The present disclosure generally relates to alternating current (AC) motors/generators, and in particular, to a homopolar ac machine which can operate as a motor or a generator.
This section introduces aspects that may help facilitate a better understanding of the disclosure. Accordingly, these statements are to be read in this light and are not to be understood as admissions about what is or is not prior art.
Nowadays AC machines used as motors or generators are ubiquitous. In particular, with the popularity of electric, hybrid, or hybrid plug-ins vehicles on a substantial rise, there is a constant demand to make these motors lighter, less expensive to manufacture all while meeting the torque density and power density demands of the vehicular market.
To date, permanent magnet alternating current (PMAC) machines have been the dominant source of motors in the car market or other markets that use AC machines. However, these machines typically utilize rare earth materials for their construction, are expensive to manufacture, while generating excellent torque densities. Non-rare earth PM machines have been realized; however, they suffer from lower torque densities. Rare earth PMs require elements, dysprosium, added to the magnet material to enable high operating temperatures which present issues of expense, market volatility, availability, and manufacturing, e.g., supply-chain. Induction machines can be used which do not have rare earth materials but do not offer the torque and power density of PM machines. Likewise, homopolar machines, eliminate or at least reduce the need for rare earth materials in their construction, however, they can rarely meet the torque density requirements in working environments.
Therefore, there is an unmet need for a novel approach in homopolar AC machines that can meet torque density requirements of demanding applications such as vehicles.
A homopolar alternating current machine (HAM) is disclosed. The HAM includes a stator having a body axially extending from a first end to a second end and further having a plurality of segments radially protruding outward from the body. Each segment includes a main winding disposed centrally about the segment, a first auxiliary winding disposed at a proximal end of the segment, and a second auxiliary winding disposed at a distal end of the segment, whereby each of the first and second auxiliary windings are coupled to each other in a parallel manner. The HAM further includes a first rotor disposed proximate the first end of the stator and a second rotor disposed proximate the second end of the stator. The HAM also includes a dc flux source corresponding to each of the first and second rotors. Substantially no excitation of the first and the second auxiliary windings of each stator segment of the plurality of segments is needed to operate the HAM. When the HAM is energized, there is substantially no DC flux in each of the main winding. Operating the HAM is associated with a substantially sinusoidal current waveform without a DC offset. The HAM can be operated as a motor or a generator.
An alternating current (AC) system for operating a homopolar AC machine (HAM) is also disclosed. The system includes a HAM. The HAM includes a stator having a body axially extending from a first end to a second end and further having a plurality of segments radially protruding outward from the body. Each segment includes a main winding disposed centrally about the segment, a first auxiliary winding disposed at a proximal end of the segment, and a second auxiliary winding disposed at a distal end of the segment, whereby each of the first and second auxiliary windings are coupled to each other in a parallel manner. The HAM further includes a first rotor disposed proximate the first end of the stator and a second rotor disposed proximate the second end of the stator. The HAM also includes a dc flux source corresponding to each of the first and second rotors. Substantially no excitation of the first and the second auxiliary windings of each stator segment of the plurality of segments is needed to operate the HAM. When the HAM is energized, there is substantially no DC flux in each of the main winding. Operating the HAM is associated with a substantially sinusoidal current waveform without a DC offset. The system also includes an interface circuit coupled to the HAM, whereby the interface circuit is adapted to operate the HAM in one of a generator or a motor, wherein the interface circuit is coupled to each of the main windings.
For the purposes of promoting an understanding of the principles of the present disclosure, reference will now be made to the embodiments illustrated in the drawings, and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of this disclosure is thereby intended.
In the present disclosure, the term “about” can allow for a degree of variability in a value or range, for example, within 10%, within 5%, or within 1% of a stated value or of a stated limit of a range.
In the present disclosure, the term “substantially” can allow for a degree of variability in a value or range, for example, within 90%, within 95%, or within 99% of a stated value or of a stated limit of a range.
