用于旋转超声波加工的非接触电能传输耦合器的优化设计

Optimal Design of Contactless Power Transmission Coupler for Rotating Ultrasonic Machining

旋转超声波加工设备可以采用非接触电能传输耦合器为高速旋转的超声振子提供电能,以取代传统的接触式碳刷滑环,这种非接触电能传输方式安全、稳定,且对转速没有限制。但由于主次级磁芯之间存在间隙,使其漏磁通较大,功率传输能力较低。为提高非接触旋转耦合器的功率传输能力,采用有限元仿真和实验的方法,通过对比分析不同材质及结构形式耦合器的磁通分布情况、线圈自感、线圈间互感、耦合系数、线圈交流电阻等参数,对耦合器进行了优化设计。优化后的非接触旋转耦合器具有更高的耦合能力及功率传输能力。

Rotary contactless power transmission couplers can be used for rotating ultrasonic machining equipment to provide power for high-speed rotating ultrasonic vibrators to replace the traditional contact carbon brush and slip rings.Such contactless power transmission method is safe and stable,and has no restriction on the speed.However,due to the gap between the primary and secondary magnetic cores,the leakage flux is large and the power transmission capacity is low.In order to improve the power transmission capability of the contactless rotary coupler,finite element simulation and experiments were used to optimize the design of the coupler by comparing and analyzing the magnetic flux distribution,coil self-inductance,mutual inductance between coils,coupling coefficient,coil AC resistance and other parameters of couplers with different materials and structures.The optimized contactless rotary coupler has higher coupling capacity and power transmission capacity.