Patent Application
20190156979
This application claims priority to European Application No. 17203204.7, having a filing date of Nov. 23, 2017 the entire contents of which are hereby incorporated by reference.
The following relates to the field of increasing the strength of a permanent magnet and increasing the performance of a permanent magnet machine. Particularly, the following relates to a permanent magnet for a permanent magnet machine, a permanent magnet machine, a method for manufacturing a permanent magnet for a permanent magnet machine, and a method for manufacturing a permanent magnet machine.
In today's permanent magnet machines in order to hold the permanent magnets in place in permanent magnet machines, i.e. permanent magnet wind power generators, a non-magnetic cover as well as a magnetic back plate are used to keep the magnet in place during operation and rotating, respectively of the permanent magnet machine.
A current permanent magnet module according to the known art in a sectional view in the axial direction is shown in
The permanent magnet element may be produced from powders using a sintering process. During the sintering process, there may occur shrinkage of the magnetic volume. Particularly, the density of a pressed permanent magnet element is around 4.5 g/cm3 before the sintering process and it transforms into a density of the sintered permanent magnet element after the sintering process of around 7.5 g/cm3. After the sintering process, the permanent magnet element may be machined and grinded as well as covered by a coating on all sides using different equipment and techniques.
The machining and grinding produces material waste which has to be disposed. Additionally, after the machining and grinding, the permanent magnet element may be coated using various coating types, in order to protect the permanent magnet element from corrosion.
Furthermore, the cover covering the finished permanent magnet element causes a larger electromagnetic airgap resulting in a decreased performance and efficiency as well as higher manufacturing costs since the cover is fixed to the back plate by welding. Hence, the permanent magnet module may have a complex manufacturability, a decreased strength and/or a decreased performance.
The manufacturing costs of a permanent magnet are crucial from the economic perspective of the permanent magnet machine. Further, the reliability of the permanent magnet is a key factor for the operational costs of the permanent magnet machine.
An aspect relates to a simple and reliable permanent magnet for a permanent magnet machine which is able to reduce manufacturing costs and to increase reliability as well as strength.
According to a first aspect of embodiments of the present invention, a permanent magnet for a permanent magnet machine is described. The permanent magnet comprises a base body and at least one first fixing protrusion for fixing the base body to a rotor of the permanent magnet machine. The first fixing protrusion extends from a first side of the base body. Furthermore, the base body and the at least one first fixing protrusion are formed integrally as one-piece.
The base body may be the main body of the permanent magnet. Additionally, the base body comprises a first side which delimits the base body on one side of the base body.
The fixing protrusion may be formed at the base body, i.e. the fixing protrusion may extend from the first side of the base body.
The fixing protrusion and the base body are formed monolithically as a one-piece element of a magnetic material.
The number of necessary first fixing protrusions may be adapted dependent on the requirements in the rotor, as for example dependent on the forces acting upon the permanent magnet during operation of the permanent magnet. Furthermore, the number of necessary first fixing protrusions may depend on geometrical constraints given by the rotor. Particularly, if the radial extension of the rotor is relatively small seen in the radial direction of the rotor and there is not much space in the radial direction of the rotor for fixing the permanent magnets, the number of first fixing protrusions may be high and each first fixing protrusion may have a small extension seen in the radial direction of the rotor. The radial direction may be defined as the direction running through the axis of the rotor and being perpendicular with the axis of rotation.
A third direction of the main body may be parallel to the rotational axis of the permanent magnet machine.
The at least one first fixing protrusion may have a first protrusion depth seen in the third direction. Additionally, the main body may have a main body depth seen in the third direction.
On the one hand, the first protrusion depth seen in the third direction may be equal to the main body depth. Then, the main body may particularly be coupled to the rotor over the entire main body depth.
On the other hand, the first protrusion depth seen in the third direction may be shorter (or even longer) than the main body depth seen in the third direction. However, the first protrusion depth may not extend over the main body depth seen in the third direction. Then, the fixing of the main body to the rotor via the at least one first fixing protrusion may be limited to a certain section of the extension of the main body seen in the third direction.
