Flat wire close-wound electromagnetic bearing and flywheel energy storage energy efficiency optimization system

Abstract

The invention discloses a flat wire close-wound electromagnetic bearing which comprises an iron core and a flat wire winding, a tooth part is arranged on the iron core, and the flat wire winding is wound on the tooth part of the iron core; the system further comprises an energy supply adaptation module and an energy consumption control sub-module, the energy supply adaptation module is used for being compatible with multi-source input energy and dynamically distributing power, and the energy consumption control sub-module is used for monitoring the states of the rotor and the winding in real time and dynamically adjusting energy consumption output and energy distribution; the flat wire is provided with the micro-channel penetrating through the two ends of the flat wire in the length direction, the micro-channel is filled with the phase-change material, the phase-change material achieves active temperature control by absorbing heat generated in the winding operation process, the local heat dissipation bottleneck of dense winding of the flat wire can be effectively solved, and cooperation of high filling and low heat dissipation loss is achieved.

Description

Technical Field

[0001] This invention relates to the field of flywheel energy storage technology, and in particular to a flat wire tightly wound electromagnetic bearing and a flywheel energy storage efficiency optimization system. Background Technology

[0002] Flywheel energy storage devices, with their high power density and rapid response characteristics, are increasingly widely used in scenarios such as grid frequency regulation, renewable energy consumption, and emergency power supply. Their core performance depends on the stable suspension state of the rotor during high-speed rotation and its energy conversion efficiency. As the core component for achieving contactless rotor support, the electromagnetic bearing balances the rotor's centrifugal force and external disturbances by outputting controllable electromagnetic force, making it a key component for ensuring the long-term reliable operation of the equipment.

[0003] Currently, flat wire close-wound structures are gradually being applied to the design of electromagnetic bearing windings to improve slot fill factor and reduce conductor resistance loss. However, under special operating conditions such as high-speed rotor dynamic misalignment, frequent changes in alternating magnetic fields, and localized heat concentration faced by flywheel energy storage electromagnetic bearings, existing technologies still have some limitations. For example, due to the tight arrangement of conductors and extremely small winding gaps in flat wire close-wound structures, Joule heat generated by rapid current changes and eddy current heat induced by alternating magnetic fields tend to accumulate locally during dynamic adjustment. Traditional external air cooling and liquid cooling methods are difficult to quickly penetrate into the winding interior, which not only accelerates insulation aging but also increases conductor resistance, forming a vicious cycle of "increased heat loss - increased resistance - further increased energy consumption," thus restricting the energy efficiency and lifespan of electromagnetic bearings.

[0004] Therefore, a flat wire tightly wound electromagnetic bearing and flywheel energy storage efficiency optimization system are provided to solve the above problems. Summary of the Invention

[0005] To overcome the shortcomings of existing technologies, this invention provides a flat wire tightly wound electromagnetic bearing and flywheel energy storage efficiency optimization system.

[0006] The technical solution adopted by this invention to solve its technical problem is: This invention provides a flat wire tightly wound electromagnetic bearing, comprising an iron core and a flat wire winding. The iron core has teeth, and the flat wire winding is wound around the teeth of the iron core. It also includes a power supply adaptation module and an energy consumption control submodule. The power supply adaptation module is used to be compatible with multiple energy inputs and dynamically allocate power. The energy consumption control submodule is used to monitor the rotor and winding status in real time and dynamically adjust the energy output and energy distribution. The flat wire has microchannels running through both ends of the flat wire along its length. The microchannels are filled with phase change material, which achieves active temperature control by absorbing the heat generated during the operation of the winding.

[0007] Preferably, the microchannels are spirally arranged along the length of the flat line, and the phase change material is a paraffin-graphene composite phase change material with a phase change temperature of 45℃ and a thermal conductivity of 20 W / (m²). The spiral structure increases the contact area between the phase change material and the flat wire, enabling the high thermal conductivity composite phase change material to absorb the heat generated by the flat wire winding more quickly. This achieves efficient and precise active temperature control of the flat wire winding, effectively avoiding the deterioration and damage of the winding performance caused by excessive temperature, and ensuring the long-term stable operation of the electromagnetic bearing.

