Segmented three-dimensional curved surface magnetic coupler and wireless excitation system

Abstract

The application discloses a segmented three-dimensional curved surface magnetic coupler and a wireless excitation system, and relates to the field of motor design.The magnetic coupler comprises a transmitting end curved surface assembly and a receiving end curved surface assembly arranged on the radial inner side of the transmitting end curved surface assembly.The transmitting end curved surface assembly and the receiving end curved surface assembly both comprise a segmented three-dimensional curved surface shell formed by splicing a plurality of curved surface segmented units arranged in sequence in the circumferential direction;a magnetic layer arranged on the segmented three-dimensional curved surface shell;coil skeletons formed by splicing a plurality of skeleton segmented units corresponding to the curved surface segmented units;curved surface coils;and air gaps between the two curved surface coils.The magnetic coupler has the advantages of considering both three-dimensional offset resistance and manufacturing and assembling feasibility.

Description

Technical Field

[0001] This application relates to the field of motor design, and in particular to a segmented three-dimensional curved surface magnetic coupler and a wireless excitation system. Background Technology

[0002] Currently, wireless excitation systems typically employ a transmitting coil on the stator side and a receiving coil on the rotor side, achieving non-contact energy transfer across the air gap through magnetic field coupling. Existing wireless power transfer magnetic couplers mostly utilize structures such as planar circular coils, planar rectangular coils, or double D coils. While these structures can achieve good energy transfer under ideal alignment, during actual motor operation, factors such as machining and assembly errors, bearing clearance, thermal deformation, axial movement, and rotor vibration often lead to radial, axial, and angular misalignment between the transmitting and receiving ends. This results in a reduction in the effective magnetic field overlap area, a decrease in the coupling coefficient, and fluctuations in output power, ultimately affecting the stability of the rotor excitation current.

[0003] To improve energy transfer performance under offset conditions, existing technologies have proposed curved coil structures such as spherical and spherical cap surfaces, which improve the spatial distribution of the magnetic field by introducing curvature. Compared with planar structures, curved structures can improve the resistance to offset to a certain extent. However, existing curved magnetic coupling structures mostly adopt integral curved coils or integral curved support structures, which still face problems in practical engineering applications, such as the difficulty of curved winding and assembly, the difficulty of adjusting local parameters, and the inconvenience of repair and replacement after damage. Especially in the scenario of wireless excitation of electrically excited synchronous motors, how to balance the resistance to three-dimensional offset and the feasibility of manufacturing and assembly is a key issue that needs to be considered. Summary of the Invention

[0004] The purpose of this application is to provide a segmented three-dimensional curved surface magnetic coupler and wireless excitation system that takes into account both resistance to three-dimensional displacement and manufacturing and assembly feasibility.

[0005] To achieve the above objectives, this application provides the following solution: In a first aspect, this application provides a segmented three-dimensional curved surface magnetic coupler for realizing wireless excitation of the rotor of an electrically excited synchronous motor, including a transmitting curved surface assembly and a receiving curved surface assembly disposed radially inside the transmitting curved surface assembly, wherein both the transmitting curved surface assembly and the receiving curved surface assembly include: A segmented three-dimensional curved surface shell formed by splicing together multiple curved surface segments arranged sequentially along the circumference; A magnetic layer disposed on the segmented three-dimensional curved surface shell; A coil skeleton is formed by splicing together multiple skeleton segment units corresponding to the surface segment units.

[0006] Curved coil; In the transmitter curved surface assembly, the coil frame is disposed on the radial inner side of the segmented three-dimensional curved surface shell, and the curved surface coil is wound around the radial inner side of the coil frame; In the receiving end curved surface assembly, the coil frame is disposed on the radial outer side of the segmented three-dimensional curved surface housing, and the curved surface coil is wound on the radial outer side of the coil frame. There is an air gap between the two curved coils.

[0007] In some embodiments, each of the curved surface segment units is provided with a limiting structure for forming a wire bypass path; After multiple curved surface segment units are spliced ​​together, multiple limiting structures can form a continuous wire bypass path; The curved coil is wound around the coil frame along the path of the conductor.

[0008] In some embodiments, multiple curved surface segment units are spliced ​​together by snap-fitting, interlocking, screwing, gluing, or any combination thereof to form the segmented three-dimensional curved surface shell.