Furthermore, when more than at least one first fixing protrusion is provided at the first side, the more than at least one first fixing protrusion may be arranged one adjacent to another seen in the third direction. Hence, the main body may particularly be fixed to the rotor at different sections of the main body seen in the third direction. In other words, the more than at least one first fixing protrusion are formed as discontinued parts.
According to a further aspect of embodiments of the present invention, a permanent magnet machine is described. The permanent magnet machine comprises a rotor and an above-defined permanent magnet.
The rotor may be an inner rotor or an outer rotor. On the one hand, if the rotor is an inner rotor, the permanent magnet is fixed to an outer side of the rotor seen in a radial direction of the rotor. On the other hand, if the rotor is an outer rotor, the permanent magnet is fixed to the inner side of the rotor seen in the radial direction of the rotor.
The radial direction of the rotor may be parallel to the radial direction of the permanent magnet machine.
The permanent magnet is fixed to the rotor such that the first side of the permanent magnet is in contact with either the radially inner surface of the rotor or the radially outer surface of the rotor, dependent on whether the rotor is an outer rotor or an inner rotor.
According to a further aspect of embodiments of the present invention, a method for manufacturing a permanent magnet for a permanent magnet machine is described. The method comprises forming a base body having a first side, and forming at least one first fixing protrusion. Furthermore, the base body and the at least one first fixing protrusion are formed integrally as one-piece.
According to a further aspect of embodiments of the present invention, a method for manufacturing a permanent magnet machine is described. The method comprises providing an above-defined permanent magnet for a permanent magnet machine, providing a rotor, and inserting the permanent magnet into the rotor.
Particularly, the above-described permanent magnet may have an increased mechanical strength when a pressing tool having the same shape as the base body and the at least one fixing protrusion, is used to form the base body and the at least one fixing protrusion in a common process step. Omitting the cover and the step of welding the cover to the base plate may have the further advantage that the manufacturing costs are lower. Additionally removing the back plate may have the further advantage that the manufacturing costs may even be lower. Furthermore, the performance may be higher due to smaller electromagnetic airgaps as well as due to a geometrically larger base body and hence more magnetic material. Additionally, the fixation may be stronger because a magnetic attraction between the base body and the rotor steel may add to the geometrical holding force of the fixing protrusion and the rotor.
According to a further exemplary embodiment of the present invention, the permanent magnet further comprises at least one second fixing protrusion extending from the first side, wherein the second fixing protrusion is arranged adjacent to the at least one first fixing protrusion.
The at least one second fixing protrusion may be formed by the same method as the at least one first fixing protrusion. Particularly, the base body, the at least one first fixing protrusion, and the at least one second fixing protrusion are formed in one common process step, such as pressing in a mould, sintering, or rapid prototyping.
The at least one second fixing protrusion is arranged adjacent to the at least one first fixing protrusion according to embodiments of the present invention means that the first fixing protrusion and the second fixing protrusion are distanced to each other. However, the first fixing protrusion and the second fixing protrusion may both extend from the first side.
Particularly, the first fixing protrusion and the second fixing protrusion may be of different shape. Particularly, the first fixing protrusion and the second fixing protrusion may have mirror-inverted geometries. Thereby, a holding force of the permanent magnet to the rotor may be increased.
According to a further exemplary embodiment of the present invention, the at least one first fixing protrusion is formed in a cross-sectional view in the shape of a L, a T, a rectangle, a square or a rhomboid.
The cross-sectional view may be defined as the sectional representation in which the first side is shown as a respective boundary line. Additionally, in the cross-sectional view a plane is shown which is parallel to a plane which is held by two radial vectors of the permanent magnet machine extending rectangular to each other.
L-shaped and T-shaped fixing protrusions may provide an enhanced holding force in the radial direction because of the short leg extending in a radial direction of the rotor when the permanent magnet is mounted into the rotor.
The shape of a rectangle may advantageously provide enhanced holding forces because the contacting area between the fixing protrusion and a wall of a groove in the rotor may be increased and hence the friction force between the rotor and the fixing protrusion may be increased.