[0008] Preferably, an elastic buffer layer is provided between the flat wires. The elastic buffer layer is made of insulating material. The elastic buffer layer is used to prevent the flat wires from being directly squeezed and deformed. This prevents the flat wires from being directly squeezed and deformed, thus protecting the structural integrity of the flat wires, extending the service life of the flat wires, and ensuring the stable operation of the electromagnetic bearing winding.

[0009] Preferably, an elastic buffer layer is disposed between every three turns of flat wire. The elastic buffer layer is made of a composite material of modified silicone rubber and glass fiber cloth, which not only ensures insulation, but also utilizes the elasticity of modified silicone rubber and the strength of glass fiber cloth to better disperse the pressure between the flat wires, thereby achieving a more effective flat wire protection effect and improving the reliability and stability of the winding.

[0010] Preferably, the elastic buffer layer is provided with micro protrusions, and the array of micro protrusions is distributed on both sides of the elastic buffer layer. The micro protrusions are arranged in a circle, with a diameter of 0.1 mm and a spacing of 2 mm between two adjacent micro protrusions. This increases the contact friction between the elastic buffer layer and the flat wire, further stabilizes the position of the flat wire, and achieves the effect of enhancing the stability of the winding structure. At the same time, it facilitates the elastic deformation of the micro protrusions for buffering.

[0011] Preferably, the flat wire is provided with a nano-magnetic coating. The nano-magnetic coating is used to guide the magnetic field to form a closed magnetic circuit along the surface of the flat wire and the iron core teeth, thereby reducing air gap and leakage magnetic loss and achieving the effect of improving the magnetic field utilization efficiency and operating performance of the electromagnetic bearing.

[0012] Preferably, the nano-magnetic coating is an Fe-Ni-Cr nano-magnetic coating. The surface of the nano-magnetic coating is passivated to improve corrosion resistance. While ensuring good magnetic permeability, the corrosion resistance of the coating is improved, thereby extending the service life of the coating and ensuring the long-term stable magnetic permeability of the electromagnetic bearing.

[0013] Preferably, the cross-section of the iron core teeth is designed as an arc with a radius of 5mm, which allows for a higher fit between the iron core and the flat wire, thereby increasing the contact area between the two and improving the magnetic field transmission efficiency, thus enhancing the overall performance of the electromagnetic bearing.

[0014] Preferably, the power supply adapter module includes a wide-voltage compatible DC-DC converter, a low-consumption lithium titanate energy storage unit, and a power supply priority distributor. The wide-voltage compatible DC-DC converter is used to convert the AC power from the power grid into stable DC power to power the electromagnetic bearing and the energy consumption control submodule. The low-consumption lithium titanate energy storage unit is used to start in the event of an external power supply failure to provide emergency power to the core components. It also adapts to the instantaneous energy consumption during the initial startup of the special structure, achieving the effects of multi-source power supply compatibility, stable power supply, and emergency protection for the electromagnetic bearing, ensuring the reliable operation of the electromagnetic bearing under different operating conditions.

