibre lengths (71A, 71B) form a winding fibre (70) that is in a winding pattern for forming one or more windings of the power conversion system, and the winding fibre lengths (71A, 71B) are divided into several groups, comprising the steps of: dividing the structural fibre lengths (20) into at least a first group (21) and a second group (22); dividing the winding fibre lengths (71A, 71B) into several groups corresponding to a number of phases and the number of parallel branches of each phase, winding the winding fibre lengths (71A, 71B) on a number of storages (81A) accommodated in at least two movable magazines (31, 32), at least one movable magazine (31, 32) being located at opposite sides of the electromagnetic mat (10) being produced along a plane defined by the electromagnetic mat (10), the step of winding comprising at least the following steps: (i) moving the first group (21) of structural fibre lengths (20) in a first direction substantially perpendicular to the plane defined by the electromagnetic mat (10) being produced, and moving the second group (22) of structural fibre lengths (20) in a second direction opposite from the first direction, to have the structural fibre lengths (20) of the two groups (21, 22) at a predetermined angle to the plane defined by the electromagnetic mat (10) being produced, (ii) inserting a selected number of winding fibre lengths (71A, 71B) into an opening formed between the structural fibre lengths (20) of the first (21) group and second group (22) so that the winding fibre lengths (71A, 71B) extend across the structural fibre lengths (20), and (iii) retaining the winding fibre lengths (71A, 71B) in position by moving the first group (21) and second group (22) of the structural fibre lengths (20) so that the groups (21, 22) swap positions at least once, or by using at least one other group of the structural fibre lengths (20) in a similar manner, thereby forming various patterns of structural fibres (20) and winding fibre (70) overlaps.

20. The method according to claim 19, wherein the step (iii) of retaining the winding fibre lengths (71A, 71B) in a position includes changing direction of the first group (21) and second group (22) of structural fibre lengths (20) at least two times in a rotational motion, thereby forming a twist (23) of the structural fibre lengths (20).

21. The method according to claim 19, further comprising, during the step (ii) of inserting the selected number of winding fibre lengths (71A, 71B) into the opening formed between the structural fibre lengths (20) of the two groups (21, 22), transferring the at least one storage (81A) and its respective winding fibre lengths (71A, 71B) from the movable magazine (31, 32) on one side of electromagnetic mat (10) to another movable magazine (31, 32) on the other side of the electromagnetic mat (10).

22. The method according to claim 21, further comprising moving the movable magazines (31, 32) in a predefined motion in order to have the storages (81A) of the winding fibres (71A, 71B) which is going to be inserted next in a preferred position relative to the opening formed by the two groups (21, 22) of structural fibre lengths (20).

23. The method according to claim 20, further comprising moving the movable magazines (31, 32) in a predefined motion in order to have the storages (81A) of the winding fibres (71A, 71B) which is going to be inserted next in a preferred position relative to the opening formed by the two groups (21, 22) of structural fibre lengths (20).

24. The method according to claim 19, further comprising moving the movable magazines (31, 32) in a predefined motion in order to have the storages (81A) of the winding fibres (71A, 71B) which is going to be inserted next in a preferred position relative to the opening formed by the two groups (21, 22) of structural fibre lengths (20).

25. The method according to claim 19, further comprising pushing the inserted winding fibre lengths (71A, 71B) towards the beginning of the electromagnetic mat (10) after insertion, before retaining them in position.

26. The method according to claim 19, further comprising winding the electromagnetic mat (10) directly on a stator or rotor component of an electric machine.

27. The method according to claim 19, further comprising altering the winding design during production, thereby enabling production of a variety of electromagnetic mats (10) or a multiple of the same electromagnetic mat (10) in one continuous process.

28. The method according to claim 19, further comprising controlling and adjusting tension on the winding fibre lengths (71A, 71B) being inserted.

29. The method according to claim 19, further comprising producing parts of the electromagnetic mat (10) with auxiliary fibres.

30. An apparatus for production of a multiphase electromagnetic mat (10) for forming current carrying components of a power conversion system, the electromagnetic mat (10) comprising structural fibre lengths (20) and a plurality of winding fibre lengths (71A, 71B), wherein the winding fibre lengths (71A, 71B) form a winding fibre (70) that is in a winding pattern for forming one or more windings of the power conversion system, comprising: storages (81A) for storing several groups (21, 22) of the winding fibre lengths (71A, 71B) accommodated in at least two movable magazines (31, 32) by holders (51A, 51B), at least one movable magazine (31, 32) being located at each side of the electromagnetic mat (10) being produced along a plane defined by the electromagnetic mat (10); means (85) for moving the groups (21, 22) of the structural fibre lengths (20) in different directions in a reciprocal manner; and at least one transfer mechanism (40, 41, 42) for transferring the storages (81A) from a movable magazine (31, 32) on one side of the electromagnetic mat (10) to a movable magazine (31, 32) on the other side of the electromagnetic mat (10).

31. The apparatus according to claim 30, wherein the means (85) for moving the groups (21, 22) in different directions is configured for rotational movement of the structural fibre lengths (20).