The shape of a square may particularly result in increased magnetic forces between the base body and the rotor, because the contact area between a base surface of the base body and a surface of the rotor being in contact with the base surface of the base body may be increased.
The shape of a rhomboid may particularly provide a compromise between the above-described advantages.
According to a further exemplary embodiment of the present invention, the base body further comprises a second side opposite the first side, a third side and a fourth side, each interconnecting the first side and the second side, and distanced to one another. The permanent magnet further comprises at least one third fixing protrusion extending from the third side and/or at least one fourth fixing protrusion extending from the fourth side.
The first side and the second side are spaced apart from each other at the same time the third side and the fourth side are spaced apart from each other and interconnect the first side and the second side. Hence, in the cross-sectional view defined above, the first side, the second side, the third side and the fourth side delimit the base body.
The at least one third fixing protrusion and the at least one fourth fixing protrusion may be formed by the same method as the at least one first fixing protrusion.
Providing at least one third fixing protrusion and at least one identic fourth fixing protrusion may result in symmetric holding forces transmitted at the at least one third fixing protrusion and the at least one fourth fixing protrusion.
When different forces act at a first position where the at least one third fixing protrusion is fixed to the rotor and at a second position where the at least one fourth fixing protrusion is fixed to the rotor, there may be provided solely either the at least one third fixing protrusion or the at least one fourth fixing protrusion dependent on whether the force acting on the first position or the force acting on the second position is higher. Additionally, it may be possible to provide the at least one third protrusion and the at least one fourth protrusion with different shapes to react on different forces at the first position and the second position.
According to a further exemplary embodiment of the present invention, the permanent magnet is uncovered, in particular uncoated.
The permanent magnet being uncovered, in particular uncoated means according to the present application that the base body and/or the at least one fixing protrusion may not be surface treated after the manufacturing by sintering. The covering and/or coating may be omitted because after sintering, the base body and the at least one fixing protrusion, respectively, may be covered by a layer of oxide that may protect the base body and the at least one fixing protrusion, respectively, from corrosion.
Particularly, not all of the surfaces of the base body and/or the fixing protrusion are uncovered, in particular uncoated. For example solely one, two, three, four or five side surfaces may be uncovered, in particular uncoated. However, it may be understood that all side surfaces may be provided uncovered, in particular uncoated.
According to an alternative exemplary embodiment of the present invention, the permanent magnet is unmachined and/or ungrinded.
The permanent magnet being unmachined and/or ungrinded means according to the present application that the base body, the at least one fixing protrusion or the base body together with the at least one fixing protrusion may be used as it comes out of the oven without any additional or extra post-processing.
The permanent magnet may be used uncovered, in particular uncoated, and unmachined and/or ungrinded because the permanent magnet is sintered. The permanent magnet may be of any size or geometry, e.g. cuboid or bread loaf shaped.
Using the permanent magnet uncovered, in particular uncoated, and unmachined and/or ungrinded may be also suitable for bigger permanent magnets because the shrinkage of a larger permanent magnet compared and in relation to its dimensions may be less significant.
Particularly, omitting the step of machining and/or grinding and/or covering, in particular coating, may result in a cost reduction of the permanent magnet. Therefore, it also results in a cost reduction of the permanent magnet machine.
Particularly, not all of the surfaces of the base body and/or the fixing protrusion are unmachined and/or ungrinded. For example solely one, two, three, four or five side surfaces may be unmachined and/or ungrinded. However, it may be understood that all side surfaces may be provided unmachined and/or ungrinded.
According to a further exemplary embodiment of the present invention, the rotor comprises at least one groove, wherein the at least one groove is formed such that a shape of the at least one groove corresponds to a shape of the at least one first fixing protrusion, and wherein the at least one first fixing protrusion is coupled to the groove.
The at least one fixing protrusion may be coupled to the groove by inserting each of the at least one fixing protrusion in a respective groove and by formfitting each of the at least one fixing protrusion to a respective groove.
Each of the at least one groove may extend along an extending direction. Additionally, when more than one groove is provided in the rotor, the grooves may particularly extend parallel with respect to each other.