[0009] In some embodiments, the magnetic layer is one of a flexible ferrite layer, a soft magnetic composite material layer, or a discrete magnetic unit array; And / or, the magnetic layer is composed of a plurality of magnetic segment units respectively disposed on a plurality of the curved surface segment units.

[0010] In some embodiments, after multiple curved surface segmentation units are spliced ​​together, multiple magnetic segmentation units can form a continuous magnetic layer.

[0011] In some embodiments, the curved coil is formed by continuously winding a single wire across multiple skeleton segment units; Alternatively, the curved coil is formed by connecting multiple segmented windings wound on each skeleton segment unit in series, parallel, or a combination of series and parallel.

[0012] In some embodiments, the number of surface segmentation units is 3 to 12.

[0013] In some embodiments, the curvature of the transmitter curved surface assembly and / or the receiver curved surface assembly is 30°-180°.

[0014] In a second aspect, this application provides a wireless excitation system for an electrically excited synchronous motor, including a transmitter excitation power supply device, a receiver excitation power supply device, and a segmented three-dimensional curved surface magnetic coupler as described in the first aspect. The transmitting curved surface component of the segmented three-dimensional curved surface magnetic coupler is connected to the transmitting excitation power supply device, and the receiving curved surface component of the magnetic coupler is connected to the receiving excitation power supply device.

[0015] The curved coil in the receiving end curved component has a wire suitable for passing through the inside of the shaft, the inside of the rotor part, or the wire groove opened along the shaft axis of the electrically excited synchronous motor, and the wire is connected to the receiving end excitation power supply device.

[0016] According to the specific embodiments provided in this application, the following technical effects are disclosed: This application provides a segmented three-dimensional curved surface magnetic coupler and a wireless excitation system. By adopting a three-dimensional curved surface configuration, the spatial coverage of the magnetic field is expanded. This ensures that even when there are three-dimensional offsets (radial, axial, and angular) between the curved surface components at the transmitting and receiving ends, a large effective magnetic field overlap area and a stable coupling coefficient are maintained, thereby ensuring the stability and reliability of the wireless excitation power supply. Building upon this, by decomposing the complex integral curved surface shell, magnetic layer, and coil frame into multiple simple segmented units, the complex integral curved surface manufacturing task is broken down into multiple simple segmented unit manufacturing tasks. This significantly reduces the difficulty of processing, manufacturing, coil winding, and on-site assembly, improving manufacturing and assembly feasibility and production efficiency. Simultaneously, the modular segmented design makes localized repair and replacement possible. When a segment is damaged, only the corresponding unit needs to be replaced, greatly reducing the overall lifecycle maintenance cost. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram illustrating the application of a segmented three-dimensional curved surface magnetic coupler in one embodiment of this application; Figure 2 This is a schematic diagram of a segmented three-dimensional curved surface magnetic coupler in one embodiment of this application; Figure 3 This is a schematic diagram of the air gap structure in one embodiment of this application; Figure 4 This is a schematic diagram of the structure of the rotating shaft and its internal wire channel in one embodiment of this application; Figure 5 This is a schematic diagram of the geometric parameters of a segmented three-dimensional curved surface shell in one embodiment of this application; Figure 6 This is a schematic diagram of the Y-axis offset of a segmented three-dimensional curved surface magnetic coupler in one embodiment of this application; Figure 7 This is a schematic diagram of the X-axis offset of a segmented three-dimensional curved surface magnetic coupler in one embodiment of this application; Figure 8 This is a schematic diagram of the Z-axis offset of a segmented three-dimensional curved surface magnetic coupler in one embodiment of this application. Detailed Implementation

[0019] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0020] To make the above-mentioned objectives, features and advantages of this application more apparent and understandable, the application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0021] The specific embodiments of this application provide a segmented three-dimensional curved surface magnetic coupler, which aims to solve the problems that existing curved surface magnetic coupling structures mostly adopt integral curved surface coils or integral curved surface support structures, which still face problems such as the difficulty of curved surface winding and assembly, difficulty in adjusting local parameters, and inconvenience in repair and replacement after damage in practical engineering applications.

[0022] Figure 1 This is a schematic diagram illustrating the application of a segmented three-dimensional curved surface magnetic coupler in one embodiment of this application. Figure 2 This is a schematic diagram of a segmented three-dimensional curved surface magnetic coupler in one embodiment of this application.