[0015] A flywheel energy storage efficiency optimization system includes a flywheel body, a drive motor, and an electromagnetic bearing assembly. The electromagnetic bearing assembly uses the aforementioned flat wire tightly wound electromagnetic bearing and also includes a spiral microchannel phase change cooling pump, an energy consumption control submodule, an embedded multi-parameter sensor group, and a remote communication module. The spiral microchannel phase change cooling pump is connected to the microchannel in the flat wire tightly wound electromagnetic bearing to drive the phase change material circulation for active temperature control. The energy consumption control submodule is integrated into the original intelligent control unit of the equipment to monitor the rotor and winding status in real time and dynamically adjust the energy output and energy distribution. The embedded multi-parameter sensor group is used to collect winding temperature, vibration amplitude, coil inductance, rotor offset, and speed parameters. The remote communication module is used to upload the equipment status to a remote monitoring center. The power supply priority distributor is preset with a "low-loss system with cooperative structure". The power supply priority is set as follows: "Single-winding electromagnetic bearing > Helical microchannel phase change heat pump > Energy consumption control submodule > Embedded multi-parameter sensor group > Remote communication module". Intelligent relay groups enable dynamic on / off switching and power regulation of each component. By integrating the helical microchannel phase change heat pump, energy consumption control submodule, embedded multi-parameter sensor group, and remote communication module, and working closely with the flat-wire tightly wound electromagnetic bearing using an innovative collaborative structure, the system achieves comprehensive technical effects such as efficient heat dissipation, dynamic stability adjustment, precise status monitoring and data support, remote monitoring and management, priority power supply optimization, and structural performance breakthroughs. This significantly improves the energy efficiency ratio, operational stability, and reliability of the flywheel energy storage system, while reducing operation and maintenance costs and energy consumption. This provides strong support for the widespread application of flywheel energy storage in scenarios such as grid frequency regulation and new energy consumption.

[0016] The beneficial effects of this invention are: 1. Flat wire integrated structure with layered staggered tight winding and spiral microchannel phase change heat dissipation: High slot fill factor is ensured by layered staggered tight winding, while spiral microchannels are opened inside the flat wire and filled with composite phase change material to solve the local heat dissipation bottleneck of flat wire tight winding and achieve high filling and low heat dissipation loss synergy.

[0017] 2. Protective structure between the tightly wound flat wire layers with elastic buffer insulation layer and positioning buckle: A modified silicone rubber composite buffer layer is set between the tightly wound flat wire layers, which is used in conjunction with the iron core positioning buckle to fix the winding. This does not affect the slot fill factor, but can also distribute dynamic stress and avoid flat wire deformation and interlayer short circuit.

[0018] 3. Synergistic Magnetic Circuit Structure of Nanoscale Magnetic Coating, Arc-Shaped Iron Core Teeth, and Closely Wound Flat Wire: By coupling the nanoscale magnetic coating on the flat wire surface and the arc-shaped iron core teeth with the closely wound flat wire, air gap and leakage magnetic loss are reduced, electromagnetic force output density is increased, and the limitation of poor compatibility between the closely wound structure and magnetic permeability characteristics is overcome. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. The accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0021] Figure 1 This is a schematic diagram of the structure of the flat wire tightly wound electromagnetic bearing of the present invention; Figure 2 This is a schematic diagram of the microchannel structure on the flat wire of the present invention.

[0022] The reference numerals in the figures include: 1. Flat wire winding; 2. Raised section; 3. Elastic buffer layer; 11. Microchannel. Detailed Implementation

[0023] Reference Figures 1 to 2 A flat wire tightly wound electromagnetic bearing includes an iron core and a flat wire winding 1. The iron core has teeth, and the flat wire winding 1 is wound around the teeth of the iron core. It also includes a power supply adapter module and an energy consumption control submodule. The power supply adapter module is used to be compatible with multiple energy inputs and dynamically allocate power. The energy consumption control submodule is used to monitor the rotor and winding status in real time and dynamically adjust the energy output and energy distribution. The flat wire has microchannels 11 that run through both ends of the flat wire length direction. The microchannels 11 are filled with phase change material. The phase change material achieves active temperature control by absorbing the heat generated during the operation of the winding.

