DE102012222194A1 - Method for producing transverse flux machine, involves inserting primary sub-segments in conductor ring, and bonding mechanically primary sub-segments with one another to circular primary ring - Google Patents

Abstract

The method involves providing a conductor ring (8) for each phase of the transverse flux. A circular portion is provided at an outer periphery of the primary sub-segments (3) arranged in flux guide (1) with two radial flux guiding support (5). The primary sub-segments are inserted in the conductor ring such that the flux guiding support is projected beyond the end faces. The inserted primary sub-segments are bonded mechanically with one another to a circular primary ring (6). An independent claim is included for a transverse flux machine.

Description

The invention relates to a designed as a transverse flux machine dynamoelectric machine and a method for their preparation. The transverse flux machine can be designed both as a permanently excited or electrically excited machine and as a reluctance machine.

The transversal flux machine can be used, for example, in the field of electromobility as a traction machine. In addition, however, an application of the transverse flux machine in stationary applications in particular in the industrial environment is conceivable.

A transverse flux machine distinguishes itself in comparison to conventional radial flux machines in particular by the simplicity of their winding. On the other hand, in the case of the transversal flux machine, it is more complicated to produce the soft-magnetic bodies for the stator and the rotor.

From the EP0799519B1 is a transversal flux machine with conductor ring is known, which is surrounded by U-shaped, soft magnetic bodies from three sides, wherein a magnetic circuit of soft and / or hard magnetic parts is periodically closed, which is arranged by two radially outside of the conductor rings air gaps from the respective U- shaped, soft magnetic body are separated. A high efficiency and a high power density are achieved in this machine with low manufacturing costs, characterized in that the magnetically active parts of the rotor or stator are arranged partially axially within the ends of the U-shaped soft magnetic body. Furthermore, the document shows a wheel hub drive with a three-phase transverse flux machine of the type described above, whose torque is supported by permanent excitation. Also, this document is a five-phase transverse flux machine refer to, which is designed as a reluctance motor.

The invention has for its object to facilitate the production of transversal flux machines or to provide an easy to manufacture transversal flux machine. This object is achieved by a method for producing a transverse flux machine with the method steps according to claim 1. Furthermore, the object is achieved by a transverse flux machine with the features according to claim 9.

Advantageous embodiments of the invention can be found in the dependent claims.

According to the invention, a conductor ring is first provided for each phase of the transverse flux machine. The conductor ring is therefore a pre-wound phase coil, which can be made, for example, from an insulated enameled copper wire. However, an embodiment of the conductor ring as an aluminum coil can also be advantageous, since about 50% to 60% of the weight can be saved compared to copper coils with the same ohmic resistance by using aluminum as the conductor material.

According to the invention further part-circular primary part segments are arranged with arranged on an outer periphery of the primary sub-segments, advantageously U-shaped, flux guides provided, which have two radial flow-conducting legs. As a primary part is here, as usual in electrical engineering, the element of the dynamoelectric machine called, which carries the field-exciting coils. Thus, the primary part can be both the stator and the rotor. In order to dispense with a contact by means of slip rings, the design of the primary part advantageously offers itself as a stator. In such an embodiment, therefore, the secondary part would be designed as a rotor.

The primary part segments are circular arc-shaped. If several primary subsegments are lined up, they approximately form a full circle. The number of primary subsegments is preferably selected according to production-optimizing aspects. For example, a primary segment can cover an angle of 115 degrees. When juxtaposing three primary subsegments a not completely closed circle is thus formed. The juxtaposition of the primary sub-segments would result in this example 345 degrees. The remaining 15 degrees to the filling of the primary part segments to a full circle can be advantageously formed by a closure element, which is needed to connect the two open ends of the three juxtaposed primary part segments together.

However, before these primary part segments are connected to one another, according to the invention they are first inserted into the conductor ring in such a way that the legs abut one of the two axial end sides of the guide ring, the legs projecting outward in the radial direction over the end faces.

In an advantageous embodiment of the invention in this case the flux guides are U-shaped designed with a axialflussleitenden base element, adjacent to each one of the legs. The part-circular primary part segments are inserted in this embodiment in the conductor ring, that the base elements lie radially inward on the conductor ring.

