Applicant hereby claims foreign priority benefits under U.S.C. § 119 from Chinese Patent Application Serial No. CN201310743080.5 filed on Dec. 30, 2013, the contents of which are incorporated by reference herein.
The present invention relates to the field of electric motor technologies, and in particular, to an electric motor, a compressor, and a method for controlling the electric motor or compressor.
Most current electric motors are rare-earth permanent magnet synchronous motors. Costs of such electric motors are greatly affected by prices of rare earths. As a result, the electric motors have high costs and unstable prices. If the electric motor is applied in a compressor such as a frequency-variable compressor, the compressor also has high costs and an unstable price.
Embodiments of the present invention provide an electric motor and a compressor having the electric motor. The electric motor is a ferrite motor, such as a permanent magnet synchronous motor, so that costs of the electric motor are significantly reduced. A compressor using this electric motor has the same performance as a conventional compressor (such a compressor using a rare-earth permanent magnet motor), but has lower costs than the compressor using the rare-earth permanent magnet motor.
Embodiments of the present invention also provide a method for controlling an electric motor or a compressor. When the compressor is started and is running, a heating element is configured to heat a ferrite magnet of a rotor in the electric motor, so as to prevent the ferrite magnet from being demagnetized irreversibly.
According to an embodiment of the present invention, an electric motor provided. The electric motor includes: a stator; single-phase or multiphase windings disposed on the stator; and a rotor, where the rotor includes a permanent magnet, and at least part of the permanent magnet is ferrite.
According to an aspect of the present invention, the electric motor further includes: a heating element disposed on a surface of or near the ferrite magnet of the rotor and used for heating the ferrite magnet.
According to another embodiment of the present invention, a compressor is provided. The compressor includes:
According to the technical solution of the present invention, ferrite is used in the electric motor, so that costs of the electric motor can be reduced. In addition, a permanent magnet synchronous motor is used in a compressor such as a variable-speed compressor, and in this way, costs of the variable-speed compressor are significantly reduced, and the performance thereof is basically the same as that of a compressor using a rare-earth permanent magnet synchronous motor. In an embodiment, a heating element may be used to heat the ferrite in the electric motor, thereby preventing the ferrite from being demagnetized. In another embodiment, by controlling an input current of the electric motor or the compressor, the ferrite in the electric motor can be protected from irreversible demagnetization at a low temperature, thereby improving the reliability of the compressor.
Referring to
As shown in
As shown in
The compressor using the electric motor may be any suitable compressor, for example, a compressor used for a refrigerating system, such as a variable-speed compressor or a variable-speed scroll compressor. The electric motor may be any electric motor running in a low-temperature environment, for example, a permanent magnet synchronous motor, a built-in permanent magnet motor, or any other suitable electric motor running in a low-pressure chamber of a compressor. The lowest temperature of the environment where the electric motor is located can be −40° C. The windings of the stator of the permanent magnet synchronous motor may be centralized windings or distributed windings. The material of the windings may be copper or other electric conductive materials such as aluminum. The rotor of the permanent magnet synchronous motor may be a surface rotor or a built-in rotor. The coercivity (at a temperature of 20° C.) in the ferrite magnet may be greater than or equal to 300 kA/m. A working voltage of the variable-speed compressor may be a medium or low voltage less than 640V.
For an application of an electric motor such as a permanent magnet synchronous motor in a low-pressure chamber of a variable-speed compressor, a drive of the variable-speed compressor may have a function of controlling a maximum allowable working current of the compressor at a low temperature, so as to prevent the ferrite magnet in the electric motor of the compressor from irreversible demagnetization.
