Method and apparatus for producing multiphase electromagnetic mats for current carrying components of power conversion systems

Abstract

The present invention provides a production method and apparatus for a multiphase electromagnetic mat (10) for forming a current-carrying component of a power conversion system, wherein the electromagnetic mat (10) comprises: a structural fiber section (20) divided into at least two groups (21, 22); and a winding fiber section (71A, 71B) divided into a number of groups corresponding to the number of phases and the number of parallel conductors of one phase, wherein the winding fiber section (71A, 71B) is held in place by the groups (21, 22) of the structural fiber section (20).

Description

[0001] The present invention relates to a method for producing a multiphase electromagnetic pad for forming a current-carrying component of a power conversion system, according to one aspect of the present invention.

[0002] The present invention also relates to a production apparatus for a multiphase electromagnetic pad for forming a current-carrying component of a power conversion system, according to another aspect of the present invention. Background Technology

[0003] Multiphase electromagnetic pads can be used in a wide range of power conversion applications, such as rotating motors, linear and planar motors, transformers, heaters, and chargers. The function of the electromagnetic pad is to carry current and generate an electromagnetic field that interacts with other components of the power conversion system.

[0004] Motors are a major application area for electromagnetic pads because various series of motors exist (so-called slotless or ironless motors) in which the stator or rotor components may partially or wholly include electromagnetic pads. These pads are shaped to form cylinders in rotating motors or remain flat in linear or planar motors. These components typically have pads molded in a resin to form composite parts. In slotless motors, the composite parts are usually attached to a ferromagnetic core, while in ironless motors (also known as coreless or hollow motors), the pads molded in resin typically represent separate composite parts, such as the stator or rotor.

[0005] A typical method for producing windings for ironless or slotless motors is to wind conductors onto a certain shape / mandrel. This shape may include the motor's ferromagnetic core, or simply a temporary shape that can be removed later.

[0006] For example, US4691746A discloses a method for producing a flat stator for an axial flux rotary motor, which includes winding a conductor around a disc-shaped profile, and CN1868010A describes forming an annular winding of a slotless motor by winding a conductor around an annular core, while CN103620916A and US4644209A propose methods for winding around a short cylinder.

[0007] Numerous patent applications, such as US4320319A, US4151964A, JPS58204751A, JPS583550A, GB2048729A, JPS54114709A, and JPS5518875A, disclose methods for winding a conductor around an elongated cylindrical shape. The winding patterns obtained by these methods are characterized by conductors wound at an angle relative to the axis of the cylinder. The windings also have more than one layer.

[0008] All methods are partially or fully automated, and therefore corresponding machines have been proposed in many publications.

[0009] Only a few publications (such as JPH09271158A and WO2019074375A1) describe the electromagnetic pads for motors as flat sheets. It is assumed that the pads are first made into flat sheets, where each sheet consists of windings and can be divided into individual electromagnetic pads or segments, which can then be shaped to form the stator or rotor of the motor. The appendix discloses the structure of an electromagnetic pad formed according to the principle of JPH09271158A. Figure 1 JPH09271158A fails to disclose a method for producing multiple consecutive windings of electromagnetic pads for use in multiphase motors, where the production pattern is arranged such that the electromagnetic pads can be used without the additional steps of cutting and rewiring that would result in expensive and suboptimal products.

[0010] A mechanism and method for introducing a wave winding from a prefabricated wave winding pad into a stator sheet metal cladding slot is known from US 2018294702 A1. This invention discloses a mechanism for introducing a wave winding from a prefabricated wave winding pad into a rotor or stator body, the mechanism having receiving means for receiving and holding the rotor or stator body and feeding means for feeding the wave winding pad to the receiving means. The receiving means further includes an introduction means that can isolate the winding of the winding pad and introduce the winding into the rotor or stator body in the depth direction of the slot.