Accordingly, after this method step, the conductor ring is located inside the U. The radial flow-conducting legs of this U protrude beyond the overall cross section of the conductor ring inside the U formed by the flux. The protruding over the conductor ring piece of each leg is used to deflect the flow through the legs primarily radially flowing in an axial direction. The axial flow thus closes between the two legs over an air gap, which lies radially outside of the conductor ring. Within this air gap, the torque is formed to drive the dynamoelectric machine.

After inserting the part-circular primary part segments in accordance with the invention a fully circular primary part ring is formed by the fact that the inserted primary part segments are mechanically connected to each other.

In an advantageous embodiment of the invention, the flux guides are attached form-fitting and / or non-positively before inserting the primary part segments on a part-circular support ring of the primary part segments. For example, the base elements have on their side facing the carrier ring a dovetail-shaped profile which engages in corresponding grooves of the carrier material and thus produces a frictional connection. Accordingly, this embodiment describes a kind of modular system for the production of the primary part, in which application-dependent standardized flux guide can be applied to the carrier ring in any number.

A good magnetic conductance effect in an advantageous embodiment of the invention made of a soft magnetic material flux guides. To reduce eddy current losses, it is also advantageous to use stacked electrical steel sheets for the production of flux guides. In contrast, more complex geometries, in particular for the flux guides, are easier to produce by sintering in an advantageous development of the invention.

To build a transverse flux machine, at least one conductor ring per phase is required. Accordingly, at least m primary sub-rings are required to form an m-phase transverse flux machine. Furthermore, this number is to be multiplied by the number of pole pairs so that necessary primary sub-rings result for an m-phase machine with the pole pair number p p.

To form a primary part of such a transverse flux machine, therefore, a plurality of primary part rings advantageously have to be axially stacked on one another. Thus, a kind of modular system results in which different phase and pole pair numbers can be made possible by using the primary sub-rings described above. Furthermore, it is also possible to meet higher power requirements by stacking several primary sub-rings of the same phase and the same pole pair.

The formation of the stack structure for the primary part can now be done in various ways.

In a first embodiment, first a plurality of part-circular primary part segments are assembled axially before they are inserted into a corresponding number of conductor rings. In this case, therefore, the individual primary subsegments are first stacked on one another, wherein the number is expediently oriented to the phase and pole pair number of the machine as well as the power requirement. These stacks of primary segment segments are then inserted into the conductor rings and finally circumferentially connected to other stacks of primary segment segments, resulting in a full circular ring of stacked full circle primary section rings.

Also possible is an embodiment of the invention in which a plurality of fully circular primary part rings are joined together axially to form a primary part corresponding to the phase and pole pair number of the transverse flux machine. In this case, therefore, the fully circular primary segment segments are first produced individually and then stacked one after the other. Of course, a combination of the two last-mentioned embodiments of the invention is conceivable in which first, for example, the number of phases according to primary sub-segments are stacked and then connected to a full circle. Such packages can be created, for example, for each pair of poles first in this way and then assembled axially.

• – Bereitstellen eines Sekundärteilbandes für ein Sekundärteil der Transversalflussmaschine,
• – Befestigen von Sekundärteilelementen auf einer Innenseite des Sekundärteilbandes,
• – Biegung des Sekundärteilbandes zu einem den Primärteilring umschließenden Sekundärteilring derart, dass die Sekundärteilelemente radial außerhalb des Leiterringes liegend zwischen den beiden radialflussleitenden Schenkeln eintauchen, sodass diese jeweils über einen Luftspalt in axialer Richtung betrachtet von den Schenkeln beabstandet sind, und
• – Verbinden der Enden des Sekundärteilbandes zu einem vollkreisförmigen Sekundärteilring.

In a further advantageous embodiment of the invention, the following further method steps for the formation of the transverse flux machine are provided:

• Providing a secondary part band for a secondary part of the transverse flux machine,
• Attaching secondary part elements on an inner side of the secondary part band,
• Bending the secondary part band to a secondary part ring enclosing the primary part ring such that the secondary part elements dive radially outwardly of the conductor ring between the two radially flow-guiding legs, so that they are spaced apart from the legs by an air gap in the axial direction, and
• - Connecting the ends of the secondary belt part to a fully circular secondary part ring.