A novel approach in homopolar AC machines is presented that can meet torque density requirements of the vehicular market. Towards this end, several different Dual Rotor Homopolar AC Machines (DHAM) are presented as a novel rotating electric machine which can operate either as a motor or as a generator. Each of these versions has a novel dual rotor topology and utilizes both radial and axial flux paths. Furthermore, each of these configurations includes a segmented stator, including a plurality of segments, whereby each segment includes a main winding centrally disposed about the corresponding stator segment and two auxiliary windings each disposed on either side of the main winding. In each case, there is a DC flux source incorporated into the machine. The DC flux source may be a set of permanent magnets (rare earth or non-rare earth permanent magnets), or alternatively a field winding disposed about the stator body but corresponding to each rotor. In either case, each rotor includes said DC flux source. In the permanent magnets case, the permanent magnets can be coupled to a corresponding rotor and thus rotate as the rotor rotates. Alternatively, in the case of field windings, the field winding is mounted between each rotor and the stator body and is thus stationary. These six versions include: 1) a stationary permanent magnet version, whereby each permanent magnet is decoupled from a corresponding rotor and thus is stationary with respect to the rotor, 2) a rotating PM machine, whereby each permanent magnet is coupled to the corresponding rotor and thus configured to rotate with the rotor, 3) a field winding version whereby the permanent magnets are replaced with field windings that are positioned between the stator body and a corresponding rotor in a stationary manner. Each of the above versions can be presented with a segmented stator that has A) uniform stator segments; and B) short and long stator segments, making up the six versions. It should be noted that various embodiments for the permanent magnets are possible, e.g., a superconducting puck, as discussed below.
Where permanent magnets are used, the permanent magnets can have heavy-rare-earth materials, with atomic numbers ranging from 62-71, which includes dysprosium, in combination with other materials. Many commonly used neodymium iron boron magnets include dysprosium, and are thus considered heavy-rare-earth. Alternatively, the permanent magnets may be constructed from non-heavy-rare-earth material that is selected from the group consisting of Nd2Fe14B, AlNiCo, ferrite, PtCo, MnAlC, and a combination of one or more thereof.
There are several different windings: the main windings and auxiliary windings. The power transfer to the machine is through the main windings of the machine which constitute three or more phases. Nominally, a three-phase system is employed for the main windings, although any number of phases greater than two could be used. The voltage and current waveforms associated with the main windings are nominally sinusoidal, and the torque produced by the machine is nominally constant. Unlike other homopolar machines, the flux through the main winding does not have a dc bias leading to better material utilization.
The auxiliary windings of the machine (there are two: upper and lower), are coupled together in parallel as the voltage across the two windings is substantially identical, while the required currents are opposite. The local connection between terminals of the auxiliary windings on each stator segment is as follows: if the auxiliary windings are wound in the same manner (i.e., both are wound clockwise or both are wound counterclockwise), then the top and bottom terminals of the top auxiliary winding are coupled to the top and bottom terminals of the bottom auxiliary winding, respectively. If however, the two auxiliary windings are wound opposite one-another, then the top and bottom terminals of the top auxiliary winding are coupled to the bottom and top terminals of the bottom auxiliary winding, respectively Alternatively, the auxiliary windings can be terminaled (i.e., end of each auxiliary winding can be brought out to a corresponding terminal for excitation) outside the machine, for situations in which minute excitation of the auxiliary windings is desirable. Thus, as a whole, little or no excitation of the auxiliary winding is required. The role of the auxiliary winding is to distribute the flux in the desired fashion, which in turn allows the same amount of average power to be delivered to the main windings with a lower peak and rms phase currents for the same peak voltage than would otherwise be possible (which is analogous to operating at a higher power factor).