[0023] exist Figure 1 In the diagram, the curved surface assembly at the transmitting end is marked as 10, the curved surface assembly at the receiving end is marked as 20, the excitation synchronous motor is marked as 30, and the rotor windings, shaft, and internal wire channels of the excitation synchronous motor are marked as 31, 32, and 33, respectively. Figure 2 In the transmitter curved surface assembly 10, the segmented three-dimensional curved surface shell, coil frame, and curved surface coil are labeled as 11, 12, and 13, respectively. In the receiver curved surface assembly 20, the segmented three-dimensional curved surface shell, coil frame, and curved surface coil are labeled as 21, 22, and 23, respectively.

[0024] Reference Figure 1 and Figure 2 In one specific embodiment, the segmented three-dimensional curved surface magnetic coupler is mainly used for wireless excitation of electrically excited synchronous motors, and includes a transmitting curved surface assembly and a receiving curved surface assembly disposed on its radial inner side.

[0025] Specifically, both the transmitter and receiver curved surface components employ an innovative layered, segmented design in their core structure. This design is based on a segmented three-dimensional curved surface shell. This shell is not a traditional monolithic structure, but rather composed of multiple circumferentially arranged segmented curved surface units. The purpose of this design is to decompose a complex, difficult-to-manufacture monolithic three-dimensional curved surface into multiple standardized segmented units with simple structures and easy precision manufacturing, fundamentally solving the problems of high manufacturing difficulty, high cost, and low yield of monolithic curved surface structures.

[0026] A magnetic layer is incorporated into the segmented three-dimensional curved shell. This magnetic layer provides a predetermined path with low magnetic resistance for the high-frequency alternating magnetic field, effectively confining the magnetic lines of force within the coupler and reducing leakage to the external space. This allows for more efficient energy convergence from the transmitter to the receiver. By incorporating the magnetic layer, the inefficiency and electromagnetic interference caused by magnetic field divergence in wireless power transmission are effectively resolved, achieving precise magnetic flux guidance and efficient energy coupling.

[0027] In order to accurately form the curved coil for energy transmission, a coil skeleton is also provided, which is formed by splicing together multiple skeleton segment units corresponding to the curved segment units.

[0028] Similar to the housing, the coil frame is also composed of multiple frame segment units corresponding to the curved surface segment units. This segmented frame design inherits the advantages of segmented manufacturing. More importantly, the coil frame is designed with structures to regulate the conductor path, providing a physical reference for the subsequent winding of the curved surface coil.

[0029] A curved coil is wound around a coil frame. This curved coil is a key component for electromagnetic energy conversion. The curved coil at the transmitting end generates an alternating magnetic field, while the curved coil at the receiving end induces the magnetic field and generates current. By precisely winding the coil on a frame with a specific three-dimensional curvature, a three-dimensional coupling field with a wide overlap area is formed between the transmitting and receiving coils. This is the core physical basis for the solution's ability to resist three-dimensional offset. Compared to planar coils, whose coupling area decreases sharply when offset occurs, the three-dimensional curved coil of this application can still maintain a considerable effective coupling area even with radial, axial, or angular offsets, thus maintaining the stability of the coupling coefficient.

[0030] To ensure coordinated operation between the transmitter and receiver, this specific embodiment incorporates a tailored structural design. In the transmitter's curved surface assembly, the coil frame is located radially inner to the segmented three-dimensional curved surface housing, while the curved coil is further wound radially inner to the coil frame. Correspondingly, in the receiver's curved surface assembly, the coil frame is located radially outer to its segmented three-dimensional curved surface housing, and the curved coil is wound radially outer to the coil frame. In this way, when the receiver's curved surface assembly is mounted radially inner to the transmitter's curved surface assembly, the curved coils of both can be brought close together with their concave and convex surfaces facing each other, leaving only a necessary air gap for non-contact rotation, as shown in the attached diagram. Figure 3 As shown. This "face-to-face" arrangement allows magnetic field lines to cross the air gap through the shortest path and couple from the transmitting coil to the receiving coil, maximizing mutual inductance and optimizing energy transfer efficiency.

