Development of Coil Winding and Magnet Assembly Manufacturing Processes for a Ferrite Based Permanent Magnet Generator

铁氧体永磁发电机线圈绕组和磁体组装制造工艺的开发

• 批准号: 76341
• 金额: $ 46.62万
• 依托单位: TIME TO ACT LIMITED
• 依托单位国家: 英国
• 项目类别: Collaborative R&D
• 财政年份: 2021
• 资助国家: 英国
• 起止时间: 2021 至 无数据
• 项目状态: 已结题
• 来源: https://gtr.ukri.org/projects?ref=76341
• 关键词: Development; Coil; Winding; Magnet; Assembly

The UK has set an ambitious target to increase its offshore wind capacity to 30GW by 2030\. However, to achieve this target, it is reliant on imported wind turbines. The Covid-19 pandemic has highlighted this dependency and vulnerability to disruption, particularly in terms of the supply of critical raw materials, such as rare-earth magnets. For these reasons, it is of strategic importance that the UK develops its own wind turbine supply chain to meet its renewable energy targets. This would significantly reduce exposure to market risks, whist simultaneously supporting the development of its own manufacturing sector. GreenSpur believes it has a solution that will catalyse the development of a new UK wind turbine generator supply chain.All wind turbine Permanent Magnet Generators (PMGs) use conventional designs that rely on one key material, rare-earth magnets. GreenSpur, a Time To Act subsidiary, has invented and patented a new and highly innovative approach, with a PMG that substitutes scarce and expensive rare earth magnets for cheap and abundant ferrite magnets. The global wind turbine market currently uses large volumes of rare-earth magnets, materials almost exclusively sourced from China (\>80%), with supply shortages forecast from the mid-2020s onwards (Roskill). GreenSpur's innovation can eliminate this supply chain risk, which will prove crucial in the coming years and decades.The long-term vision of GreenSpur's project is to stimulate the development of a UK supply chain and manufacturing network that can build multi-MW generators for the UK wind market. This project follows on from two successful projects; (i) a 250kW prototype testing at Blyth in August 2019 validating the technology and manufacturing processes and (ii) a 'Business-led innovation in response to Covid' project, to identify potential UK based manufacturing and engineering partners to support the commercialisation of GreenSpur's technology.GreenSpur has now successfully identified several UK manufacturers. This project aims to develop:(i) the manufacturing processes to pre-production rates for:a.the unique aluminium strip coils,b.the magnetization of large magnet assemblies supporting multi-MW generator configurations (up to 5MW), and(ii) a production line monitoring system to verify key coil design specifications.This project is in collaboration with established partner, Warwick Manufacturing Group (WMG) and will be supported by specialist manufacturing subcontractors. The project will improve GreenSpur's manufacturing readiness level in support of supplying rare-earth free generators to the UK wind turbine market by the mid-2020s.

英国已经制定了一个雄心勃勃的目标，到2030年将其海上风电装机容量提高到30GW。然而，要实现这一目标，它依赖进口风力涡轮机。新冠肺炎疫情突显了这种依赖和易受干扰的脆弱性，尤其是在稀土磁体等关键原材料的供应方面。出于这些原因，英国发展自己的风力涡轮机供应链以实现其可再生能源目标具有重要的战略意义。这将大大减少对市场风险的敞口，同时支持本国制造业的发展。GreenSpur相信它有一个解决方案，将催化开发一种新的英国风力涡轮机发电机供应链。所有风力涡轮机永磁发电机(PMG)都使用依赖于一种关键材料-稀土磁体的传统设计。Time to Act的子公司GreenSpur发明了一种新的高度创新的方法，并为其申请了专利，其中的PMG用稀有而昂贵的稀土磁体取代了廉价而丰富的铁氧体磁体。全球风力涡轮机市场目前使用大量的稀土磁体，材料几乎全部来自中国(80%)，预计从2020年代中期开始供应短缺(罗斯基尔)。GreenSpur的创新可以消除这种供应链风险，这将在未来几年和几十年被证明是至关重要的。GreenSpur项目的长期愿景是刺激英国供应链和制造网络的发展，该网络可以为英国风电市场制造多兆瓦发电机。该项目源于两个成功的项目：(I)2019年8月在Blyth进行的250kW原型测试，验证了技术和制造流程；(Ii)“响应Covid的商业主导创新”项目，以确定潜在的英国制造和工程合作伙伴，以支持GreenSpur的技术商业化。GreenSpur现已成功确定了几家英国制造商。该项目旨在开发：(I)生产前的生产工艺：A.独特的铝带线圈，B.支持多兆瓦发电机配置(高达5 MW)的大型磁体组件的磁化，以及(Ii)验证关键线圈设计规范的生产线监控系统。该项目与已建立的合作伙伴华威制造集团(WMG)合作，并将得到专业制造分包商的支持。该项目将提高GreenSpur的制造准备水平，以支持到2020年代中期向英国风力涡轮机市场供应不含稀土的发电机。