[0024] With the above-described structural setup, during use, the basic electromagnetic architecture is constructed by winding the flat wire winding 1 around a toothed iron core. Simultaneously, a power supply adapter module enables compatibility with multiple energy inputs and dynamic power distribution. Combined with the energy consumption control submodule, which monitors the rotor and winding status in real time and dynamically adjusts energy output and distribution, and the phase change material in the microchannels 11 running through both ends of the flat wire actively absorbs and controls the temperature of the winding's operating heat, this series of technologies work synergistically to achieve efficient utilization and precise management of electromagnetic bearing energy, stable monitoring of operating status, and effective temperature control. Ultimately, this achieves the desired effects of improving energy utilization efficiency, enhancing system operational stability, extending equipment lifespan, and ensuring long-term stable operation.

[0025] Specifically, the microchannel 11 is spirally arranged along the length of the flat line, and the phase change material is a paraffin-graphene composite phase change material with a phase change temperature of 45℃ and a thermal conductivity of 20W / (m). K), the spiral structure increases the contact area between the phase change material and the flat wire, enabling the composite phase change material with high thermal conductivity to absorb the heat generated by the operation of the flat wire winding 1 more quickly, achieving efficient and precise active temperature control of the flat wire winding 1, effectively avoiding the deterioration and damage of the winding performance caused by excessive temperature, and ensuring the long-term stable operation of the electromagnetic bearing.

[0026] Specifically, the flat wire winding 1 is composed of multiple flat wires.

[0027] Specifically, an elastic buffer layer 3 is set between the flat wires. The elastic buffer layer 3 is made of insulating material. The elastic buffer layer 3 is used to prevent the flat wires from being directly squeezed and deformed. It can prevent the flat wires from being directly squeezed and deformed, thus achieving the effect of protecting the structural integrity of the flat wires, extending the service life of the flat wires, and thus ensuring the stable operation of the electromagnetic bearing winding.

[0028] Specifically, the elastic buffer layer 3 is disposed between every three turns of flat wire. The elastic buffer layer 3 is made of a composite material of modified silicone rubber and glass fiber cloth, which not only ensures insulation, but also utilizes the elasticity of modified silicone rubber and the strength of glass fiber cloth to better disperse the pressure between the flat wires, thereby achieving a more effective flat wire protection effect and improving the reliability and stability of the winding.

[0029] Specifically, the elastic buffer layer 3 is provided with micro protrusions 2. The array of micro protrusions 2 is distributed on both sides of the elastic buffer layer 3. The micro protrusions 2 are arranged in a circle with a diameter of 0.1mm and a spacing of 2mm between two adjacent micro protrusions 2. This increases the contact friction between the elastic buffer layer 3 and the flat wire, further stabilizes the position of the flat wire, and achieves the effect of enhancing the stability of the winding structure. At the same time, it facilitates the elastic deformation of the micro protrusions 2 for buffering.

[0030] Specifically, a nano-magnetic coating is provided on the flat wire. The nano-magnetic coating is used to guide the magnetic field to form a closed magnetic circuit along the surface of the flat wire and the iron core teeth, reducing air gap and leakage magnetic loss, thereby improving the magnetic field utilization efficiency and operating performance of the electromagnetic bearing.

[0031] Specifically, the nano-magnetic coating is an Fe-Ni-Cr nano-magnetic coating. The surface of the nano-magnetic coating is passivated to improve corrosion resistance. While ensuring good magnetic permeability, the corrosion resistance of the coating is improved, thereby extending the service life of the coating and ensuring the long-term stable magnetic permeability of the electromagnetic bearing.

[0032] Specifically, the cross-section of the iron core teeth is designed as a circular arc with a radius of 5mm, which allows for a higher degree of fit between the iron core and the flat wire, thereby increasing the contact area between the two and improving the magnetic field transmission efficiency, thus enhancing the overall performance of the electromagnetic bearing.