[0031] In summary, the segmented three-dimensional curved surface magnetic coupler in this specific embodiment, by adopting a three-dimensional curved surface configuration, expands the spatial coverage of the magnetic field. This ensures that even with three-dimensional offsets (radial, axial, and angular) between the transmitting and receiving curved surface components, a large effective magnetic field overlap area and a stable coupling coefficient are maintained, thereby guaranteeing the stability and reliability of wireless excitation power supply. Building upon these advantages, by decomposing the complex integral curved surface shell, magnetic layer, and coil frame into multiple simple segmented units, the complex overall curved surface manufacturing task is broken down into multiple simple segmented unit manufacturing tasks. This significantly reduces the difficulty of processing, manufacturing, coil winding, and on-site assembly, improving production efficiency. Simultaneously, the modular segmented design makes localized repair and replacement possible; when a segment is damaged, only the corresponding unit needs to be replaced, greatly reducing the overall lifecycle maintenance cost.

[0032] In some embodiments, each curved surface segment unit is provided with a limiting structure for forming a wire winding path; after multiple curved surface segment units are spliced ​​together, multiple limiting structures can form a continuous wire winding path; the curved surface coil is wound on the coil frame along the wire winding path.

[0033] Specifically, to ensure the curved coil can be precisely and securely fixed on the complex curved surface, each curved segment unit is equipped with a limiting structure to form the winding path of the conductor. These limiting structures can be winding slots, conductor limiting slots, conductor transition slots, or conductor positioning parts, etc. When multiple skeleton segment units are spliced ​​into a complete coil skeleton, these limiting structures distributed on each skeleton segment unit can be connected end to end to form a continuous and smooth overall conductor winding path. The curved coil is wound along this preset path. This design solves the problems that easily occur when winding on an unguided curved surface, such as conductor slippage, uneven turn spacing, and irregular coil shape. Through physical structural constraints, it ensures that each turn of the coil is precisely in the designed position, thereby ensuring that the final magnetic field distribution is highly consistent with the theoretical design, providing a process guarantee for achieving a high-performance, highly consistent magnetic coupler.

[0034] In some embodiments, the function of the coil frame can be integrated with the segmented three-dimensional curved surface housing. Specifically, the limiting structure can be integrally formed directly on the inner or outer wall of each curved surface segment unit, for example, by injection molding to directly form the winding groove. In this case, the curved surface segment unit itself acts as part of the coil frame, and the curved coil can be directly wound on the assembled segmented three-dimensional curved surface housing. This design simplifies the number of parts, reduces assembly complexity, and thus further reduces manufacturing costs.

[0035] In some embodiments, multiple curved surface segment units are spliced ​​together by snap-fitting, interlocking, screwing, gluing, or any combination thereof to form a segmented three-dimensional curved surface shell.

[0036] Specifically, the splicing methods for multiple curved surface segment units can be varied to adapt to different assembly requirements and working environments. For example, snap-fit ​​or interlocking joints, such as dovetail joints, can be used. This method allows for quick assembly, requires no additional fasteners, and facilitates rapid installation and maintenance. Threaded connections can also be used, where adjacent curved surface segment units are fastened together with screws. This method offers high connection strength and reliability, and is suitable for applications with significant vibration. Adhesive bonding can also be used, employing high-temperature resistant, high-strength structural adhesive to bond the curved surface segment units together. This method creates a seamless, airtight structure and avoids electromagnetic interference that may arise from metal fasteners. Of course, any combination of these methods can be used depending on actual needs. For example, threaded connections can be used in critical areas, while snap-fit ​​connections can be used in non-critical areas, balancing reliability and economy. This flexible and diverse splicing method greatly enhances the engineering applicability of the invention.

[0037] In some embodiments, the magnetic layer is one of a flexible ferrite layer, a soft magnetic composite material layer, or a discrete magnetic unit array. Furthermore, the magnetic layer is composed of multiple magnetic segmented units respectively disposed on multiple curved surface segmented units.

[0038] Specifically, this invention provides several options for the implementation of the magnetic layer. In one embodiment, the magnetic layer can be a single, flexible ferrite layer. This flexible material can adhere well to the inner wall of the assembled curved shell, forming a continuous magnetic shielding layer. The process is simple and the cost is low. In another embodiment, the magnetic layer can also be a soft magnetic composite material layer. For example, soft magnetic powder can be mixed with polymer materials and then injection molded or pressed to create a more complex magnetic core structure. In yet another embodiment, the magnetic layer can be an array of multiple discrete magnetic units. That is, multiple small, standardized magnetic material blocks (such as ferrite blocks) are attached or embedded in the inner wall of the segmented curved unit in an array. The advantage of this approach is that the local magnetic field can be finely controlled by adjusting the density, material, or orientation of the discrete units, and local replacement can be easily performed when a magnetic unit is damaged.

