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

英国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30吉瓦。然而，为了实现这一目标，它依赖于进口风力涡轮机。Covid-19大流行凸显了这种依赖性和对中断的脆弱性，特别是在稀土磁铁等关键原材料的供应方面。由于这些原因，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。这将大大减少市场风险敞口，同时支持本国制造业的发展。GreenSpur相信它有一个解决方案，将促进新的英国风力发电机供应链的发展。所有的风力涡轮机永磁发电机（pmg）都使用传统的设计，依赖于一种关键材料，稀土磁铁。GreenSpur是Time To Act的子公司，它发明了一种高度创新的新方法，并为其申请了专利，这种PMG可以用稀缺而昂贵的稀土磁铁代替廉价而丰富的铁氧体磁铁。全球风力涡轮机市场目前使用大量稀土磁铁，材料几乎完全来自中国（80%），预计从本世纪20年代中期开始供应短缺（Roskill）。GreenSpur的创新可以消除这种供应链风险，这在未来几年和几十年将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，为英国风电市场建造多兆瓦的发电机。这个项目是继两个成功的项目之后进行的；(i) 2019年8月在Blyth进行了250kW的原型测试，验证了技术和制造流程；（ii）“应对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技术的商业化。GreenSpur现在已经成功地确定了几家英国制造商。该项目旨在开发：(i)生产过程的预生产率：a。独特的铝带卷，b。支持多兆瓦发电机配置（高达5MW）的大型磁铁组件的磁化，以及（ii）生产线监控系统，以验证关键线圈设计规格。该项目是与合作伙伴华威制造集团（WMG）合作，并将由专业制造分包商提供支持。该项目将提高GreenSpur的制造准备水平，以支持到本世纪20年代中期向英国风力涡轮机市场供应无稀土发电机。

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.