[0033] Specifically, the power supply adaptation module includes a wide voltage adaptation unit, an emergency energy storage unit, and a power supply priority distributor. The wide voltage adaptation unit is used to convert the AC power from the power grid into stable DC power to power the electromagnetic bearing and the energy consumption control submodule. The lithium titanate low-consumption energy storage unit is used to start up in the event of an external power supply failure to provide emergency power to the core components. At the same time, it adapts to the instantaneous energy consumption at the initial stage of the special structure's startup, achieving the effects of multi-source power supply compatibility, stable power supply, and emergency protection for the electromagnetic bearing, ensuring the reliable operation of the electromagnetic bearing under different operating conditions.

[0034] Specifically, the wide voltage adaptation unit is a wide voltage adaptation DC-DC converter, and the emergency energy storage unit is a low-power lithium titanate energy storage unit.

[0035] A flywheel energy storage efficiency optimization system includes a flywheel body, a drive motor, and an electromagnetic bearing assembly. The electromagnetic bearing assembly uses the aforementioned flat wire tightly wound electromagnetic bearing and also includes a spiral microchannel phase change cooling pump, an energy consumption control submodule, an embedded multi-parameter sensor group, and a remote communication module. The spiral microchannel phase change cooling pump is connected to the microchannel 11 in the flat wire tightly wound electromagnetic bearing to drive the phase change material circulation for active temperature control. The energy consumption control submodule is integrated into the original intelligent control unit of the equipment to monitor the rotor and winding status in real time and dynamically adjust the energy output and energy distribution. The embedded multi-parameter sensor group is used to collect winding temperature, vibration amplitude, coil inductance, rotor offset, and speed parameters. The remote communication module is used to upload the equipment status to a remote monitoring center. The power supply priority allocator is preset with a "low-voltage" parameter including a cooperative structure. The power supply priority is set as follows: "loss-inducing single-winding electromagnetic bearing > spiral microchannel phase change heat pump > energy consumption control submodule > embedded multi-parameter sensor group > remote communication module". Intelligent relay groups enable dynamic on / off switching and power regulation of each component. By integrating the spiral microchannel phase change heat pump, energy consumption control submodule, embedded multi-parameter sensor group, and remote communication module, and working closely with the flat wire tightly wound electromagnetic bearing using an innovative collaborative structure, the system achieves comprehensive technical effects such as efficient heat dissipation, dynamic stability adjustment, accurate status monitoring and data support, remote monitoring and management, priority power supply optimization, and structural performance breakthroughs. This significantly improves the energy efficiency ratio, operational stability, and reliability of the flywheel energy storage system, while reducing operation and maintenance costs and energy consumption. This provides strong support for the widespread application of flywheel energy storage in scenarios such as grid frequency regulation and new energy consumption.

[0036] This system, based on the core concept of "source reduction + high-efficiency energy supply," addresses the bottleneck of flat wire tightly wound structures in flywheel energy storage electromagnetic bearings. It innovatively adds a collaborative structure of "11-layer spiral microchannel heat dissipation layer + elastic buffer insulation layer + nano-magnetic coating," while optimizing the energy supply module and control logic to construct a collaborative operation system of "low-consumption support - on-demand energy supply - intelligent regulation," achieving the dual goals of stable rotor levitation and improved equipment energy efficiency. The core components and operating logic are as follows: (i) Low-loss single-winding electromagnetic bearing with cooperative structure As the core component of the rotor suspension support, based on the "nanocrystalline alloy iron core + flat wire dense winding", three special structures are added to form an integrated design of "material-structure-function", which solves the problems of heat dissipation, stress and magnetic permeability from the source: Flat wire body and spiral microchannel 11 heat dissipation layer: The flat wire is made of high-purity oxygen-free copper with a cross-sectional size of 8mm × 2mm. Spiral microchannels 11 are formed along the length of the flat wire, penetrating both ends. The interior is filled with a paraffin-graphene composite phase change material with a phase change temperature of 45℃ and a thermal conductivity of 20W / (m²). K); Working logic: When the winding temperature rises to 45℃, the composite phase change material absorbs heat and changes from solid to liquid. The heat is quickly transferred to the flat wire surface through thermal convection in the microchannel 11. When the temperature drops below 40℃, the material solidifies and releases heat. Together with the external air cooling system, a dual heat dissipation mechanism of "active phase change heat dissipation + passive air cooling" is formed to ensure that the maximum winding temperature is controlled below 60℃.