[0039] Furthermore, the magnetic layer itself can be designed as a segmented structure, consisting of multiple magnetic segment units respectively set on multiple curved surface segment units. This design, which segments synchronously with the shell, makes the manufacturing and assembly process more unified and simplified.

[0040] Preferably, after multiple curved surface segment units are spliced ​​together, the multiple magnetic segment units can form a continuous magnetic layer, so that the spliced ​​overall magnetic layer maintains a magnetic flux guiding surface that is compatible with the overall curved surface.

[0041] In some embodiments, the curved coil is formed by continuously winding a single wire across multiple skeleton segment units; or, the curved coil is formed by connecting multiple segmented windings wound on each skeleton segment unit in series, parallel, or a combination of series and parallel.

[0042] Specifically, there are several options for forming curved coils. One method involves continuously winding a single conductor across multiple frame segment units. The process involves first assembling all the frame segment units into a complete curved frame, then placing this frame on a winding device and winding it using a single continuous conductor (such as Litz wire) along the continuous winding path formed on the frame. Coils formed in this way have no joints, good electrical continuity, and high reliability. Another method involves connecting multiple segmented windings wound separately on each frame segment unit through series, parallel, or a combination of series and parallel connections. This involves first winding a segmented coil on each independent frame segment unit, forming multiple standardized "coil modules." During final assembly, these segmented coils are connected according to the designed electrical connection method (series connection to increase induced voltage, parallel connection to increase current carrying capacity) using pre-reserved terminals or solder points. The advantage of this approach is that it breaks down the complex overall winding task into simple segmented winding, eliminating the need for large, dedicated curved surface winding equipment, making production organization more flexible, and also enabling modular maintenance and replacement.

[0043] In some embodiments, the geometry of the magnetic coupler is optimized to achieve optimal anti-offset performance and coupling efficiency within the limited space at the motor end. Specifically, the number of curved surface segment units ranges from 3 to 12. Too few segments result in excessively large individual segments, negating the advantages of segmented manufacturing; too many segments lead to cumbersome splicing processes, increased cumulative errors, and excessive space occupation by the connection structure. 3 to 12 segments represent a good balance between manufacturing convenience and structural integrity. Experiments and simulations have verified that this range can accommodate most motor sizes and achieve good overall performance.

[0044] In some embodiments, the curvature of the transmitter curved component and / or receiver curved component is 30°-180°. The curvature determines the "coverage" range of the curved coil in space. A smaller curvature (e.g., 30 degrees) is close to a plane and is suitable for applications with extremely limited axial dimensions; a larger curvature (e.g., 150 degrees or a hemisphere close to 180 degrees) means that the coil has a large extension in both the radial and axial directions, forming a "magnetic bowl" that "encloses" the receiver. When radial or axial offset occurs, although the receiver's position in the "bowl" changes, it remains within the effective coverage of the "bowl," thus greatly maintaining the stability of the coupling coefficient. The range of 30 to 180 degrees covers various configurations from shallow dish shapes to deep bowl shapes, allowing designers to flexibly choose the appropriate curvature according to the requirements for anti-offset capability in different directions.

[0045] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0046] For example, in one embodiment, a high-performance and easily implemented combination scheme is provided. In this scheme, the number of curved segment units is eight, and they are spliced ​​together by screwing, ensuring the structural stability and detachability; the magnetic layer is a stable and easily mounted flexible ferrite layer; and the curved coil is continuously wound using a single conductor with excellent electrical performance. This combination scheme integrates the convenience of segmented manufacturing, the reliability of screwing, the economy of flexible ferrite, and the high reliability of continuous winding, constituting a technically mature, high-performance, and cost-controllable preferred solution, which is very suitable for large-scale industrial production.

[0047] The segmented three-dimensional curved surface magnetic coupler of the present invention will be described in detail below through a complete specific embodiment.