[0011] The applicant's WO2019074375A1 describes both the structure and a method for producing electromagnetic mats, and also discloses a machine for producing electromagnetic mats. Figures 16a to 16c of WO2019074375A1, for example, disclose the production of electromagnetic mats using twinning. Reference is made to the machine shown in WO2019074375A1. Figure 2 The machine includes a wound electromagnetic pad ( Figure 2 Rotating circular component Figure 2 90% of the content). Double twisting cannot produce single-layer mats; furthermore, it introduces the problem of winding fibers ( Figure 2 30) is fixed to the structural fiber ( Figure 2 The problem lies in 20). Therefore, WO2019074375A1 failed to disclose a machine for producing single-layer mats.

[0012] The prior art has not disclosed a method for producing electromagnetic pads with conductors arranged perpendicular to the length of the electromagnetic pad.

[0013] The solutions in the prior art fail to disclose a method for producing electromagnetic pads suitable for making single-layer windings.

[0014] The prior art has not disclosed a method for the continuous production of electromagnetic mats with continuous windings having multiple phases or multiple conductors.

[0015] Another drawback of existing technology solutions is their failure to disclose scalable and flexible / adjustable production methods tailored to different use cases.

[0016] Furthermore, the prior art has not disclosed an apparatus for realizing a method of producing an electromagnetic pad having conductors arranged perpendicular to the length of the electromagnetic pad and having continuous uncut windings.

[0017] Existing technologies have failed to publicly meet the requirements for scalable and flexible production of iron-free and slotless components, while also achieving a production method with a high conductor fill factor.

[0018] Low weight and compactness of current-carrying components are crucial for the performance of power conversion systems. Achieving low weight and compactness involves providing a high conductor fill factor within the electromagnetic pad and orienting the conductors perpendicular to the direction of motion of the main magnetic field in the power conversion system to maximize electromagnetic force.

[0019] Low cost is crucial for the market acceptance of power conversion systems. Therefore, fully automated, flexible, and adjustable production methods and corresponding equipment are essential.

[0020] Currently, automated winding equipment is very expensive and is tailored to the types of machines described in the aforementioned prior art. Therefore, new methods and devices are needed.

[0021] Customized products offer higher performance, but are associated with higher costs and more cumbersome methods due to expensive reprocessing. Highly flexible and scalable production methods will enable the mass production of low-cost customized products. Summary of the Invention

[0022] Purpose

[0023] The main objective of this invention is to provide a method and apparatus for producing multiphase electromagnetic pads that partially or completely solves the aforementioned shortcomings of the prior art.

[0024] The object of this invention is to provide a method and apparatus for producing multiphase electromagnetic pads that can be customized for the design and characteristics of motors in a simple manner.

[0025] The object of the present invention is to provide a method and apparatus for producing multiphase electromagnetic pads that result in lower production costs for both mass production and small-batch production.

[0026] The object of this invention is to provide a method and apparatus for producing multiphase electromagnetic mats in an automated, scalable and flexible manner.

[0027] The object of the present invention is to provide a method and apparatus for producing multiphase electromagnetic pads, wherein the multiphase electromagnetic pads are used to produce stators or rotors of motors, the stators or rotors being formed by multiphase electromagnetic pads that can be rolled up or folded to form stator or rotor components, which can be used in rotary motors, linear motors or planar motors.

[0028] Other objects of the present invention will become clear from the following description, claims and drawings.

[0029] This invention

[0030] According to one aspect of the invention, a method for manufacturing a multiphase electromagnetic pad for forming a current-carrying component of a power conversion system is defined. Preferred features of the method are described in the dependent claims.

[0031] According to another aspect of the invention, a production apparatus for a multiphase electromagnetic pad used to form a current-carrying component of a power conversion system is defined. Preferred features of the apparatus are described in the dependent claims.

[0032] The multiphase electromagnetic pad according to the invention is made of structural fibers arranged mainly along the length of the electromagnetic pad and wound fibers that intersect the structural fibers and are arranged mainly in the transverse direction of the length of the electromagnetic pad, wherein the structural fibers hold the wound fibers in place.

