This patent is an extension of Patent WO 2012/128646 1A “Coil assembly for three phased transversal axial flux multi disk machines”, which includes machines with other phase numbers, winding patterns and manufacturing techniques.
WO 2012/1286461A describes how a 3 phased axial flux PM-motor can be made from coil elements where you get a completely flat coil by making cuts in the thread so the coil elements fit together in a jigsaw.
The most important new in this patent application contra WO 2012/128646 1A is general claims on other types of coils and optimal solutions for coil shape and production methods.
In this patent we keep the numbering from patent WO 2012/128646 1A but new details has numbering form 100-111. New figures have numbering from 20-28.
Slots with the same number contain wires from the same phase. This holds for all coil slot numbering.
Coil element 15 can be made by casting or a combination off milling or punching and water cutting or wire cutting. This allows the conductor 9 in the active area under the magnet to have varying thickness. Note how the thickness increases with distance from motor shaft centre line. This gives increased current density and increase heat generation closer to centre, but this heat is very effective distributed along the conductor so it is net heat generated in the conductor which counts.
Note how the Iron 35 is visible between the coil layers 103. Also note the gap 102. It is difficult to recognize this on a standard patent drawing, but it is possible to see right through the coil through this gap. There are only 4 gaps visible on this view but there are of course gaps everywhere which cooling fluid can go through.
It is possible to make slots in other types of coil elements to make other types of coils for axial flux machines. A small change is the two phase design show in
A more significant change would be coil of wave design. The advantage of wave windings is that you do not need the connectors you need in lap windings.
To get a two phased machine coil element 109B can be skipped from the coil 109. The slots which then are not filled can then also be skipped. If coil element 109A and 109C is used directly there will be open space in coil 109, but it is easy to imagine how the slots must be moved to make an optimal two phase coil.
The lap winding coils shown in
The idea of changing the slots in some of the coil elements 15 to make assembly easier is also applicable to lap winding. This gives more types of coil elements, but also easier assembly. An example of this is shown in
For coil element 16 is shaped so that all coil slots (1A-4A) and all the connector slots 101AA-101AC are all facing up on the figure. The connector 29A is along the table. For coil element 19 is shaped so that all coil slots (1B-BA) and all the connector slots 101BA-101BC are all facing down on the figure. The connector 29B is in the air. Coil elements 16 and 19 belong to phase 1.
For coil element 17 is coil slot 3B is facing down while the rest of the coil slots 1B,2B and 4B are facing up. Connector slot 101CA is facing down while connector slot 101CB and 101CC are facing up. The connector 29C is along the table. For coil element 20 is coil slot 3D is facing up while the rest of the coil slots 1D,2D and 4D are facing down. Connector slot 101DA is facing up while connector slot 101DB and 101DC are facing down. The connector 29C is in the air. Coil elements 17 and 20 belong to phase 2.
For coil element 18 is coil slot 3E and 4E is facing down while the rest of the coil slots 1E and 2E are facing up. Connector slot 101EA and 101EB is facing down while connector slot 101EC is facing up. The connector 29C is along the table. For coil element 21 is coil slot 3F and 4F is facing up while the rest of the coil slots 1F and 2F are facing down. Connector slot 101FA and 101FB is facing up while connector slot 101FC is facing down. The connector 29F is in the air. Coil elements 18 and 21 belong to phase 3.
That a slot is facing down means that it is not visible when seen as shown on
Note that coil element 16 and 19 are identical except for the connector.
Note that coil element 17 and 20 are identical except for the connector.
Note that coil element 18 and 21 are identical except for the connector.
This means that if the connector are manufactured separate 3 types of coil elements are enough. However this will give twice as many contacts. The assembled coil elements are shown in
For a two phased motor the same arrangement as shown in
There are more possible coil configurations for axial flux machines. These configurations can be made completely flat by making coil elements with slots which fit into a flat 3D jigsaw as described here and in patent WO 2012/128646 1A.
Number | Date | Country | Kind |
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20121455 | Dec 2012 | NO | national |
Filing Document | Filing Date | Country | Kind |
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PCT/IB2013/060752 | 9/9/2013 | WO | 00 |