32. The apparatus according to claim 30, further comprising means for controlling and adjusting tension of the inserted winding fibre lengths (71A, 71B) while inserting.

33. The apparatus according to claim 30, further comprising means for synchronization of at least the motion of the movable magazines (31, 32) and the means (85) for moving the at least two groups (21, 22) of structural fibre lengths (20).

34. The apparatus according to claim 30, further comprising means (90) for pushing the inserted winding fibre lengths (71A, 71B) towards the beginning of the electromagnetic mat (10).

35. The apparatus according to claim 30, wherein the holders (51A, 51B) for the storages (81A) in the movable magazines (31, 32) take the form of openings or recesses.

36. The apparatus according to claim 30, wherein the transfer mechanism (40) comprises one or more actuators (41, 42).

37. The apparatus according to claim 30, wherein the transfer mechanism (40) comprises means for fastening and releasing the storages (81A) to and from the movable magazines (31, 32).

38. The apparatus according to claim 30, wherein the movable magazines (31, 32) are removable and replaceable.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0061] Exemplary embodiments of the present invention will below be described with references to the attached drawings, where:

[0062] FIG. 1 is a principle drawing of a structure of an electromagnetic mat according to prior art,

[0063] FIG. 2 is a principle drawing of a machine for production of an electromagnetic mat according to prior art,

[0064] FIG. 3 is a principle drawing of key elements of an apparatus (winding machine) according to the disclosure, seen in 3D perspective,

[0065] FIGS. 4A-4E show the process of insertion of the winding fibre lengths according to the disclosure,

[0066] FIG. 5 is a principle drawing of the apparatus (winding machine), seen in a top view, and

[0067] FIGS. 6A-6E show individual winding fibres and groups of winding fibres retained in a position by structural fibres.

DETAILED DESCRIPTION

[0068] Reference is now made to FIG. 1, which is a principle drawing of a structure of an electromagnetic mat according to prior art JPH09271158A. The conductor 21 is a single-phase winding. The production method is not disclosed.

[0069] Reference is now made to FIG. 2 which is a principle drawing of the machine for production of an electromagnetic mat according to prior art WO2019074375A1. The circular element 90 surrounding the electromagnetic mat can only be used for twinning as the method of making the winding.

[0070] Reference is now made to FIG. 3 which is a principle drawing of key components of an apparatus for production of an electromagnetic mat 10.

[0071] The electromagnetic mat 10 comprises structural fibre lengths 20; and a plurality of winding fibre lengths 70 (FIG. 4), 71A, 71B, wherein the winding fibre lengths are for forming a winding pattern.

[0072] The structural fibre lengths 20 are divided into two groups, namely first 21 and second 22 group. The winding fibre lengths are divided into several groups 71A, 71B corresponding to the number of phases and the number of parallel conductors of one phase. In this example, the number of groups is six. The winding fibre lengths are wound on a number of storages 81A, attachable to at least two movable magazines 31, 32, located on both sides of the electromagnetic mat 10 to be produced, seen in the plane of the electromagnetic mat. Number of storages 81A in this example is the same as number of the groups of winding fibre lengths. The movable magazines 31, 32 have holders 51A, 51B for the storages 81A. In this example, the number of holders 51A, 51B on each magazine 31, 32 is equal to the number of the groups 71A, 71B of the winding fibre 70 lengths and is six. The movable magazines 31, 32 in this example have the form of disks or cylinders rotatable around axis 60 of rotation.

[0073] The apparatus further comprises a transfer mechanism 40 for transfer of storages 81A from one magazine 31, 32 to the other. According to a further embodiment, the transfer mechanism 40 comprises means for fastening and releasing of the storages 81A to and from the movable magazines 31, 32.

[0074] Reference is now made to FIGS. 4A-4D showing the process of retaining a winding fibre 70 in a position by structural fibres 21, 22.

[0075] FIG. 4A shows moving the first group of structural fibres 21 in one direction and the second group of structural fibres 22 in opposite direction, thus creating opening between the two groups.

[0076] FIG. 4B shows adding a new winding fibre to the electromagnetic mat 10 by insertion of a new winding fibre into the opening between the two groups of structural fibres 21, 22.

[0077] FIG. 4C shows the two groups of structural fibres 21, 22 swapping the direction of the motion.

[0078] FIG. 4D shows the two groups of structural fibres 21, 22 retaining the winding fibre 70 in a position.

[0079] The FIGS. 4A-4D describe only one variant of a complete process of retaining. The process can however be more complex. FIG. 4E shows the two groups of structural fibres 21, 22 retaining the winding fibre 70 in a position by changing direction of the groups two times in different directions in a reciprocal manner, for example, a rotational motion, and thus forming a twist 23 of the structural fibres. The rotational motion is, e.g., achieved by that means 85 for movement of the structural fibre lengths 20 is arranged for rotational motion.