[0033] Typically, the head and / or tail of an electromagnetic pad may contain components made of fibers other than wound fibers (so-called auxiliary fibers). For example, such components may be used to connect the tail of the electromagnetic pad to a circular component forming, for example, a motor stator.

[0034] Specialized equipment (referred to herein as the "apparatus") is used to realize the method of producing electromagnetic mats. The purpose of the apparatus is to classify the wound fibers, with the aim of maintaining multiple wound fibers in the electromagnetic mat continuously wound into one or more prescribed patterns in a continuous process.

[0035] An apparatus according to the present invention comprises at least the following components:

[0036] - Multiple reservoirs containing wound fibers or auxiliary fibers located on each side of the electromagnetic pad to be produced, wherein the reservoirs can be in many shapes, such as rectangular, circular, etc.

[0037] - At least two movable boxes, which accommodate the reservoir by means of retainers integrated in or on the movable boxes, wherein, viewed from the same plane as the electromagnetic pad to be produced, at least one movable box is located on each side of the electromagnetic pad, wherein the movable boxes can be of various shapes (e.g., rectangular, circular, linear, annular, etc.).

[0038] - A conveying mechanism for transferring / delivering a reservoir with wound fibers from one reservoir in a movable box on one side of the electromagnetic mat to be produced to another reservoir in another movable box on the other side of the electromagnetic mat to be produced.

[0039] It should be understood that a box may have fixed parts such as shafts or frames as well as one or more movable parts. Therefore, the term "movable box" means that the box has movable elements and does not mean that the entire box should be movable.

[0040] According to one embodiment of the device, the transfer mechanism includes a retainer for securing the reservoir to a movable box and a component for releasing it from the retainer.

[0041] The cartridge according to the invention can be manufactured as removable, replaceable, or interchangeable to reload the winding fibers and auxiliary fibers into the reservoir. The reservoir can be directly rewound in the device or replaced by a fully or partially wound reservoir. The type of reservoir can be changed during operation.

[0042] The method for producing an electromagnetic mat according to the present invention includes dividing structural fiber segments into at least two groups G1, G2, ..., Gn, where n is an integer greater than 1, i.e., the first, second, ..., nth group.

[0043] The method according to the invention further includes dividing the wound fiber segments into several groups W1, W2, ..., Wn corresponding to the number of phases and the number of parallel branches of each phase, and winding the wound fiber segments onto a plurality of reservoirs housed in at least two movable boxes, wherein, viewed from the plane of the electromagnetic pad to be produced, at least one movable box is located on each side of the electromagnetic pad.

[0044] In the method according to the invention, the wound fibers are divided into at least two groups W1, W2, ..., Wtotal, wherein the total number of wound fibers Wtotal corresponds to the total number of parallel branches in all phases.

[0045] According to the method of the present invention, each of the winding fiber groups W1, W2, ..., Wn is wound onto a dedicated reservoir. The reservoir should contain a length of winding fiber sufficient to produce an electromagnetic pad of a given design, or a portion or several electromagnetic pads.

[0046] The reservoir is housed in a movable box that can be moved to position the dedicated reservoir at the optimal insertion point for the next winding fiber to become part of the electromagnetic pad.

[0047] According to other embodiments of the method according to the invention, it includes holding the head of the wound fiber in place on one side of the electromagnetic pad to be produced, such that the reservoir can be transferred to the other side of the electromagnetic pad, and the wound fiber can be held in place by the structural fiber, and a “normal process” can begin.

[0048] One cycle of the winding process according to this method includes at least the following steps:

[0049] The first group G1 of structural fiber segments is moved in a first direction that is substantially perpendicular to the plane of the electromagnetic pad to be produced, and the second group G2 of structural fiber segments is moved in a second direction, so that the two groups of structural fiber segments are at an angle to the plane of the electromagnetic pad to be produced. The second direction is the opposite of the first direction.

[0050] A selected number of wound fiber segments are inserted into the opening formed between the first and second groups of structural fiber segments, such that the wound fiber segments extend across the structural fiber segments.