[0048] In one embodiment, the segmented three-dimensional curved surface magnetic coupler includes a transmitter curved surface assembly and a receiver curved surface assembly disposed opposite to each other. The transmitter curved surface assembly is fixed to the stator end cover, the inner side of the housing, or a mounting support fixedly connected to the stator. The receiver curved surface assembly is fixed to the rotor end face, the rotor support disk, or a mounting base that rotates synchronously with the rotor. A coupling air gap is formed between the transmitter and receiver curved surface assemblies. The receiver curved surface assembly rotates synchronously with the rotor to form a non-contact magnetic coupling energy transfer channel between the transmitter and receiver.

[0049] Each curved surface component includes at least a segmented three-dimensional curved surface shell, a magnetic layer disposed on the curved surface shell, a coil frame disposed inside the magnetic layer, and a curved surface coil wound on the coil frame. (Refer to...) Figure 5 A curved shell is a three-dimensional curved surface load-bearing structure formed along a predetermined curvature, and its geometric parameters include at least the surface radius. R t Maximum diameter of curved surface D t Curvature of the surface β t and surface thickness T t The transmitter and receiver curved surface components can use the same surface curvature, or they can use matching curved surface configurations with different surface curvatures depending on the difference in installation space between the stator and rotor sides.

[0050] The segmented three-dimensional curved shell is formed by splicing together multiple curved surface segments arranged sequentially along the circumference. Each curved surface segment can be divided into multiple sub-units along the curvature direction. The number of sub-units in each curved surface segment is denoted as . N s Each sub-unit has a corresponding curved support surface and connection boundary. Adjacent sub-units and adjacent curved surface segments can be connected by snap-fit, interlocking, screwing, gluing, or combinations thereof to form a continuous curved surface. (Refer to...) Figure 5 Preferably, each sub-unit adopts an equal circumferential angle distribution, in which case the circumferential included angle corresponding to each sub-unit is... α i satisfy: ; Surface arc length corresponding to a single sub-unit l i satisfy: ; in, R i The radius of curvature of a single sub-unit.

[0051] When a non-equal segmented layout is used, the circumferential angle of each sub-unit is... α i They may not be equal, but they satisfy: .

[0052] By segmenting the structure as described above, the processability and assembly flexibility of the curved surface can be improved while ensuring the overall coverage of the curved surface.

[0053] A magnetic layer is disposed on the inner or outer surface of each curved surface segment unit, and is preferably a flexible ferrite layer, a soft magnetic composite material layer, or a discrete magnetic unit array. The magnetic layer can be configured as multiple magnetic segment units, each corresponding to a curved surface segment unit. Each magnetic segment unit is attached, embedded, or fixed to the surface of its corresponding curved surface segment unit to constrain the magnetic flux path, reduce magnetic leakage, and enhance the directional magnetic coupling capability between the transmitter and receiver. Preferably, the magnetic segment units are continuously arranged along the curved surface direction so that the spliced ​​overall magnetic layer maintains a magnetic flux guiding surface adapted to the overall curved surface.

[0054] The coil bobbin is located inside or outside the magnetic layer. The bobbin is formed by splicing multiple bobbin segment units, each corresponding to a specific curved surface segment unit. Each bobbin segment unit has winding slots, wire limiting slots, wire transition slots, or wire positioning parts to define the winding trajectory of the wire along the curved surface, ensuring a continuous and orderly spatial winding path on the curved surface formed by the segmented splicing. After the bobbin segment units are assembled, the winding slots and wire positioning parts together form an integral winding channel extending along the curved surface, reducing wire offset and local warping during the curved surface winding process.

[0055] The curved coil is mounted on a coil frame. The curved coil can be formed by continuously winding a single wire across multiple frame segments to create a single curved coil, or by winding multiple segmented winding units separately and then connecting them in series, parallel, or a series-parallel combination to form a single curved coil. The number of turns of the curved coil at the transmitting end is denoted as... N tx The number of turns of the curved coil at the receiving end is denoted as... N rx Specifically, the curved coils at the transmitting end and the receiving end are wound along predetermined curved paths of their respective curved skeletons, so that the transmitting end and the receiving end have a large magnetic field coverage overlap area in both the centering state and the offset state.

[0056] The output terminal of the curved coil at the receiving end is connected to the excitation power supply device at the receiving end via a wire channel. The wire channel can be located inside the rotating shaft, inside the rotor support, or in a wire groove opened along the axial direction of the rotating shaft to achieve the lead-out and protection of the rotating side wires. The excitation power supply device at the receiving end includes at least a rectifier module and a filter module, and may also include a voltage regulator module or an energy storage module if necessary. The DC output current after rectification and filtering is delivered to the rotor excitation winding of the electrically excited synchronous motor to establish the rotor excitation magnetic field.