Since the primary part ring is non-rotatably in communication with the conductor ring, the secondary part advantageously forms the rotor of the machine, since it carries no current-carrying coils.

For example, if the transversal flux machine is a permanent-magnet machine, the secondary part elements would have to be formed with permanent magnets. However, it is also an embodiment of the transverse flux machine according to the invention conceivable in which the secondary part elements are designed only as soft iron pieces. Such a type of machine is a transverse flux reluctance machine in which the torque generated by the machine is caused only by circumferentially changing magnetic conductances.

The proposed here production of the secondary part is based heavily on the known production of a needle roller cage, as for example in DE19881885C1 is described. For this purpose, the secondary band is first cut off, for example, from an endless belt to the appropriate length. The individual secondary part elements, which may be made, for example, of electric sheets, ferrites or plastic-sheathed rare earth magnets, are then positioned on the secondary part belt in high numbers and with high accuracy. Thereafter, the secondary part is bent around the primary part. It is conceivable that only during the bending process, a sufficient positive connection between the secondary part elements and the secondary section band is created, similar to the case of the already mentioned Nadelellagerkäfigfertigung the case. The secondary part elements are arranged radially above the conductor ring following this manufacturing step. Upon rotation of the rotor, the secondary part elements move in the gap formed by the legs of the U-shaped flux guide.

In the production of the transverse flux machine is provided in an advantageous embodiment of the invention that the primary part rings are connected to the secondary part rings to motor rings and these are then joined together according to the phase and Polpaarzahl the transverse flux machine. In this case, therefore, a complete motor ring is first produced for each phase. According to a modular principle now various embodiments of a transverse flux machine can be formed by selecting any number of motor rings.

In the following the invention will be described in more detail with reference to the embodiments shown in the figures.

Show it:

1 a flux guide in frictional connection with a carrier ring,

2 a fully circular primary section ring,

3 several axially stacked primary sub-rings,

4 a sectional view of a transverse flux machine according to an embodiment of the invention,

5 a schematic representation of a secondary section band,

6 the secondary section band after 5 after being equipped with secondary part elements,

7 a section through a pocket of equipped with a secondary part element secondary belt and

8th this in 7 shown band after a bending process.

Based on 1 to 3 The production of a stator of a transversal flux reluctance machine will first be explained by way of example.

So shows 1 first a flux conductor 1 in frictional connection with a carrier ring 2 a primary segment 3 , The part-circular carrier ring 2 is hereinafter along its lateral surface with further equidistantly spaced Flussleitstücken 1 stocked.

The flux guides 1 are constructed to minimize eddy current losses from stacked and mutually insulated electrical sheets. Each flux conductor 1 comprises a base element 4 and two adjacent legs 5 , base element 4 and thighs 5 together form a U-shape.

2 shows a fully circular primary section ring 6 , This comprises a plurality of circumferentially adjacent primary subsegments 3 , each of which, by itself, span an angle of 115 degrees. With three such primary subsegments, the overall result is an angle of 345 degrees after being connected together. To close such a ring is also a closure part 7 used, which spans the remaining 15 degrees, so that there is a 360 degree full circle.

Between the thighs 5 each flux guide 1 there is a conductor ring 8th , The conductor ring 8th lies with its radially inwardly directed side on the base element 4 of the flux conductor 1 at. The front ring is bordered by the conductor ring 8th each to one of the legs 5 each flux conductor 1 ,

The conductor ring 8th has initially been made separately by a corresponding annular coil, for example made of aluminum was wound. In this ladder ring 8th are then the primary subsegments 3 inserted successively from the inside, so that the arrangement shown results. After all three primary subsegments 3 in the conductor ring 8th are inserted, the closure part 7 inserted and closed the circle.

As can be seen, the length of the legs 5 chosen such that this is the conductor ring 8th protrude radially. Will the conductor ring 8th energized, a magnetic flux within the base element 4 each flux conductor 1 initially guided in the axial direction and then in the radial direction through the highly permeable legs 5 guided. The magnetic flux closes between the thighs 5 each flux conductor 1 in the above the conductor ring 8th projecting area.

The in 2 shown fully circular primary section ring 6 can operate only one phase of the transversal flux machine. To form a complete primary part is at least one primary part ring 6 necessary per phase.