[0051] By moving the first group G1 of the structural fiber segments in the second direction and moving the second group G2 of the structural fiber segments in the first direction such that the groups G1 and G2 of the structural fiber segments exchange positions at least once, or by using at least one other group G3, ..., Gn of the structural fiber segments in a similar manner to keep the winding fiber segments in place, it becomes possible to form various patterns of overlapping structural fibers and winding fibers.

[0052] The method according to the invention may further include the step of pushing the inserted wound fiber segment toward the head of the electromagnetic pad to be produced.

[0053] The selected number of wound fiber segments may include one group (e.g., W1) or several groups.

[0054] When a selected number of wound fiber segments are inserted into an opening formed between at least two groups of structural fiber segments, at least one reservoir to which the wound fiber segments belong is transferred from a movable box on one side of the electromagnetic pad to be produced to another movable box on the other side of the electromagnetic pad to be produced.

[0055] According to other embodiments of the invention, it includes controlling and adjusting the tension of the inserted wound fiber segments.

[0056] According to other embodiments of the invention, it includes holding the wound fiber segment in place by changing the orientation of the group of structural fiber segments at least twice in a rotational motion, thereby forming a twist of the structural fiber segment.

[0057] The method according to the invention further includes, after the first cycle is completed, performing a next cycle of the winding process, i.e., inserting a new selected number of winding fiber segments (e.g., W2) into the electromagnetic pad to be produced (between groups G1 and G2 of structural fiber segments or between other combinations of groups of structural fiber segments). The cycle continues until winding fibers in all groups of winding fibers W1, W2, ..., Wtotal have been added to the structure of the electromagnetic pad to be produced.

[0058] The method according to the invention also includes a predefined movement of the movable box so that the reservoir of the wound fiber group will then be inserted into an optimal position relative to the opening formed between two or more groups of structural fiber segments.

[0059] The method according to the invention further includes, while all the winding fibers W1, W2, ... Wtotal are inserted into the electromagnetic pad and held in place, performing a new insertion sequence involving the mentioned groups in the same or different order, so that the process continues.

[0060] The direction of fiber insertion (from one side of the electromagnetic pad to be produced or vice versa) is determined during the design process. This lays the foundation for various winding patterns. Of course, once a winding is inserted from one side, it must be inserted from the opposite side the next time a winding is inserted.

[0061] When producing an electromagnetic sheet comprising several electromagnetic pads, the winding fibers W1, ..., Wtotal of the newly formed electromagnetic pad have their "end lines" held in place within the final electromagnetic pad. The "end lines" should be made long enough that, when cut, the divided winding fibers(s) can be used as "end lines" for both the first and last electromagnetic pads.

[0062] If the current-carrying component of the motor is made of multiple layers, the electromagnetic pad of the component can have segments of different lengths while having the same winding pattern, as the circumference increases between the layers. The distance between the wound fibers should be variable so that it can be increased when producing segments of longer layers. For multi-layered structures of current-carrying components, increasing the incremental step size should be achievable.

[0063] Between segments forming different layers, the method according to the invention includes inserting buffers to accommodate the "jump" that the electromagnetic pad must make when transitioning from "layer N" to "layer N+1", where N is an integer greater than 1. This gap can be formed by the device either by changing the parameters of the device at that moment (e.g., reducing the tension in the structural fibers), by inserting auxiliary fibers (e.g., winding fibers with non-electromagnetic properties), or by performing incremental steps as described above.

[0064] Electromagnetic sheets can be made from several electromagnetic pads of different designs (different winding patterns) produced sequentially, one after another, connected in series. According to the invention, new winding fibers, such as Wtotal+1, can be added to the process to accommodate more parallel windings (in some or more phases), or winding fibers can be removed for the same but opposite reasons. This means that, with the invention, a continuous process for manufacturing electromagnetic pads of different designs can be achieved without stopping production or reorganizing / reprocessing the device. According to other embodiments of the invention, if the reservoir can hold multiple winding fibers, winding fibers can be added to the reservoir, or new reservoirs can be added or removed during the process. Unused reservoirs can be part of the device, not part of production.