[0057] Reference Figure 6 , Figure 7 and Figure 8 During motor operation, the curved surface component at the receiving end may experience radial displacement relative to the curved surface component at the transmitting end. δ x , δ y axial offset δ z and angular offsets around the X and Y axes θ x , θ yThe segmented three-dimensional curved surface magnetic coupler expands the magnetic field coverage space through its curved surface configuration and constrains the magnetic field distribution and coil path through its segmented curved surface shell, segmented magnetic layer, and segmented frame. This allows the receiving end to maintain a large effective magnetic field overlap area even when offset occurs, thereby reducing the change in coupling coefficient under offset conditions. Its coupling relationship can be expressed as: ; Under offset conditions, the coupling coefficient can be expressed as: ; in, M For mutual intuition, k The coupling coefficient is... L tx For the self-inductance of the curved coil at the transmitting end, L rx The self-inductance of the curved coil at the receiving end.

[0058] This embodiment uses a segmented three-dimensional curved surface structure to enable offset conditions. k Maintaining a high level and reducing fluctuation amplitude improves the stability of wireless excitation power supply. The above formula is only used to illustrate the electromagnetic coupling relationship of the structure in this embodiment under offset conditions and does not constitute a limitation of the optimization method of this invention.

[0059] In this embodiment, the central axes of the curved surfaces of the transmitter and receiver are coaxial or approximately coaxial with the motor's rotation axis; alternatively, the transmitter and receiver curved surfaces are installed in a non-completely coaxial, compensated manner to accommodate end space constraints and installation tolerances. Preferably, the curved surface openings of the transmitter and receiver curved surfaces are arranged opposite to each other to form a magnetic field converging region facing the coupling air gap.

[0060] In this embodiment, the number of curved surface segment units is 3 to 12; the curvature of the curved surface is 30°-180°; the radius of the curved surface is selected according to the installation radius of the motor end and the size of the target coupling area; the thickness of the magnetic layer, the thickness of the curved surface shell, and the thickness of the frame are determined jointly based on mechanical strength, magnetic flux constraint capability, and installation space. The above parameters are used to limit the preferred range of the device structure of the present invention to adapt to wireless excitation systems for electrically excited synchronous motors of different power levels and different size specifications.

[0061] The present invention also provides a wireless excitation system for an electrically excited synchronous motor, including a transmitter excitation power supply device and a receiver excitation power supply device, as well as a segmented three-dimensional curved surface magnetic coupler provided by the present invention.

[0062] In the segmented three-dimensional curved surface magnetic coupler, the transmitting end curved surface component is connected to the transmitting end excitation power supply device, and the receiving end curved surface component of the magnetic coupler is connected to the receiving end excitation power supply device.

[0063] This system is a specific application of the aforementioned segmented three-dimensional curved surface magnetic coupler. The system includes a transmitting-end excitation power supply device and a receiving-end excitation power supply device, as well as the segmented three-dimensional curved surface magnetic coupler provided in any of the aforementioned embodiments, which serves as the core energy transmission channel. By integrating the segmented three-dimensional curved surface magnetic coupler into the motor end, this system achieves non-contact excitation energy transmission from the stator side to the rotor side without requiring slip ring brush contact power supply, and maintains good excitation output stability even with three-dimensional misalignment and assembly errors.

[0064] Specifically, in this system, the transmitting curved coil assembly of the magnetic coupler is electrically connected to the transmitting excitation power supply device located in the stationary part of the motor (such as the housing or stator end cover); while the receiving curved coil assembly of the magnetic coupler is electrically connected to the receiving excitation power supply device located in the rotating part of the motor (such as the rotor). The transmitting excitation power supply device is responsible for converting external power (such as a battery or grid) into high-frequency alternating current, driving the transmitting coil to generate an alternating magnetic field. The receiving coil induces high-frequency alternating current in the alternating magnetic field, which is then rectified, filtered, and regulated by the receiving excitation power supply device, ultimately outputting a stable and reliable direct current to supply the rotor windings of the electrically excited synchronous motor to establish the required excitation magnetic field. In this way, this system completely replaces the traditional brush and slip ring structure, realizing non-contact power supply to the rotor windings.