[0080] Reference is now made to FIG. 5 providing some more details of the process and the apparatus. The winding process includes at least the following steps: [0081] using means 85 for moving the structural fibre lengths of the first group 21 in a first direction, substantially perpendicular to the plane of the electromagnetic mat 10 to be produced and moving the structural fibre lengths of the second group 22 in a second direction, the second direction being in opposite direction of the first direction, to have the structural fibre lengths of the two groups 21, 22 at a certain angle to the plane of the electromagnetic mat 10 to be produced, [0082] inserting the selected number of winding fibre lengths 70 into the opening formed by the structural fibre lengths of the first 21 and second 22 group so that the winding fibre lengths extend across the structural fibre lengths in transversal direction to the length of the electromagnetic mat 10, [0083] pushing the inserted winding fibre lengths towards the beginning of the electromagnetic mat 10, with the help of means 90 for pushing the winding fibre length, [0084] retaining the winding fibre lengths in position by moving the first group 21 of the structural fibre lengths in the second direction and moving the second group 22 of the structural fibre lengths in the first direction so that the groups swap positions.

[0085] The formed electromagnetic mat 10 is moving in the direction 95 away from the movable magazines 31, 32.

[0086] The means 90 for pushing the winding fibre length(s) can be turned to a certain angle in the transversal direction of the electromagnetic mat 10 to make a skew of the winding pattern.

[0087] While inserting the selected number of winding fibre lengths into the opening formed by the structural fibre lengths of the two groups 21, 22, the at least one storage 81A the winding fibre lengths belongs to is transferred from the magazine 31, 32 on one side of electromagnetic mat 10 to the magazine 31, 32 on the other side of the electromagnetic mat 10 with the help of transfer mechanism parts 41, 42, such as one or more actuators.

[0088] The winding process further comprises predefined motion of the magazines 31, 32 in order to have the storages 81A of the phase group (winding group) which is going to be inserted next in the position closest to the opening formed by the groups 21, 22 of structural fibre lengths, in the examples in FIGS. 4A-4E, shown as lifted and lowered positions. This can be achieved by rotation of the movable magazines 31, 32 around the axis 60 of rotation.

[0089] FIG. 5 is an example of how the components may look. For example, in some other possible embodiments the transfer mechanism does not have to be moving.

[0090] Reference is now made to FIGS. 6A-6D showing some examples of how the winding fibres can be combined and retained in a position by the structural fibres.

[0091] FIG. 6A shows configuration where each phase has two winding fibres A, B, C, respectively, in a row, each retained individually in position by the groups 21, 22 of structural fibres.

[0092] FIG. 6B shows configuration where each phase has two winding fibres A, B, C, respectively, in a row, retained in position together by the groups 21, 22 of structural fibres.

[0093] FIG. 6C shows configuration where three winding fibres A, B, C, respectively, of three different phases are retained in position together by the groups 21, 22 of structural fibres.

[0094] FIG. 6D shows six bunches/groups of three winding fibres A, B, C, respectively, each bunch belonging to the same phase.

[0095] FIG. 6E shows two bunches of seven winding fibres A, B, C, respectively, each bunch belonging to the same phase.

[0096] The above described embodiments can be combined and modified to form other embodiments which are within the scope of the claims.

[0097] The disclosed embodiments are also applicable for production of the electromagnetic mat and simultaneously rolling it on a cylindrical form. In some embodiments, the cylindrical form can comprise a ferromagnetic core of an electric machine. The cylindrical form can have the same axis of rotation as the magazines or a different axis of rotation.

[0098] In a further modification, the apparatus can be placed in any position and at any angle in relation to the earth surface.

[0099] In a further modification, the magazines containing the winding fibres on each side of the electromagnetic mat can come in any shapes.

[0100] In a further modification, the motion of the magazine can be translatory.

[0101] In a further modification, the storages and holders for storages can come in any shapes.

[0102] In a further modification, the transfer mechanism can come in any configuration.

[0103] In a further modification, there are means for controlling width of the produced electromagnetic mat.

[0104] In a further modification, the means for pushing the winding fibre length can be turned to a certain angle in the transversal direction.

[0105] In a further modification, multiple layers of sheets S1, S2, etc. may be produced at the same time (where the sheets are parallel to each other but shifted a distance) in the direction perpendicular to the plane of the first sheet S1.

[0106] In a further modification, when winding multiple layers of sheets, winding fibres from one sheet could be introduced in other sheets in a process where the sheets are then combined to create a multilayer sheet.

LIST OF DESIGNATIONS

[0107] 10—electromagnetic mat

[0108] 20—structural fibres

[0109] 21—first group of structural fibres

[0110] 22—second group of structural fibres

[0111] 23—twist

[0112] 31—first magazine

[0113] 32—second magazine

[0114] 40—transfer mechanism

[0115] 41—transfer mechanism part 1

[0116] 42—transfer mechanism part 2

[0117] 51A—holders for storage of group W1 on a first magazine

[0118] 51B—holders for storage of group W2 on a second magazine

[0119] 60—axis of rotation

[0120] 70—winding fibres

[0121] 71A—winding fibres of group W1

[0122] 71B—winding fibres of group W2

[0123] 81A—storages of group W1 on the first magazine

[0124] 85—means for moving the structural fibre length

[0125] 90—means for pushing the winding fibre length

[0126] 95—direction of moving of the mat