[0065] Once the electromagnetic sheet is complete, the winding fibers extending from the electromagnetic pad to the reservoir must be cut. The reservoir must be rewound (if it does not hold enough winding fibers to restart the process of another electromagnetic sheet) or the reservoir must be replaced, and the process repeated to obtain new electromagnetic pads of the same or different design. The electromagnetic sheet at this point contains one or more electromagnetic pads connected in series, which can be divided into individual electromagnetic pads. Each electromagnetic pad can be shaped to form its designated electromagnetic component, such as a cylindrical winding.

[0066] When this method is automated, software that adapts to the sorting and order of data transferred from the storage becomes part of the method and apparatus. This software will enable the flexible production of electromagnetic mats with different winding patterns.

[0067] Other preferred features and advantageous details of the invention will become clear from the following illustrative description, claims and drawings.

[0068] Example

[0069] Hereinafter, exemplary embodiments of the present invention will be described with reference to the accompanying drawings, wherein:

[0070] Figure 1 It is a schematic diagram of the structure of electromagnetic pads based on existing technology.

[0071] Figure 2 It is a schematic diagram of a machine used to produce electromagnetic mats based on existing technology.

[0072] Figure 3 This is a schematic diagram of the key components of the device (winding machine) according to the present invention, viewed from a 3D perspective.

[0073] Figure 4 a- Figure 4 e illustrates the insertion process of the wound fiber segment according to the present invention.

[0074] Figure 5This is a schematic diagram of the device (winding machine) according to the present invention, viewed from top view, and...

[0075] Figure 6 a- Figure 6 e shows the individual wound fibers and groups of wound fibers held in place by the structural fibers.

[0076] Now for reference Figure 1 , Figure 1 This is a schematic diagram of the electromagnetic pad structure based on existing technology JPH09271158A. Conductor 21 is a single-phase winding. No manufacturing method has been disclosed.

[0077] Now for reference Figure 2 , Figure 2 This is a schematic diagram of a machine used to produce electromagnetic mats according to existing technology WO2019074375A1. The 90 circular elements surrounding the electromagnetic mat can be used for double twisting as a winding manufacturing method.

[0078] Now for reference Figure 3 , Figure 3 This is a schematic diagram of a key component of the production apparatus for the electromagnetic pad 10 according to the present invention.

[0079] The electromagnetic pad 10 includes structural fiber segments 20 and a plurality of wound fiber segments 71A, 71B, wherein the wound fiber segments are used to form a wound pattern.

[0080] The structural fiber segment 20 is divided into two groups, namely, a first group 21 and a second group 22. The wound fiber segment is 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 6. The fiber segment is wound on a plurality of reservoirs 81A that can be attached to at least two movable boxes 31, 32, which are located on either side of the electromagnetic pad 10 as viewed from the plane of the pad to be produced. In this example, the number of reservoirs 81A is the same as the number of groups of the wound fiber segment. The movable boxes 31, 32 have retainers 51A, 51B for the reservoirs 81A. In this example, the number of retainers 51A, 51B on each box 31, 32 is equal to the number of groups 71A, 71B of the wound fiber segment, and is 6. In this example, the movable boxes 31, 32 are in the form of a disc or cylinder rotatable about a rotation axis 60.

[0081] The apparatus also includes a transfer mechanism 40 for transferring the reservoir 81A from one cartridge 31, 32 to another. According to other embodiments of the invention, the transfer mechanism 40 includes components for securing the reservoir 81A to and releasing it from the movable cartridges 31, 32.

[0082] The process of holding the wound fiber 70 in place by structural fibers 21 and 22 is now shown with reference to the illustration. Figure 4 ad.

[0083] Figure 4 a shows the first group 21 of structural fibers being moved in one direction and the second group 22 of structural fibers being moved in the opposite direction, thereby forming an opening between the two groups.

[0084] Figure 4 b illustrates adding new wound fibers to the electromagnetic pad 10 by inserting new wound fibers into the opening between the two groups 21, 22 of the structural fibers.