[0037] Elastic buffer insulation layer: An elastic buffer insulation layer is set between every three turns of flat wire. It is made of "modified silicone rubber + glass fiber cloth" composite material, with micro bumps of 0.1mm in diameter and 2mm in spacing evenly distributed between the layers. Working logic: When the rotor's dynamic offset causes the local stress on the winding to increase, the elastic buffer layer 3 disperses the stress through the deformation of the micro-protrusions, preventing the flat wire from being directly squeezed and deformed; the glass fiber cloth enhances the interlayer insulation performance, raising the breakdown voltage to over 3kV, and preventing additional energy consumption caused by interlayer partial discharge.

[0038] Nanoscale magnetic coating coupled with iron core: Fe-Ni-Cr nanoscale magnetic coating is prepared on the outer surface of flat wire using magnetron sputtering process. The coating surface is passivated to improve corrosion resistance. The cross-section of the nanocrystalline alloy iron core teeth is designed as an arc with a radius of 5mm, which improves the fit between the iron core and the flat wire to 95%, and reduces the air gap length between the winding and the iron core from 0.3mm to 0.15mm. Working logic: The nano-magnetic coating guides the magnetic field to form a closed magnetic circuit along the surface of the flat wire and the teeth of the iron core; the reduction of the air gap increases the electromagnetic force output density, and no additional excitation current is required during dynamic adjustment, further reducing energy consumption.

[0039] Overall winding process: The "layered dense winding + positioning buckle" process is adopted. After every three turns of flat wire are wound, they are fixed by the plastic positioning buckle preset in the iron core teeth to ensure that the overall concentricity deviation of the winding is ≤0.05mm. After the winding is completed, the openings of the microchannel 11 at both ends of the winding are sealed, leaving only the liquid inlet and outlet interfaces to ensure that the microchannel 11 does not leak liquid for a long time and maintains stable heat dissipation performance.

[0040] (II) High-efficiency power supply adaptation module To address the energy consumption characteristics of electromagnetic bearings with collaborative structures, the parameters and logic of the power supply module are optimized to ensure synergy between energy supply and structural function, thereby improving power supply efficiency and reliability. The core components consist of a wide voltage-adaptive DC-DC converter, a low-power lithium titanate energy storage unit, and a power supply priority distributor.

[0041] Wide voltage compatible DC-DC converter: The input voltage range covers 220V / 380V AC mains and 48V / 72V equipment backup batteries; a new temperature voltage compensation function is added, which collects the winding temperature in real time through an embedded temperature sensor. When the temperature is >50℃, the output voltage is automatically increased by 3%-5% to compensate for the decrease in electromagnetic force caused by the increase in wire resistance and avoid affecting the levitation stability.

[0042] Lithium titanate low-power energy storage unit: with a capacity of 80-250Wh, using lithium titanate electrode material, and a cycle life of over 20,000 cycles; normally in a low-power standby state, it only starts up when there is an external power failure to provide emergency power to the core components, while also adapting to the instantaneous energy consumption at the initial stage of special structure startup.

[0043] Power supply priority allocator: presets the power supply priority of "low-loss single-winding electromagnetic bearing with cooperative structure > spiral microchannel phase change heat pump > energy consumption control submodule > embedded multi-parameter sensor group > remote communication module", and realizes dynamic on / off and power regulation of power supply to each component through intelligent relay group.

