Additive Ferromagnetic Helix Laminations for Electrical Machines
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Solution Overview
Problem
Conventional methods for manufacturing laminated components for electrical machines are cumbersome and inefficient, particularly in creating complex topologies and minimizing eddy current losses, due to limitations in stamping and aligning ferromagnetic laminations.
Innovation Solution
An additive manufacturing process is used to fuse ferromagnetic material particles together to form complex parts like helices, spirals, and other topologies, with thin insulating layers to minimize eddy current losses and allow for the integration of cooling channels and winding spaces, enabling the production of parts with high stacking factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional stamping and assembly methods are used to manufacture laminated parts, then manufacturing simplicity is maintained, but manufacturing precision and ability to create complex topologies deteriorate
Solution Approach 1:
The ferromagnetic core is divided into multiple thin laminations that are stacked together. Each lamination can be manufactured with precise complex topologies using additive manufacturing, and the segmentation allows for reduced eddy current losses while maintaining manufacturing feasibility through layer-by-layer construction
Solution Approach 2:
The patent transitions from conventional 2D stamping to 3D additive manufacturing, enabling complex three-dimensional topologies that cannot be achieved with traditional planar stamping methods. This dimensional change allows for optimized magnetic flux paths and integrated cooling channels
2Loss of energy
If lamination insulation is increased to minimize eddy current losses, then energy loss reduction is improved, but stacking factor deteriorates
Solution Approach 1:
The patent uses thin insulating films or coatings on the laminations rather than thick insulation layers. This approach provides sufficient electrical isolation to minimize eddy current losses while maintaining a high stacking factor of 97-98% by minimizing the volume occupied by insulating material
Solution Approach 2:
The patent optimizes the insulation thickness parameter to achieve the minimum required value that provides adequate electrical isolation. By precisely controlling the insulation layer thickness, the design achieves both energy loss reduction and high stacking factor
3Manufacturing precision
If ferromagnetic material is compacted into dense cores to increase magnetic flux density, then magnetic performance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple manufacturing operations into a single additive manufacturing process. The ferromagnetic laminations are built layer-by-layer directly in their final compacted configuration, eliminating separate compaction steps and achieving high magnetic flux density through controlled layer stacking
Solution Approach 2:
The additive manufacturing process performs preliminary compaction and positioning of ferromagnetic material during the building process itself. Each layer is deposited and compacted in place before the next layer is added, achieving the desired density and magnetic flux density without subsequent complex compaction operations
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces eddy current losses, increases magnetic flux density, and allows for the manufacture of complex topologies with improved efficiency and flexibility, achieving a high stacking factor of 97-98% by minimizing the volume of insulating material.
Implementation Method 1
applying a beam or beams of energy to a successive plurality of ferromagnetic material particles and fusing them together to form a ferromagnetic helix
Implementation Method 2
fusing them together to form a ferromagnetic helix
Implementation Method 3
disposing an insulating material on the ferromagnetic helix
Implementation Method 4
compressing the ferromagnetic helix to form a compressed ferromagnetic helix
Data Source
AI summary
A method of making a component of a radial or axial flux electrical machine is provided. An additive manufacturing process is used to manufacture a plurality of laminas, including applying beams of energy to a successive plurality of ferromagnetic material particles and fusing them together to form a ferromagnetic helix or spiral, disposing an insulating material on said ferromagnetic helix or spiral, compressing the ferromagnetic helix or spiral to form a compressed ferromagnetic helix or spiral, and fixing the compressed ferromagnetic helix or spiral. A method of making a component of a transverse flux electrical machine is provided, including using an additive manufacturing process.