[0085] Figure 4 c shows two groups 21 and 22 of structural fibers that exchange motion directions.

[0086] Figure 4 d shows two groups 21, 22 of the structural fibers holding the wound fiber 70 in place.

[0087] Figure 4 The ad only describes a variation of a complete hold process. However, the process can be much more complex. Figure 4 e illustrates two groups 21, 22 of structural fibers that hold the wound fiber 70 in place and thereby form the structural fiber twist 23 by changing the orientation of the group twice during rotational motion. For example, rotational motion is achieved by arranging a component 85 for movement of the structural fiber segment 20 for the rotational motion.

[0088] The reference now provides some more details about the process and apparatus. Figure 5 The winding process includes at least the following steps:

[0089] Using component 85, the first group 21 of structural fiber segments is moved in a first direction substantially perpendicular to the plane of the electromagnetic pad 10 to be produced, and the second group 22 of structural fiber segments is moved in a second direction such that the two groups 21, 22 of structural fiber segments are at an angle to the plane of the electromagnetic pad 10 to be produced, the second direction being the opposite of the first direction.

[0090] - Insert a selected number of wound fiber segments into the opening formed by the first group 21 and the second group 22 of the structural fiber segments, such that the wound fiber segments extend across the structural fiber segments in the transverse direction of the length of the electromagnetic pad 10.

[0091] -The inserted wound fiber segment is pushed toward the head of the electromagnetic pad 10 by means of the component 90 for pushing the wound fiber segment.

[0092] -The wound fiber segment is held in place by moving the first group 21 of the structural fiber segment in the second direction and moving the second group 22 of the structural fiber segment in the first direction to exchange the positions of the two groups.

[0093] The formed electromagnetic pad 10 moves away from the movable boxes 31 and 32 in direction 95.

[0094] The component 90 for pushing (one or more) winding fiber segments can rotate at an angle in the lateral direction of the electromagnetic pad 10 to make the winding pattern diagonal.

[0095] When a selected number of wound fiber segments are inserted into the opening formed by the two groups 21, 22 of the structural fiber segments, at least one reservoir 81A to which the wound fiber segments belong is transferred from the boxes 31, 32 on one side of the electromagnetic pad 10 to the boxes 31, 32 on the other side of the electromagnetic pad 10 by means of the transfer mechanism components 41, 42 (such as one or more actuators).

[0096] The winding process also includes predefined movements of boxes 31 and 32 so that the reservoir 81A of the phase group (winding group) will be inserted into a position closest to the opening formed by the groups 21 and 22 of the structural fiber segments. Figure 4 a- Figure 4 The example in e shows the raised and lowered positions. This can be achieved by rotating the movable boxes 31, 32 about the rotation axis 60.

[0097] Figure 5 This is an example of how a component can look. For instance, in some other possible embodiments, the conveying mechanism may not necessarily be moving.

[0098] The references now show some examples of how wound fibers can be assembled and held in place by structural fibers. Figure 6 ad.

[0099] Figure 6 a shows an arrangement in which each phase has two wound fibers A, B, C arranged in a row, each wound fiber being individually held in place by groups 21, 22 of structural fibers.

[0100] Figure 6 b shows an arrangement where each phase has two wound fibers A, B, C arranged in a row, the wound fibers being held in place together by groups 21, 22 of structural fibers.

[0101] Figure 6 c shows the configuration in which three wound fibers A, B, and C of three different phases are held in place together by groups 21 and 22 of structural fibers.

[0102] Figure 6d shows six bundles / three groups of three wound fibers A, B, and C, each bundle belonging to the same phase.

[0103] Figure 6 e shows two bundles of seven wound fibers A, B, and C, each belonging to the same phase.

[0104] The above embodiments can be combined and modified to form other embodiments within the scope of the claims.

[0105] Modified form

[0106] The present invention is also applicable to the production of electromagnetic mats and the simultaneous rolling of them into cylindrical shapes. In some embodiments, the cylindrical shape may include a ferromagnetic core of a motor. The cylindrical shape may have the same axis of rotation as the housing or a different axis of rotation.