[0044] Operating Logic: Under normal operating conditions, the wide-voltage adaptable DC-DC converter directly converts the AC power from the grid into stable DC power to power the electromagnetic bearing and energy consumption control submodule. The cooling pump operates at a base speed of 1500 r / min, the sensor group collects data at a frequency of 1 kHz, and the communication module uploads device status every 30 seconds. In standby mode, the power priority distributor automatically reduces the sampling frequency of the sensor group to 200 Hz and shuts down the remote communication module. At the same time, the DC-DC converter reduces the power supply current of the electromagnetic bearing to the "floating critical current" to reduce standby energy consumption. In the event of an external power failure, the lithium titanate low-power energy storage unit completes the power supply switch within <10 ms and provides emergency power to the electromagnetic bearing and cooling pump through the DC-DC converter. After the grid is restored, it automatically switches back to grid power and uses a 0.1C trickle charge mode to charge the energy storage unit, avoiding lifespan degradation caused by high current charging.

[0045] (III) Energy Consumption Control Submodule The FPGA logic controller, integrated into the original intelligent control unit of the equipment, adds a "structural status-energy consumption" linkage control strategy, which dynamically adjusts energy consumption output and energy distribution by monitoring the rotor and winding status in real time.

[0046] Condition monitoring and data acquisition: The embedded multi-parameter sensor group collects parameters such as winding temperature, vibration amplitude, coil inductance, rotor offset, and rotation speed in real time, with a data update frequency of ≥1kHz to ensure accurate condition perception.

[0047] Hierarchical control logic: In steady-state control, the control submodule stabilizes the electromagnetic bearing current at the "floating critical current" while monitoring the energy storage unit's charge level. Grid power replenishment is only initiated when the charge level is less than 20%. The cooling pump maintains its base speed to avoid excessive energy consumption. If the winding temperature exceeds 45°C, the cooling pump speed is immediately increased to 2500 r / min, while the excitation winding current fluctuation is controlled within ±5% to prevent further heat accumulation. When the temperature is less than 40°C, the cooling pump's base speed and current adjustment range are restored. If the winding vibration amplitude exceeds 0.1 mm, a gradual current adjustment is used, reducing the current change rate from 5 A / ms to 2 A / ms. This, combined with the elastic buffer layer 3, disperses stress and reduces dynamic force impact. If the coil inductance decreases by more than 10%, the excitation current frequency is finely adjusted from 1 kHz to 1.2 kHz. This, combined with a nano-magnetic coating, compensates for magnetic flux loss and prevents increased energy consumption.

[0048] Under extreme operating conditions, the emergency energy-saving mode is immediately triggered, cutting off the power supply to non-core components such as the communication module and data storage module, and concentrating energy to supply the electromagnetic bearing and cooling pump; if the mechanical auxiliary bearing intervenes, the output of the energy storage unit is simultaneously cut off to prevent the components from being damaged by the inrush current; after the rotor stabilizes, the power supply to non-core components and the charging of the energy storage unit are gradually restored.

[0049] It is worth noting that the layered staggered close winding in this application is a close winding process that switches layers every three turns and reserves space for functional layers. That is, the layered method makes each layer of winding staggered relative to the previous layer, thereby improving the slot filling rate (reducing gaps) and avoiding local overheating between windings, so as to improve the slot filling rate and be compatible with heat dissipation / buffering layers. The positioning buckle is a plastic fixing component pre-set in the iron core teeth, which fixes the winding every three turns and seals the microchannel 11 to ensure concentricity and heat dissipation sealing. Both together ensure the compactness of the winding structure and the reliability of its function.

[0050] The above descriptions provide one or more embodiments in conjunction with specific details, but do not imply that the specific implementation of the present invention is limited to these descriptions. Any methods or structures that are similar to or identical to those of the present invention, or any technical deductions or substitutions made based on the concept of the present invention, should be considered within the scope of protection of the present invention.