To form a complete primary part therefore several primary sub-rings 6 stacked axially, as shown in the illustration 3 can be seen. In the figure are six primary sub-rings 6 stacked axially. The primary part rings 6 are by a spacer band 9 separated from each other. The spacer band 9 defines the angular position of the individual primary part rings to each other.

For the production of the spacer tape 9 First, an endless belt was cut to circumferential length of the primary part. At the distance to the distance band 9 adjacent Flussleitstücke 1 then pockets for receiving the thighs 5 the flux guides 1 stamped. After that, the distance band 9 bent into a closed ring. Due to the position of the stamped pockets, the angular positioning of the primary part rings 6 guaranteed among each other.

Here, the individual primary sub-rings 6 based on the angular position z. B. be built twisted by 60 degrees. This has the advantage that, for example, when used as a wheel hub drive, in particular an electrified two-wheeler cable passage can be placed over spokes to the inside.

4 shows a sectional view of a transverse flux machine according to an embodiment of the invention. Here is a secondary part 10 , which serves as a rotor of the transversal flux machine, to the in 3 Stator shown been built around. The secondary part 10 can also be performed segmented so that the individual part-circular secondary part elements can be individually put around the stator before they are connected together at their abutting edges.

The illustrated abutment 10 is from a secondary band 11 built on the individual secondary part elements 12 are applied. These secondary part elements 12 serve as rotor teeth, which via an axially aligned air gap in each case to one of the legs 5 the flux guides 1 are spaced.

The production of the secondary part 10 can be analogous to the production of the primary part segments 3 respectively. That is, the individual secondary part elements 12 become positive and / or non-positive with the secondary section band 11 for the production of the secondary part 10 connected.

5 schematically shows a secondary section band 11 , with which a rotor ring for three phases of a transversal flux machine is built up. The secondary section band 11 was cut from an endless belt to the circumferential length of the transverse flux machine. Subsequently, rectangular recesses were hereafter called pockets 13 referred to, in the secondary section band 11 punched. For each of the phases is a series of pockets 13 intended. In these bags 13 will now be secondary part elements 12 positioned. This manufacturing step works analogously to the placement of a needle roller cage with the corresponding rolling elements.

Of course, that can be done in 5 shown secondary section band 11 also be formed single-breasted, so it only has a number of pockets 13 for receiving the secondary part elements 12 contains exactly one phase.

In 6 is the secondary section band 11 to 5 after being fitted with the secondary part elements 12 to recognize. Only after the assembly is the secondary section belt 11 bent into a ring shape around the primary part. During this bending process, the secondary part elements dip 12 , which represent the rotor teeth of the transverse flux machine, in the defined by the legs of the U-shaped flux guides and extending in the circumferential direction a space, so that they energize the conductor ring with the legs 5 the flux guides 1 in electromagnetic interaction can occur.

7 shows a section through a bag 13 one with a secondary part element 12 fitted secondary section belt 11 , The bags 13 have webs 14 for receiving the secondary part element 12 on, in the noses 15 are impressed. Furthermore, the webs run 14 in the initially flat secondary band, not quite parallel to each other, but tension a slight trapezoidal shape. It is created on one side of the secondary section belt 11 a larger opening than on the other side. On the side with the larger opening becomes the secondary part element 12 inserted, which on two sides in each case one to the noses 15 corresponding groove 16 having. Through this groove 16 becomes that of the secondary part element 12 formed rotor tooth 6 first of all already form-fitting within the secondary section belt 11 supported.

8th shows that in 7 shown secondary section band 11 after a bending process. By the bending process now nestle the webs 14 of the secondary section belt 11 completely on the two sides of the rotor tooth. The noses 15 fully engage in the grooves 16 one. The result is a play-free positive and non-positive connection between the secondary section band 11 and the secondary part element 12 ,

By in the 5 to 8th described manufacturing method, the rotor of a transverse flux machine with the least manufacturing effort in analogy to a Nadellagerkäftigfertigung be prepared.