The novel DHAM configuration of the present disclosure provides several advantages: 1) The field winding in the case of field-wound type (or the permanent magnets in the case of permanent magnet type, or the use of a superconducting puck, in leu of a permanent magnet) can be stationary. This facilitates cooling, electrical connections to the field, and eliminates mechanical stresses on the field winding in high speed machines. This features also facilitates the use of superconducting field windings, if desired. For low speed machines, the magnets can be placed on the rotor and allowed to rotate, if desired. In this configuration, there is still an advantage in that the magnets are at a smaller radius than the teeth and thus experience less force, and are more easily structurally wrapped than in traditional machines since flux is not crossing a radial airgap in this region. 2) The rotors themselves are nominally lossless, which also facilitates high speed applications in that the machine can be run in a vacuum. 3) The stator structure is segmented, facilitating manufacturing, leading to a high packing factor, as well as facilitating the construction of large machines. 4) The stator structure is easy to wind. This facilitates high winding packing factor helps reduce the size of the machine and improves thermal transfer. 5) The DHAM according to the present disclosure has a wide constant power speed range. This feature advantageously makes it ideal for applications such as flywheel energy storage and electric vehicles. 6) Owing to a compact architecture, space within the machine is available for the inverter allowing one assembly of the machine and inverter in a single package. Additionally benefits of the DHAM and its various embodiments according to the present disclosure includes AC machines with stationary windings (i.e., non-rotating windings), provides large constant power speed range, and owing to its simplicity can be readily manufactured (even more easily than induction machines).
Another additional benefit of the DHAM of the present disclosure is that in the PM variety, the permanent magnets are placed in specific locations in the machine where it will see less field variation and so have less eddy currents and thus the associated heating. This also facilitates the use of superconducting windings or a superconducting puck for some applications. Thus, the thermal issues seen in PMACs do not pose a challenge. In addition, the DHAM of the present disclosure can use stationary magnets allowing them to be more easily cooled, advantageously eliminating the necessity of high temperature material selection, e.g., dysprosium, and also further avoid mechanical stresses of rotating high speeds.
Referring to
Referring to
Referring to
Referring to
As discussed above, regardless of which configuration (i.e., the DHAM 100 shown in
To better elucidate the working principals of the DHAM according to the present disclosure, reference is made to
wherein Rp is the number of rotor poles. For each phase, there are two sets of rotor teeth, the alpha teeth and the beta teeth. The reluctances between the rotor and the alpha teeth are expressed as:
R
aαe
=R
Ae
−R
Be sin(2θr) (2)
R
bαe
=R
Ae
−R
Be sin(2θr+2π/3) (3)
R
cαe
=R
Ae
−R
Be sin(2θr−2π/3) (4)
The reluctances between the rotor and the beta teeth are expressed:
R
aβe
=R
Ae
+R
Be sin(2θr) (5)
R
bβe
=R
Ae
+R
Be sin(2θr+2π/3) (6)
R
cβe
=R
Ae
+R
Be sin(2θr−2π/3) (7)
where RAe and RBe are constants. The final ‘e’ in the subscript stands for ‘effective’ in the sense of being a parallel combination of all rotor poles. In particular,
Having defined the reluctances, torque may be expressed as:
where the flux terms are depicted in
Next, is to develop mathematical relationship that describe control of the flux in the phase legs. The alpha leg fluxes are described as:
Φaαe=Φdc+Φac cos(2θr+ϕ) (11)
Φbαe=Φdc+Φac cos(2θr+ϕ+2π/3) (12)
Φcαe=Φdc+Φac cos(2θr+ϕ−2π/3) (13)
The beta leg fluxes are described as:
Φaβe=−Φdc+Φac cos(2θr+ϕ) (14)
Φbbe=−Φdc+Φac cos(2θr+ϕ+2π/3) (15)
Φcβe=−Φdc+Φac cos(2θr+ϕ−2π/3) (16)
It should be noted that φdc and Φac are constants for a given operating point describing the dc and ac amplitude of the flux, as well as the quantity ϕ is also a constant for a given operating point.
Substitution of the reluctance profiles according to equations 2-7 and the desired fluxes expressed by equations 11-16, the electromagnetic torque may be expressed as:
T
e=6RpRBeΦdcΦac cos ϕ (17)
As indicated by equation 17, the torque is proportional to the product of Φdc and Φac, and is, ideally, constant, thus expressing an advantageous and desirable property of the DHAM according to the present disclosure.
