公开(公告)号：US11502588B2

公开(公告)日：2022-11-15

申请号：US16231102

申请日：2018-12-21

Applicant: ABB Schweiz AG

Inventor： Sheng Zhong ,  Dariusz Bednarowski ,  Colin E. Tschida ,  Darren Tremelling ,  Lukasz Malinowski

IPC: H02K15/12 ,  H02K15/02 ,  H02K1/18 ,  H02K5/15 ,  H02K15/14 ,  H02K5/08

Abstract: A method for manufacturing a polymeric electrical machine includes manufacturing a stator including a laminated stator core and a plurality of windings including winding overhangs; applying a surface treatment to the stator core constructed to reduce defects at an interface between a polymeric material and the stator core and enhance adherence between the polymeric material and the stator core; mounting the stator onto a mandrel; inserting the stator into an electrical machine housing mold; molding an electrical machine housing including a stator band with an integral non-drive end endplate, including overmolding the stator and winding overhangs within the stator band; molding a drive end endplate, including forming polymeric ribs in the drive end endplate and overmolding a metallic structure into the endplate, the metallic structure enhancing mechanical stiffness of the endplate; installing a rotor assembly into the electrical machine housing; and installing the endplate onto the electrical machine housing.

公开(公告)号：US10855151B2

公开(公告)日：2020-12-01

申请号：US15848649

申请日：2017-12-20

Applicant: ABB Schweiz AG

Inventor： Elio Alberto Perigo ,  Cherif Ghoul ,  Darren Tremelling ,  Sheng Zhong ,  Colin Tschida ,  Giulio Secondo

IPC: H02K15/02 ,  H02K15/03 ,  H02K1/27 ,  H02K15/16 ,  H02K7/04 ,  B29C43/00 ,  B29C45/00 ,  H02K1/32 ,  H02K15/12 ,  H02K9/06

Abstract: A method of balancing a rotor and/or fixing rotor components includes arranging a plurality of generally like laminations side by side in a stack to form at least a part of a rotor. The rotor has a rotational center axis and each of the laminations having a plurality of apertures that cooperate to form passages that extend axially along a length of the stack. In accordance with an aspect of the method, a polymer based fixation material is filled in the passages in a manner to fix the laminations together in the stack. With the fixation material, a sprue is formed, projecting from an axial face of the stack. In accordance with another aspect of the method, a weight of the sprue is adjusted to rotationally balance the rotor about the rotor center axis.

公开(公告)号：US10574174B2

公开(公告)日：2020-02-25

申请号：US15859463

申请日：2017-12-30

Applicant: ABB Schweiz AG

Inventor： Alessandro Castagnini ,  Darren Tremelling ,  Elio Alberto Perigo ,  Giulio Secondo ,  Liming Liu

IPC: H02P31/00 ,  H01F13/00 ,  H02K15/03 ,  H02K1/27 ,  H02K1/20

Abstract: A method for operating an electrical machine having a stator and having a rotor with permanent magnets, includes: running the electrical machine; determining, while performing the running of the electrical machine, whether the permanent magnets have been demagnetized; finding, while running the electrical machine, the q-axis responsive to a determination that the permanent magnets have been demagnetized; firing a current pulse through the stator, while running the electrical machine, when the q-axis reaches a desired position relative to a selected stator phase, wherein the current pulse is constructed to remagnetize the permanent magnets; and continuing to run the electrical machine.

公开(公告)号：US20190207550A1

公开(公告)日：2019-07-04

申请号：US15859463

申请日：2017-12-30

Applicant: ABB Schweiz AG

Inventor： Alessandro Castagnini ,  Darren Tremelling ,  Elio Alberto Perigo ,  Giulio Secondo ,  Liming Liu

IPC: H02P31/00 ,  H01F13/00 ,  H02K1/27 ,  H02K1/12 ,  H02K11/20 ,  H02K15/03

Abstract: A method for operating an electrical machine having a stator and having a rotor with permanent magnets, includes: running the electrical machine; determining, while performing the running of the electrical machine, whether the permanent magnets have been demagnetized; finding, while running the electrical machine, the q-axis responsive to a determination that the permanent magnets have been demagnetized; firing a current pulse through the stator, while running the electrical machine, when the q-axis reaches a desired position relative to a selected stator phase, wherein the current pulse is constructed to remagnetize the permanent magnets; and continuing to run the electrical machine.

公开(公告)号：US20190207490A1

公开(公告)日：2019-07-04

申请号：US15859439

申请日：2017-12-30

Applicant: ABB Schweiz AG

Inventor： Cherif Ghoul ,  Darren Tremelling ,  Sheng Zhong ,  Parag Upadhyay

IPC: H02K15/03

CPC classification number: H02K15/03

Abstract: A method for manufacturing for an electrical machine includes: stacking a plurality of rotor laminations to form an axial rotor segment, the rotor segment formed of at least two laminations, each lamination having a plurality of openings therein, the openings forming a plurality of rotor poles in the rotor segment, each pole having a plurality of passages formed from the openings; rotating the rotor segment to place a first pole of the plurality of poles in an alignment position; injecting into the passages of the first pole a polymer bonded permanent magnet (PBM) material in molten form, wherein the (PBM) material includes magnetic particles suspended within a polymeric matrix; subjecting the first pole to a desired magnetic field to align the magnetic particles into a desired orientation prior to solidification of the (PBM) material; and solidifying the (PBM) material to form permanent magnets within the passages of the first pole.

公开(公告)号：US20190190358A1

公开(公告)日：2019-06-20

申请号：US15848649

申请日：2017-12-20

Applicant: ABB Schweiz AG

Inventor： Elio Alberto Perigo ,  Cherif Ghoul ,  Darren Tremelling ,  Sheng Zhong ,  Colin Tschida ,  Giulio Secondo

IPC: H02K15/03 ,  H02K1/27 ,  H02K15/02

CPC classification number: H02K15/03 ,  B29C43/00 ,  B29C45/00 ,  H02K1/27 ,  H02K1/32 ,  H02K7/04 ,  H02K9/06 ,  H02K15/024 ,  H02K15/12 ,  H02K15/165

Abstract: A method of balancing a rotor and/or fixing rotor components includes arranging a plurality of generally like laminations side by side in a stack to form at least a part of a rotor. The rotor has a rotational center axis and each of the laminations having a plurality of apertures that cooperate to form passages that extend axially along a length of the stack. In accordance with an aspect of the method, a polymer based fixation material is filled in the passages in a manner to fix the laminations together in the stack. With the fixation material, a sprue is formed, projecting from an axial face of the stack. In accordance with another aspect of the method, a weight of the sprue is adjusted to rotationally balance the rotor about the rotor center axis.