SBIR Phase II: SBIR Phase II Spray-Formed Soft Magnetic Material for Efficient Hybrid-Field Electric Machines

SBIR II 期：用于高效混合场电机的 SBIR II 期喷射成型软磁材料

• 批准号: 1230458
• 负责人: Martin Hosek
• 金额: $ 49.98万
• 依托单位: Persimmon Technologies Corporation
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2012
• 资助国家: 美国
• 起止时间: 2012-09-01 至 2015-08-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1230458&HistoricalAwards=false
• 关键词: SBIR; Phase; II; Spray; Formed

This Small Business Innovation Research (SBIR) Phase II project aims to develop a novel soft magnetic material and fabrication process for magnetic circuits of electric machines, such as winding cores of electric motors. The technology utilizes a unique single-step near net-shape fabrication process based on metal spray deposition to produce an isotropic metal microstructure characterized by small domains with high permeability, high saturation and low coercivity with a controlled formation of insulation boundaries that limit electric conductivity between neighboring domains. The resulting material provides an excellent three-dimensional magnetic path while minimizing energy losses associated with eddy currents. It can replace anisotropic laminated winding cores, which currently constrain the design of conventional electric motors to geometries with two-dimensional magnetic paths. As a further objective of the project, a new hybrid-field motor topology, with three-dimensional magnetic paths enabled by the proposed material and fabrication process, is being developed.The broader impact/commercial potential of this project is to enable production of electric motors with improved performance and efficiency while reducing cost and material scrap associated with manufacturing of motor winding cores. Electric motors are used extensively in a growing number of applications, including robotics, semiconductor and LED process equipment, industrial automation, electric vehicles, heating, ventilation and air conditioning systems, appliances, power tools, medical devices, and military and space exploration applications. These markets drive an increasing demand for electric motors with improved performance, higher efficiency, and lower cost. Considering the extensive use of electric motors globally, the disruptive change resulting from the proposed hybrid-field motor technology with spray-formed winding cores is expected to provide significant commercial, societal and environmental benefits, including improved manufacturing efficiency, waste reduction, and energy conservation.

该小型企业创新研究（SBIR）第二阶段项目旨在开发用于电机磁路的新型软磁材料和制造工艺，例如电动机的绕组铁芯。该技术利用基于金属喷射沉积的独特的单步近净形制造工艺来产生各向同性金属微结构，其特征在于具有高磁导率、高饱和度和低磁导率的小域，以及限制相邻域之间的导电性的绝缘边界的受控形成。所得材料提供了出色的三维磁路，同时最大限度地减少了与涡流相关的能量损失。它可以取代各向异性叠层绕组铁芯，目前限制了传统电机的设计与二维磁路的几何形状。该项目的另一个目标是开发一种新的混合磁场电机拓扑结构，该拓扑结构具有通过所提出的材料和制造工艺实现的三维磁路。该项目的更广泛影响/商业潜力是能够生产具有更高性能和效率的电机，同时降低与电机绕组铁芯制造相关的成本和材料废料。电动机广泛应用于越来越多的应用中，包括机器人、半导体和LED工艺设备、工业自动化、电动汽车、供暖、通风和空调系统、电器、电动工具、医疗设备以及军事和太空探索应用。 这些市场推动了对具有更高性能、更高效率和更低成本的电动机的需求不断增长。考虑到电动机在全球的广泛使用，所提出的具有喷涂成型绕组芯的混合磁场电动机技术所带来的颠覆性变化预计将提供显着的商业，社会和环境效益，包括提高制造效率，减少浪费和节能。