Next consideration is the flux through the main winding (e.g., 108 of
Φae=Φaαe+Φaβe (18)
Substituting equations 11 and 14 into equation 18, provides the following relationship:
Φae=2Φac cos(2θr+ϕ) (19)
From equation 19, the main component of the voltage across one of the a-phase legs is given
which shows another desirable property of the DHAM—that is, the DHAM of the present disclosure is fundamentally, a sinusoidal voltage machine.
Having derived the voltage relationship, next current relationships in each of the main windings is derived. Referring to
F
as
=R
aαeΦaαe+RaβeΦaβe (21)
The relationship expressed in equation 21 takes advantage of the fact that there is a virtual magnetic core (i.e. no MMF drop) between the two rotors. Substituting equation (2), (5), (11), and (14) into (21) provides
F
as
=Ni
asl=2RAeΦac cos(2θr+ϕ)−2RBeΦdc sin(2θr) (22)
whereas iasl is the current in one a-phase stator leg. From equation 22, another attractive feature of the DHAM can be observed according to the present disclosure—that the current waveform is also sinusoidal.
After having considered the main windings, reference is now made back to
F
axu
=Ni
axu
=R
aαeΦaαe−RaβeΦaβe−Ffd (23)
F
axl
=Ni
axl
=−R
aαeΦaαe+RaβeΦaβe+Ffd (24)
It can be concluded that We conclude that the current need in the upper and lower auxiliary windings is equal in magnitude and opposite in sign; thus, iaux=−iaxl.
It is further observed that substitution of equations (2), (5), (11), and (14) into (23) and (24) results in:
F
axu
=−F
fd+2RAeΦdc+RBeΦac sin ϕ−RBeΦac sin(4θr+ϕ) (25)
F
axl
=F
fd−2RAeΦdc−RBeΦac sin ϕ+RBeΦac sin(4θr+ϕ) (26)
Substituting field MMF expressed below in (27) in (25) and (26) the expression for the control winding MMFs will then be provided in (28) and (29):
F
fd=2RAeΦde+RBeΦae sin ϕ (27)
F
axu
=−R
BeΦac sin(4θr+ϕ) (28)
F
axl
=R
BeΦac sin(4θr+ϕ) (29)
From these relationships it can be seen that the control winding currents are purely sinusoidal with no DC offset as expressed below:
The voltages across the auxiliary windings of one leg are given by
Since the ac component of Φaαe is equal to the ac component of Φaβe as observed from equations (11) and (14), their time derivatives are equal, and hence the auxiliary winding voltages need to be equal, that is νaxu=νaxl. If the auxiliary windings are viewed as a pair, since their voltages are the same, their currents need to be opposite. In essence, this can be achieved by simply tying the two coils together and allowing the coils to be self-excited. Thus no further excitation is necessary. One way of looking at this is that by tying the auxiliary winding together, use of Lenz's law to ensures that equal ac parts are present, similar to a current transformer. Thus, advantageously there is no need to drive another set of windings, resulting in a major benefit of the DHAM of the present disclosure.
Referring to
The interleaved stator arrangement (i.e., the stator 206 of the DHAM 200, shown in
The DHAM configuration shown in
As discussed herein, the DHAM according to the present disclosure can be operated as a generator or as a motor. In each case, the DHAM of the present disclosure is coupled to an interface circuit adapted to operate the DHAM accordingly. The interface circuitry is coupled to each of the main windings of each stator segment. Additionally, the interface circuitry may also be coupled to each of the auxiliary windings, if energization of the auxiliary windings is desirable.
Those having ordinary skill in the art will recognize that numerous modifications can be made to the specific implementations described above. The implementations should not be limited to the particular limitations described. Other implementations may be possible.
The present patent application is related to and claims the priority benefit of U.S. Provisional Patent Application Ser. No. 63/109,606 filed Nov. 4, 2020 titled DUAL ROTOR HOMOPOLAR AC MACHINE, the contents of which is hereby incorporated by reference in its entirety into the present disclosure.
This invention was made with government support under DE-EE0008711 awarded by the Department of Energy. The government has certain rights in the invention.
Number | Date | Country | |
---|---|---|---|
63109606 | Nov 2020 | US |