Claims

1. A flat wire close-wound electromagnetic bearing, comprising a core and a flat wire winding (1), the core being provided with tooth portions, and the flat wire winding (1) being wound around the tooth portions of the core; characterized in that: It also comprises a power supply adaptation module and an energy consumption control submodule, the power supply adaptation module is used for compatible multi-source input energy and dynamic power distribution, the energy consumption control submodule is used for real-time monitoring of rotor and winding state, dynamic adjustment of energy consumption output and energy distribution; The flat wire is provided with a microchannel (11), and a phase change material is arranged in the microchannel (11). The phase change material realizes active temperature control by absorbing heat generated during winding operation.

2. A flat wire, close wound electromagnetic bearing according to claim 1, characterized in that: The micro-channels (11) are arranged in a spiral along the length direction of the flat wire, the phase change material is a paraffin-graphene composite phase change material, the phase change temperature is 45 DEG C, and the thermal conductivity is 20 W / (m K).

3. A flat wire, close wound electromagnetic bearing according to claim 1, characterized in that: An elastic buffer layer (3) is arranged between the flat wires, the elastic buffer layer (3) is made of insulating material, and the elastic buffer layer (3) is used to prevent the flat wires from being directly extruded and deformed.

4. A flat wire, close wound electromagnetic bearing according to claim 3, wherein: The elastic buffer layer (3) is arranged between every three turns of flat wires, and the elastic buffer layer (3) is made of a composite material of modified silicone rubber and glass fiber cloth.

5. A flat wire, close wound electromagnetic bearing according to claim 3 or 4, characterised in that: The elastic buffer layer (3) is provided with a micro convex (2), the micro convex (2) is arrayed on the front and back sides of the elastic buffer layer (3), the micro convex (2) is circular, the diameter of the micro convex (2) is 0.1mm, and the distance between adjacent two micro convexes (2) is 2mm.

6. A flat wire, close wound electromagnetic bearing according to claim 1, characterized in that: The flat wire is provided with a nano magnetic conductive coating, the nano magnetic conductive coating is used to guide the magnetic field to form a closed magnetic circuit along the surface of the flat wire and the tooth part of the iron core, and reduce air gap and magnetic loss.

7. A flat wire, close wound electromagnetic bearing according to claim 6, characterized in that: The nano magnetic conductive coating is an Fe-Ni-Cr coating, and the surface of the nano magnetic conductive coating is passivated to improve corrosion resistance.

8. A flat wire, close wound electromagnetic bearing according to claim 1, wherein: The tooth part of the iron core is designed as a circular arc with a radius of 5mm, so that the flat wire is more closely attached to the iron core.

9. A flat wire, close wound electromagnetic bearing according to claim 1, wherein: The power supply adaptation module comprises a wide voltage adaptation unit, an emergency energy storage unit and a power supply priority distributor, the wide voltage adaptation unit is used to convert grid alternating current into stable direct current to supply power to the electromagnetic bearing and the energy consumption control submodule; the emergency energy storage unit is used to start when external power supply fails, to provide emergency power supply for core components, and to adapt to the instantaneous energy consumption of special structure at the initial start.

10. A flywheel energy storage energy efficiency optimization system comprising a flywheel body, a drive motor and an electromagnetic bearing assembly; characterized by, The electromagnetic bearing assembly adopts the flat wire close-wound electromagnetic bearing of any one of claims 1-9, further comprising a spiral microchannel phase change heat dissipation pump, an energy consumption control submodule, an embedded multi-parameter sensor group and a remote communication module; the spiral microchannel phase change heat dissipation pump is connected with the microchannel (11) in the flat wire close-wound electromagnetic bearing, and is used to drive the phase change material to circulate to realize active temperature control; the energy consumption control submodule is integrated in the original intelligent control unit of the device, and is used to monitor the rotor and winding state in real time, and dynamically adjust the energy consumption output and energy distribution; the embedded multi-parameter sensor group is used to collect winding temperature, vibration amplitude, coil inductance value, rotor offset and rotating speed parameters; the remote communication module is used to upload the device state to the remote monitoring center.

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