The extending direction of the at least one groove may particularly be parallel to the axis of rotation of the rotor. Hence, the permanent magnet may have an extension being parallel to the axis of rotation.
According to an alternative exemplary embodiment of the present invention, the permanent magnet is fixed to the rotor such that the permanent magnet and the rotor are unmovable with respect to each other.
The rotor and the permanent magnet being unmovable with respect to each other means according to the present application that the form fit may be a press fit between each groove and each fixing protrusion.
Hence, a relative movement between the rotor and the permanent magnet may be suppressed and therefore a magnetic fluctuation caused by the relative movement may be eliminated.
According to a further exemplary embodiment of the present invention, the base body and the at least one first fixing protrusion are formed in one common process step.
The base body and the at least one first fixing protrusion being formed in one common step means according to the present application that the base body and the fixing protrusion may for example be sintered together at the same time. Furthermore, the base body and the fixing protrusion may be formed by rapid prototyping e.g. in one common burning process.
According to a further exemplary embodiment of the present invention, the permanent magnet machine comprises the permanent magnet which is formed uncovered, in particular uncoated.
According to a further exemplary embodiment of the present invention, the permanent magnet machine comprises the permanent magnet which is formed unmachined and/or ungrinded.
According to a further exemplary embodiment of the present invention, the method further comprises after inserting the permanent magnet into the rotor, providing an extra layer of coating or spray coating to both, the rotor and the permanent magnet.
By coating or spray coating both, the rotor and the permanent magnet after fixing the permanent magnet to the rotor, all surfaces which may come in contact with a fluid, particularly air, being present in the permanent magnet machine, are additionally protected for example against corrosion. Furthermore, surfaces of the rotor and surfaces of the permanent magnet which solely come in contact with each other may be provided without any coating. This may cause reduced manufacturing costs because an additional surface treatment of these surfaces may be omitted.
It has to be noted that embodiments of the invention have been described with reference to different subject-matters. In particular, some embodiments have been described with reference to apparatus type claims whereas other embodiments have been described with reference to method type claims. However, a person skilled in the art will gather from the above and the following description that, unless otherwise notified, in addition to any combination of features belonging to one type of subject-matter also any combination between features relating to different subject-matters, in particular between features of the apparatus type claims and features of the method type claims is considered as to be disclosed with this application.
Some of the embodiments will be described in detail, with references to the following Figures, wherein like designations denote like members, wherein:
The illustrations in the drawings are schematically. It is noted that in different figures, similar or identical elements are provided with the same reference signs.
The permanent magnet 100 comprises a bread loaf shaped base body 110 and a rectangular shaped first fixing protrusion 121.
The first fixing protrusion 121 extends from the first side 111 of the base body 110 and is arranged in the middle of the base body seen in a first direction 131 corresponding to the circumferential direction of the rotor. It may be understood that the first fixing protrusion may also be arranged at any other circumferential position at the first side (not shown in
In
The width of the rectangular shaped first fixing protrusion 121 is larger than the height of the first fixing protrusion 121 which extends parallel to a second direction 132.
A second side 112 is opposite the first side 111 and a third side 113 and a fourth side 114 interconnect the first side 111 and the second side 112, and are distanced to each other. The second direction 132 is rectangular to the first direction 131 and is defined as extending from the first side 111 in the direction of the second side 112. A third direction 133 extends rectangular to the first direction 131 and the second direction 132.
Each of the first side 111, the second side 112, the third side 113 and the fourth side 114 may be shaped curved or planar depending on the given geometrical constraints or the required magnetic features.
