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.

这项小型企业创新研究（SBIR）II期项目旨在为电动机（例如电动机的绕组芯）开发一种新型的软磁料和制造工艺。该技术利用基于金属喷雾沉积的独特的单步近净形制造工艺来产生各向同性的金属微观结构，其特征是具有高渗透率，高饱和度和低强度的小域，并以受控形成的绝缘边界形成，从而限制了邻近域之间的电力电力。所得的材料提供了出色的三维磁路，同时最大程度地减少了与涡流相关的能量损失。它可以取代各向异性层压缠绕的核心，目前将常规电动机的设计限制为具有二维磁路的几何形状。作为该项目的进一步目标，正在开发一种新的混合场电动机拓扑，具有由提议的材料和制造工艺实现的三维磁路路径。该项目的更广泛的影响/商业潜力是使能够提高性能和效率的电动机生产，同时降低与机动发动机生产相关的成本和材料刮擦。电动机广泛用于越来越多的应用中，包括机器人技术，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，设备，电动工具，医疗设备，军事和太空勘探应用。 这些市场通过提高性能，提高效率和更低的成本来推动对电动机的需求不断增长。考虑到全球电动机的广泛使用，预计由拟议的混合场电动机技术带来的破坏性变化预计将提供重大的商业，社会和环境效益，包括提高制造效率，减少废物和节能。