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Electrical steel structuring, insulating and assembling by means of the laser technologies


Abstract

The main idea of this project is to use and control the characteristics of classical soft magnetic materials (high or adequate permeability and magnetic saturation, a low magnetic loss, a weak magneto-striction and noise and a high mechanical resistance) onto the surface and into the bulk in order to both optimize the electromagnetic and magneto-mechanical properties and the quality and eco-design of the assembling between the metal and the dielectric material.


Description of Projectidea

Classical soft magnetic materials, often obtained from laminated steel, are widely spread and used in electrical machines (transformers, sensors, actuators, motors, generators …). Three important characteristics required for such applications can be: a high or adequate permeability and magnetic saturation, a low magnetic loss, a weak magneto-striction and noise and a high mechanical resistance. Nowadays, the main solutions proposed are to use specific and special magnetic and resistive alloys, with some preferred magnetic orientations, in the form of insulated thin laminations assembled and joined in a stack of metal sheets.

The main properties of the bulk magnetic structure (both electromagnetic and magneto-mechanical properties) of such ferromagnetic materials are highly influenced by the sheet thickness and the geometry, the texture and the magnetic structure of the surface. It is important to have an accurate understanding of the materials behaviour in relation to intrinsic properties and industrial processes for implementations (coupled electromagnetic and magneto mechanical behaviour, chemical composition, metallographic structure, surface texture and process). The quality of the insulation between the ferromagnetic laminations and of the anisotropy, geometry, sizing and assembling of these laminations is essential to the design of the electrical and magnetic performance and the reduction of leakage, losses, vibration and noise.

The main idea of this project is to use and control these coupled characteristics onto the surface and into the bulk in order to both optimize the electromagnetic and magneto-mechanical properties and the quality and eco-design of the assembling between the metal and the dielectric material. In order to achieve these goals, a flexible, efficient and accurate technology such as the optical and LASER technology (scratching, scribing and related methods ...) might provide a significant benefit; since no other technology actually known may permit to investigate maximum possibilities with a maximum determinism onto the surface geometry, structure and texture. Some bonding – debonding capabilities and process should be investigated as well between the insulator and such a treated surface in order to contribute to the eco-design of a magnetic circuit.


Consortium of partners, already involved

The consortium is currently composed of three universities, two companies and three clusters based in France, Spain and Belgium.


Partners sought to complete the consortium

Electrical steel worker
o Materials: SiFe, NiFe, CoFe or/and NiCoFe
o Main Missions: Metallurgical Processes
Task 1: Elaborate a soft magnetic alloy (SiFe and NiCoFe) and laminated samples
Task 2: Analyse the grain distribution, boundaries and defects
Task 3: Observe the surface geometry and magnetic structure
o Secondary Missions:
Carry out some electrical, magnetic and mechanical measurements
Assemble the laminated magnetic circuits and wind the coils of Application Test Samples
Analyse Electrical, Magnetic and Acoustic tests and measurements of Application Test Samples


Voltage transformer manufacturer
o Technology: 2 or 3 Phases, BT transformers, Low Frequency
o Main Missions: Manufacture magnetic component
Task 1: Design of a prototype for the project (voltage transformer)
Task 2: Elaborate, cut and insulate the laminations
Task 3: Assemble the laminated magnetic circuits and wind the coils
Task 4: Carry out Electrical, Magnetic and Acoustic tests and measurements
o Secondary Missions:
Impacts and valorization
Industrialization
Dissemination

Rotating electrical machines Manufacturer
o Technology: Motors or Generators, Synchronous or Asynchronous
o Main Missions: Manufacture magnetic component
Task 1: Design of a prototype for the project (motor or generator)
Task 2: Elaborate, cut and insulate the laminations
Task 3: Assemble the laminated magnetic circuits and wind the coils
Task 4: Carry out Electrical, Magnetic and Acoustic tests and measurements
o Secondary Missions:
Impacts and valorisation
Industrialisation
Dissemination

Inorganic insulation factory
o Materials: Inorganic insulators with high thermal resistance for laminated magnetic circuits
o Main Missions: Adhesive Insulating Film
Task 1: Develop and optimise an adhesive insulating film
Task 2: Elaborate and deposit insulator with bonding and detaching capabilities
Task 3: Study and optimise the deposition/removal process
o Secondary Missions:
Carry out electrical measurements (metal and insulation conductivities)
Carry out water and oxygen permeability, weathering and aging tests
Elaborate, scribe, cut and insulate the laminations


Topics

FOF-06-2017:
New product functionalities through advanced surface manufacturing processes for mass production
 


Contact

Paul Bersans
 
Euronovia
 
17 avenue d‘Occitanie
31520 Ramonville Saint Agne
France
 
Homepage: http://euronovia-conseil.eu/
Email: p.bersans@euronovia-conseil.eu
Phone:
Organisation: Others

Responsible NCP

NMBP Program Committee Delegate - NCP Didier vanden Abeele
French Ministry of Higher Education and Research
didier.vanden-abeele@recherche.gouv.fr
Telephone:+33 6 78 13 81 18
France