[0107] In other modifications, the device can be placed at any location and angle relative to the Earth's surface.

[0108] In other modifications, the boxes containing wound fibers on each side of the electromagnetic pad can be of any shape.

[0109] In other modified forms, the movement of the box can be translation.

[0110] In other modifications, the memory and the holder for the memory can be of any shape.

[0111] In other modified forms, the transport mechanism can be configured in any way.

[0112] In other modifications, there are components for controlling the width of the electromagnetic pads used in production.

[0113] In other modifications, the component used to push the wound fiber segment can rotate at a certain angle in the lateral direction.

[0114] In other modifications, multiple layers of sheets S1, S2, etc., can be produced simultaneously in a direction perpendicular to the plane of the first sheet S1 (wherein the sheets are parallel to each other but offset by a certain distance).

[0115] In other modifications, when winding multi-layer sheets, the winding fibers from one sheet can be introduced into other sheets, and then the sheets are combined to form a multi-layer sheet.

[0116] List of labels

[0117] 10- Electromagnetic mat

[0118] 20- Structural Fibers

[0119] 21- The first group of structural fibers

[0120] 22- The second group of structural fibers

[0121] 23- Twist

[0122] 31- First box

[0123] 32- Second box

[0124] 40- Conveying mechanism

[0125] 41- Conveyor Mechanism Component 1

[0126] 42- Conveyor mechanism component 2

[0127] 51A - Holder for the storage of group W1 on the first box

[0128] 51B - Retainer for the storage of group W2 on the second box

[0129] 60- Rotation axis

[0130] 70- Wound Fibers

[0131] 71A - Group W1 of wound fibers

[0132] 71B - Group W2 of wound fibers

[0133] 81A - Storage of group W1 on the first box

[0134] 85 - Components for moving structural fiber segments

[0135] 90 - Components used to drive the wound fiber segments

[0136] 95- Direction of Pad Movement

Claims

1. A method for producing a multiphase electromagnetic pad (10) for forming a current-carrying component of a power conversion system, wherein, The electromagnetic pad (10) includes: Structural fiber segment (20); and Multiple wound fiber segments (71A, 71B), wherein the wound fiber segments (71A, 71B) form wound fibers (70), the wound fibers (70) having a winding pattern for forming one or more windings of the power conversion system, and wherein the wound fiber segments (71A, 71B) are divided into several groups. The method is characterized by comprising: The structural fiber segment (20) is divided into at least two groups (21, 22), namely, the first group (21), the second group (22), ..., the nth group, and the wound fiber segment (71A, 71B) is divided into several groups corresponding to the number of phases and the number of parallel branches of each phase, and the wound fiber segment (71A, 71B) is wound on a plurality of reservoirs (81A) housed in at least two movable boxes (31, 32), wherein, viewed from the plane of the electromagnetic pad (10) to be produced, at least one movable box (31, 32) is located on each side of the electromagnetic pad (10). The method includes a winding process, which comprises at least the following steps: - The first group (21) of the structural fiber segment (20) is moved in a first direction substantially perpendicular to the plane of the electromagnetic pad (10) to be produced, and the second group (22) of the structural fiber segment (20) is moved in a second direction such that the two groups (21, 22) of the structural fiber segment (20) are at an angle to the plane of the electromagnetic pad (10) to be produced, the second direction being the opposite of the first direction. - A selected number of the wound fiber segments (71A, 71B) are inserted into the opening formed between the first group (21) and the second group (22) of the structural fiber segment (20), such that the wound fiber segments (71A, 71B) extend across the structural fiber segment (20). - By moving the two groups (21, 22) of the structural fiber segment (20) so that the two groups (21, 22) exchange positions at least once, or by using at least one other group of the structural fiber segment (20) so that the at least one other group exchange positions at least once, the winding fiber segment (71A, 71B) is kept in place, thereby enabling the formation of various patterns of overlapping structural fibers and winding fibers (70).