[0065] Furthermore, in order to solve the problem of extracting energy from the rotating side, see [reference needed]. Figure 1 and Figure 4 In some embodiments, the curved coil of the receiving end curved coil assembly has a lead wire that is suitable for passing through the interior of the shaft, the rotor section, or a wire channel opened along the shaft axis of the electrically excited synchronous motor. The shaft has a specific shaft diameter and an internal wire channel through which the wire passes to connect to the receiving end excitation power supply device. This design not only protects the wire from wear and tear on rotating parts but also makes the entire rotating part structure more compact and neat, solving the engineering challenge of reliable connection and wiring in high-speed rotating environments.

[0066] This document uses specific examples to illustrate the principles and implementation methods of this application. The descriptions of the above embodiments are only for the purpose of helping to understand the methods and core ideas of this application. Furthermore, those skilled in the art will recognize that, based on the ideas of this application, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this application.

Claims

1. A segmented three-dimensional curved surface magnetic coupler for realizing wireless excitation of the rotor of an electrically excited synchronous motor, comprising a transmitting curved surface assembly and a receiving curved surface assembly disposed radially inside the transmitting curved surface assembly, characterized in that, Both the transmitting end curved surface component and the receiving end curved surface component include: A segmented three-dimensional curved surface shell formed by splicing together multiple curved surface segments arranged sequentially along the circumference; A magnetic layer disposed on the segmented three-dimensional curved surface shell; A coil skeleton is formed by splicing together multiple skeleton segment units corresponding to the curved surface segment unit; Curved coil; In the transmitter curved surface assembly, the coil frame is disposed on the radial inner side of the segmented three-dimensional curved surface housing, and the curved surface coil is wound around the radial inner side of the coil frame; In the receiving end curved surface assembly, the coil frame is disposed on the radial outer side of the segmented three-dimensional curved surface housing, and the curved surface coil is wound on the radial outer side of the coil frame. There is an air gap between the two curved coils; Each of the aforementioned curved surface segment units is provided with a limiting structure for forming a conductor bypass path; After multiple curved surface segment units are spliced ​​together, multiple limiting structures can form a continuous wire bypass path; The curved coil is wound around the coil frame along the winding path of the conductor; The curved coil is formed by connecting multiple segmented windings wound on each skeleton segment unit in series, parallel, or a combination of series and parallel.

2. The segmented three-dimensional curved surface magnetic coupler according to claim 1, characterized in that, Multiple curved surface segment units are spliced ​​together by snap-fitting, embedding, screwing, gluing, or any combination thereof to form the segmented three-dimensional curved surface shell.

3. The segmented three-dimensional curved surface magnetic coupler according to claim 1, characterized in that, The magnetic layer is one of a flexible ferrite layer, a soft magnetic composite material layer, or a discrete magnetic unit array. And / or, the magnetic layer is composed of multiple magnetic segment units respectively disposed on multiple curved surface segment units.

4. The segmented three-dimensional curved surface magnetic coupler according to claim 3, characterized in that, After multiple curved surface segment units are spliced ​​together, multiple magnetic segment units can form a continuous magnetic layer.

5. The segmented three-dimensional curved surface magnetic coupler according to claim 1, characterized in that, The number of surface segmentation units is 3 to 12.

6. The segmented three-dimensional curved surface magnetic coupler according to claim 1, characterized in that, The curvature of the curved surface component at the transmitting end and / or the curved surface component at the receiving end is 30°-180°.

7. A wireless excitation system for an electrically excited synchronous motor, comprising a transmitting excitation power supply device and a receiving excitation power supply device, characterized in that, It also includes the segmented three-dimensional curved surface magnetic coupler as described in any one of claims 1-6; The transmitting curved surface component of the segmented three-dimensional curved surface magnetic coupler is connected to the transmitting excitation power supply device, and the receiving curved surface component of the magnetic coupler is connected to the receiving excitation power supply device.

8. The wireless excitation system for an electrically excited synchronous motor according to claim 7, characterized in that, The curved coil in the receiving end curved assembly has a wire suitable for passing through the inside of the shaft, the inside of the rotor part, or the wire groove opened along the shaft axis of the electrically excited synchronous motor, and the wire is connected to the receiving end excitation power supply device.

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