LIST OF REFERENCE NUMBERS

1

flux conductor

2

part-circular carrier ring

3

Primary part segment

4

base element

5

leg

6

Primary partial ring

7

closing part

8th

Head ring

9

strip gap

10

secondary part

11

Secondary subband

12

Abutment element

13

Bags

14

web

15

nose

16

groove

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• EP 0799519 B1 [0004]
• DE 19881885 C1 [0024]

Claims (12)

Method for producing a transverse flux machine with the following method steps: - providing at least one conductor ring ( 8th ) for each phase of the transversal flux machine, - providing partial circular primary sub-segments ( 3 ) with at an outer periphery of the primary part segments ( 3 ) arranged flux guides ( 1 ), each having two radial flow-conducting legs ( 5 ), - inserting the partially circular primary segment segments ( 3 ) from the inside of the ladder ring ( 8th ) in the conductor ring ( 8th ) such that the legs ( 5 ) in each case on one of the two axial end sides of the guide ring ( 8th ), wherein the legs ( 5 ) protrude outward in the radial direction over the end faces, and - mechanical connection of the inserted primary part segments ( 3 ) with each other to a fully circular primary part ring ( 6 ). Method according to claim 1, wherein the flux conducting pieces ( 1 ) U-shaped with an axial flow-conducting base element ( 4 ), to each one of the legs ( 5 ) and the part-circular primary sub-segments ( 3 ) in the conductor ring ( 8th ), that the basic elements ( 4 ) radially inward on the conductor ring ( 8th ) issue. Method according to claim 1 or 2, wherein the flux conducting pieces ( 1 ) before the insertion of the primary sub-segments ( 3 ) on a part-circular support ring ( 2 ) of the primary sub-segments ( 3 ) are fastened in particular positive and / or non-positive. Method according to one of the preceding claims, wherein the flux guide pieces ( 1 ) are made of a soft magnetic material, in particular of stacked electric sheets or a sintered material. Method according to one of the preceding claims, wherein a plurality of part-circular primary sub-segments ( 3 ) are joined together axially before they are placed in a corresponding number of conductor rings ( 8th ) are inserted. Method according to one of the preceding claims, wherein a plurality of all-circular primary part rings ( 6 ) are joined together axially to a primary part according to the phase and pole pair number of the transverse flux machine. Method according to one of the preceding claims with the following further method steps: - providing a secondary section strip ( 11 ) for a secondary part ( 10 ) of the transversal flux machine, - fixing of secondary part elements ( 12 ) on an inner side of the secondary part belt ( 11 ), - bending of the secondary band ( 11 ) to a primary part ring ( 6 ) enclosing secondary part ring such that the secondary part elements ( 12 ) radially outside of the conductor ring ( 8th ) lying in the of the radial flow-conducting legs ( 5 ) immerse the air gap defined in the circumferential direction, and - connecting the ends of the secondary part belt ( 11 ) to a fully circular secondary part ring. Method according to claim 7, wherein the primary part rings ( 6 ) are connected to the secondary part rings to motor rings and these are then joined together according to the phase and Polpaarzahl the transverse flux machine. Transverse flux machine with - with a fully circular primary part ring, which consists of several peripherally interconnected, part-circular primary sub-segments ( 3 ), - a conductor ring ( 8th ) and - on an outer periphery of the primary part segments ( 6 ) arranged flux guides ( 1 ) each having two radial flow-conducting legs ( 5 ), each of which on one of the two axial end faces of the guide ring ( 8th ) abuts and protrudes in the radial direction outwards beyond the end faces. Transverse flux machine according to claim 9, wherein the flux conducting pieces ( 1 ) U-shaped with an axial flow-conducting base element ( 4 ), to each one of the legs ( 5 ), wherein the base element ( 4 ) radially inward on the conductor ring ( 8th ) is present. Transversal flux machine according to Claim 9 or 10, having a secondary part ring which forms the primary part ring ( 6 ) enclosing secondary part band ( 11 ), wherein on the inside of the secondary part belt ( 11 ) Secondary part elements ( 12 ) are arranged radially outside the conductor ring ( 8th ) and in which of the radial flow-conducting legs ( 5 ) are arranged in the circumferential direction defined air gap. Transverse flux machine according to claim 11, having a number of axially stacked motor rings corresponding to the number of phase and pole pairs of the transverse flux machine, each having a primary part ring ( 6 ) and an associated primary sub-ring ( 6 ) have enclosing secondary part ring.

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