2. The method according to claim 1, wherein, The method includes holding the wound fiber segments (71A, 71B) in place by changing the orientation of the two groups (21, 22) of the structural fiber segment (20) at least twice during rotational motion, thereby forming a twist (23) of the structural fiber segment (20).

3. The method according to claim 1, wherein, The method includes, while inserting a selected number of the wound fiber segments (71A, 71B) into the opening formed between the two groups (21, 22) of the structural fiber segment (20), transferring at least one reservoir (81A) to which the wound fiber segments (71A, 71B) belong from the movable box (31, 32) on one side of the electromagnetic pad (10) to another movable box (31, 32) on the other side of the electromagnetic pad (10).

4. The method according to claim 3, wherein, The method also includes a predefined movement of the movable boxes (31, 32) so that the reservoir (81A) of the wound fiber segments (71A, 71B) will be inserted into the most convenient position relative to the opening formed by the two groups (21, 22) of the structural fiber segments (20).

5. The method according to claim 1, wherein, The method includes pushing the inserted wound fiber segments (71A, 71B) toward the head of the electromagnetic pad (10) after insertion, and then holding them in place.

6. The method according to claim 1, wherein, The method includes directly winding the electromagnetic pad (10) onto the stator or rotor components of the motor.

7. The method according to claim 1, wherein, The method includes changing the winding design during production, thereby enabling the production of various electromagnetic pads (10) or multiple identical electromagnetic pads (10) in a continuous process.

8. The method according to claim 1, wherein, The method includes controlling and adjusting the tension on the inserted wound fiber segments (71A, 71B).

9. The method according to claim 1, wherein, The method includes producing a portion of the electromagnetic pad (10) using auxiliary fibers.

10. A production apparatus for a multiphase electromagnetic pad (10) used to form a current-carrying component of a power conversion system, wherein, The electromagnetic pad (10) includes: Structural fiber segment (20); and Multiple wound fiber segments (71A, 71B), wherein the wound fiber segments (71A, 71B) form wound fibers (70), and the wound fibers (70) have a winding pattern for forming one or more windings of the power conversion system. The device is characterized in that it comprises at least: - A reservoir (81A) for storing at least two groups (21, 22) of the wound fiber segments (71A, 71B) contained in at least two movable boxes (31, 32) by means of retainers (51A, 51B), wherein, viewed from the plane of the electromagnetic pad (10) to be produced, at least one movable box (31, 32) is located on each side of the electromagnetic pad (10). - Component (85), said component (85) being used to move the two groups (21, 22) of said structural fiber segment (20) in a reciprocating manner in different directions, and - At least one conveying mechanism for conveying the storage device (81A) from a movable box (31, 32) on one side of the electromagnetic pad (10) to a movable box (31, 32) on the other side of the electromagnetic pad (10).

11. The apparatus according to claim 10, wherein, The component (85) is also arranged for the rotational movement of the structural fiber segment (20).

12. The apparatus according to claim 10, wherein, The device includes components for controlling and adjusting the tension of the inserted wound fiber segments (71A, 71B) during insertion.

13. The apparatus according to claim 10, wherein, The device includes components for synchronizing the movement of at least the movable boxes (31, 32) and components (85) for moving the at least two groups (21, 22) of the structural fiber segment (20).

14. The apparatus according to claim 10, wherein, The device includes a component (90) for pushing the inserted wound fiber segments (71A, 71B) toward the head of the electromagnetic pad (10).

15. The apparatus according to claim 10, wherein, The retainer (51A, 51B) for the reservoir (81A) in the movable box (31, 32) is in the form of an opening or a recess.

16. The apparatus according to claim 10, wherein, The transmission mechanism includes one or more actuators.

17. The apparatus according to claim 10, wherein, The transfer mechanism includes components for securing the reservoir (81A) to the movable box (31, 32) and releasing it from the movable box (31, 32).

18. The apparatus according to claim 10, wherein, The movable boxes (31, 32) are movable and replaceable.

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