Controlled assembly of permanent magnet machines

Patent metadata

Field	Value
Publication number	US-2016294261-A1
Application number	US-201514679269-A
Country	US
Kind code	A1
Filing date	Apr 6, 2015
Priority date	Apr 6, 2015
Publication date	Oct 6, 2016
Grant date	—

Abstract

Provided is a control method and a control system for controlling the insertion of a plurality of magnets within an electrical machine including a stator and a rotor which rotates in relation to the stator around a rotary axis, the control system has plurality of sensors which continuously sense an air gap between the rotor and the stator, an encoder which continuously detects an angular position of the rotor, and a processor which receives data from the sensors and the encoder and determines in real-time an insertion order for inserting the plurality of magnets in a surface of the rotor and applies a feedback loop while performing the insertion process to adjust the insertion order based on changes in the data received.

First claim

What is claimed is:

1 . A control system for inserting a plurality of magnets within an electrical machine, the control system comprising:
a plurality of sensors configured to continuously sense an air gap between a rotor and a stator of the electrical machine; and a processor configured to process data received from the plurality of sensors after at least one magnet has been inserted, and to determine in real-time, an insertion order for inserting the plurality of magnets; wherein the control system performs a feedback loop during the insertion process; and wherein the insertion order is adjusted based on changes in the data received.

2 . The control system of claim 1 , further comprising an encoder configured to continuously detect an angular position of the rotor, wherein the processor further determines the insertion process based on the detected angular position.

3 . The control system of claim 1 , wherein the plurality of sensors are disposed at axial and/or radial positions along a surface of the rotor and comprise a sensing direction along x, y and z axes.

4 . The control system of claim 1 , wherein the plurality of sensors are disposed at a driven side and/or a non-driven side of the stator and comprise a sensing direction along x, y and z axes.

5 . The control system of claim 2 , wherein the encoder is further configured to detect an insertion position of the at least one magnet after insertion.

6 . The control system of claim 1 , wherein the plurality of sensors are further configured to determine structural stiffness of the electrical machine in multiple directions.

7 . The control system of claim 2 , wherein the encoder is an absolute encoder.

8 . The control system of claim 1 , wherein the feedback loop is repeatedly applied in real-time, to adjust the insertion order for inserting the plurality of magnets during the insertion process.

9 . The control system of claim 1 , wherein the processor is further configured to determine the insertion order based on historical data and current measured data.

10 . A control method to be implemented by computer including a feedback loop comprising:
inserting at least one magnet in a rotor of the electrical machine; continuously sensing, via sensors, an air gap between the rotor and a stator of the electrical machine after inserting the at least one magnet; and processing via a processor, data received from the sensors and determining, in real-time, an insertion order for inserting remaining magnets of the plurality of magnets, and applying the feedback loop while inserting the plurality of magnets.

11 . The control method of claim 10 , further comprises repeating the feedback loop at different time intervals.

12 . The control method of claim 10 , further comprises initially determining the insertion order after rotating the rotor at least one revolution and measuring a spacing of the air gap.

13 . The control method of claim 10 , further comprising:
continuously detecting via an encoder, an angular position of the rotor, and adjusting the insertion process based on the angular position detected.

14 . The control method of claim 13 , further comprising:
detecting, via the encoder, an insertion position of the at least one magnet after insertion.

15 . The control method of claim 10 , comprising:
repeatedly performing the feedback loop in real-time, to adjust the insertion order during the insertion process in order to adapt to any changes in movement of the rotor and the stator relative to each other.

16 . The control method of claim 10 , further comprising:
determining, via the plurality of sensors, structural stiffness of the electrical machine in multiple directions.

17 . The control method of claim 10 , further comprising:
determining, via the processor, the insertion order based on historical data and current measured data.

18 . A computer program product for implementing a control method including a feedback loop for inserting a plurality of magnets in an electrical machine, by computer, comprising:
inserting at least one magnet in a rotor of the electrical machine; continuously sensing, via sensors, an air gap between the rotor and a stator of the electrical machine after inserting the at least one magnet; and processing via a processor, data received from the sensors and determining, in real-time, an insertion order for inserting remaining magnets of the plurality of magnets, and applying the feedback loop while inserting the plurality of magnets.

19 . The computer program product of claim 18 , wherein the feedback loop further comprises:
continuously detecting via an encoder, an angular position of the rotor, and adjusting the insertion process based on the angular position detected.

20 . The computer program method of claim 18 , wherein the feedback loop further comprises:
repeatedly performing the feedback loop in real-time, to adjust the insertion order during the insertion process in order to adapt to any changes in movement of the rotor and the stator relative to each other.

Assignees

• Ge Energy Power Conversion Technology Ltd

Inventors

• Nies Jacob Johannes

Classifications

• H02K15/03 Primary

  having permanent magnets · CPC title

• H02K15/00

  Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines · CPC title

• H02K15/16

  Centring rotors within the stators · CPC title