The first protrusion 121 extends in the third direction 133 over the entire depth of the base body 110 seen in the third direction 133 (not shown in
The permanent magnet 100 comprises a base body 110 which is shaped and formed identical to the base body 100 in
The width seen in the first direction 131 of the first fixing protrusion 121 is larger than the height of the first fixing protrusion 121 seen in the second direction 132. The two first fixing protrusions 121 are shaped and formed identical. It may be understood that the two first fixing protrusions may also be shaped and formed different from each other, for example dependent on different loads (not shown in
Each of the two first protrusions 121 extends in the third direction 133 over the entire depth of the base body 110 seen in the third direction 133 (not shown in
The permanent magnet 100 comprises a base body 110 and one first fixing protrusion 121. The first fixing protrusion 121 is arranged in the middle of base body 110 seen in the first direction 131. It may be understood that the first fixing protrusion may also be arranged at any other circumferential position at the first side (not shown in
The first fixing protrusion 121 is rectangular shaped and has a width seen in the first direction 131 which is smaller than a height seen in the second direction 132. Hence, compared to the two first fixing protrusions 121 shown in
The permanent magnet 100 comprises the base body 110 and three first fixing protrusions 121 which are spaced apart from each other by an even distance in-between the different first fixing protrusions 121. It may be understood that distances between respective adjacent first fixing protrusions may also be uneven (not shown in
Each of the three first fixing protrusions 121 is shaped rectangular having a width in the first direction 131 which is smaller than a height in the second direction 132.
The permanent magnet 100 comprises the base body 110 which is shaped and formed as the base body 110 shown in
The first fixing protrusion 121 and the second fixing protrusion 522 are each shaped as a parallelogram in the cross-sectional view. Therefore, the three-dimensional shape of the first fixing protrusion 121 and the second fixing protrusion 522 is a parallelepiped. The extension of the first fixing protrusion 121 and the extension of the second fixing protrusion 522 each have a component in the first direction 131 and a component in the second direction 132. Additionally, the first fixing protrusion 121 and the second fixing protrusion 522 extend pointing away from each other.
The permanent magnet 100 comprises the base body 110 which is formed and shaped identical to the base body 110 shown in
The T-shaped first fixing protrusion 121 extends in the third direction 133 over the entire depth of the base body 110 seen in the third direction 133.
The first fixing protrusion 121 and the second fixing protrusion 522 are both L-shaped in the cross-sectional view. The first fixing protrusion 121 is distanced from the second fixing protrusion 522. The middle of the distance between the first fixing protrusion 121 and the second fixing protrusion 522 seen in the first direction 131 coincidence with the middle of the base body 110 seen in the first direction 131. Therefore, each of the first fixing protrusion 121 and the second fixing protrusion 522 is spaced apart from the middle of the base body 110 in the first direction 131.
The longer leg of the L-shaped first fixing protrusion 121 and the second fixing protrusion 522 extends perpendicular to the first side 111 of the base body 110. The respective shorter leg of the first fixing protrusion 121 and the second fixing protrusion 522 extend away from each other and parallel to the first direction 131.
The permanent magnet 100 comprises one third fixing protrusion 823, one fourth fixing protrusion 824, and the base body 110 which is formed and shaped as the base body 110 in
Furthermore, there are no fixing protrusions provided at the first side 111 of the base body 110.
The two first fixing protrusions 121 are distanced relative to each other in the third direction 133. Additionally, the two first fixing protrusions 121 each have a first fixing protrusion depth seen in the third direction 133 which is shorter than a main body depth seen in the third direction 133.
The outer rotor 1000 comprises rotor segments 1010 which are arranged on adjacent and in touch to another in a circumferential direction of the rotor 1000.
Each rotor segment 1010 comprises a groove 1041 which is provided on a circumferential inner surface of the outer rotor segments 1010.
The rotor 1000 comprises outer rotor segments 1010 each having a groove 1041. One first fixing protrusion 121 is inserted in each of the grooves 1041 such that one permanent magnet 100 is fixed to each rotor segment 1010 by a press fit between the first fixing protrusion 121 and the groove 1041.
In
As may be seen from
The shrinkage rate could also be taken into account in the mould. Hence, the final magnet will shrink back to the desired size and shape.
Although the present invention has been disclosed in the form of preferred embodiments and variations thereon, it will be understood that numerous additional modifications and variations could be made thereto without departing from the scope of the invention.
For the sake of clarity, it is to be understood that the use of ‘a’ or ‘an’ throughout this application does not exclude a plurality, and ‘comprising’ does not exclude other steps or elements.
| Number | Date | Country | Kind |
|---|---|---|---|
| 17203204.7 | Nov 2017 | EP | regional |