The drive sets the maximum allowable working current of the electric motor 10 according to a temperature of the rotor 12 of the electric motor 10 and a relationship table between maximum allowable working currents and temperatures of the electric motor, so as to prevent the ferrite magnet from being demagnetized irreversibly. At least one temperature measuring device may be disposed in the low-pressure chamber of the variable-speed compressor, so as to detect a temperature of the low-pressure chamber of the compressor or a temperature of the stator/rotor of the electric motor in the low-pressure chamber of the compressor. The drive of the variable-speed compressor adjusts (e.g., increases or decreases) the maximum allowable working current based on the temperature detected by the temperature measuring device, or controls whether o give an alarm based on the temperature, or controls whether to perform power-off protection for the compressor based on the temperature. The temperature of the rotor 12 of the electric motor 10 may be determined by using a temperature sensor in the low-pressure chamber, a temperature sensor on the electric motor, or a temperature sensor on the rotor. In other words, the temperature in the low-pressure chamber or the temperature of the electric motor may be used as the temperature of the rotor.
A relationship table between maximum allowable working currents and temperatures may be created, and the relationship table between maximum allowable working currents and temperatures may be obtained by means of a magnetic circuit method or magnetic field analysis/finite element analysis. In the magnetic circuit method, a magnetic circuit model corresponding to the electric motor of the compressor may be established, a relationship between maximum allowable working currents and knees of a demagnetization curve of the ferrite magnet is derived, and then, according to a relationship between knees of the demagnetization curve of the ferrite magnet and temperatures, a relationship table between maximum allowable working currents and temperatures can be obtained. In the magnetic field analysis/finite element analysis, magnetic field analysis software is used to establish a electric motor model corresponding to the compressor, and an (irreversible) demagnetization analysis is performed on the ferrite magnet in the electric motor by changing a current in the windings of the electric motor winding at a given temperature, thereby a maximum allowable working current at the given temperature is obtained. In the same manner, the relationship table between maximum allowable working currents and temperatures can be obtained by changing the given temperature.
According to the temperature of the rotor, the drive drives the electric motor to run (for example, the drive starts the electric motor or keeps the electric motor running) when a working current of the electric motor is lower than a specified threshold (for example, 80%, 85%, or 90% of the maximum allowable working current or a value between 80% and 90% of the maximum allowable working current); when the working current of the electric motor is greater than the specified threshold and lower than the maximum allowable working current, the drive generates an alarm but still keeps the electric motor running normally (for example, the drive starts the electric motor or keeps the electric motor running); when the working current of the electric motor is greater than the maximum allowable working current, the drive stops the electric motor in the compressor, for example, the drive turns off a power supply of the compressor.
As shown in
According to some implementation manners of the present invention, the heating element 122 may be made of an electric conductive material, and in particular, an electric conductive and magnetic iron sheet or a single or multiple silicon steel sheets. Alternatively, the heating element 122 may also be one or more ion blocks. When the electric motor runs at a low temperature, it may be unnecessary to apply a heating current to the heating element 122, such as a pulse current or a sine current, because when the ferrite motor 10 runs in a low-temperature environment, the windings of the stator 11 of the electric motor generate an alternating magnetic field during normal running of the electric motor, and the alternating magnetic field enables the heating element 122 to generate heat as the heating element 122 is an electric conductive material. Thereby, the ferrite magnet can be heated. Compared with the ferrite motor without a heating element, the electric motor with the heating element 122 has a higher temperature at the ferrite magnet, and can run in a larger-torque working condition.
The drive connected to the electric motor may be used to provide a heating current for the windings of the stator so that an eddy current is generated in the heating element 122 and thereby heat is generated by the heating element 122. That is, the windings of the stator of the electric motor generate a magnetic field such as an alternating magnetic field which enables the heating element to generate an eddy current and to generate heat. The heating current may be a pulse current (or a pulse voltage), a sine current, a high-frequency pulse current (or a high-frequency pulse voltage), or a high-frequency sine current, and the eddy current generated in the heating element 122 enables the heating element 122 to generate heat and to heat the ferrite magnet. Specifically, when the ferrite motor is in a low-temperature environment (for example, the temperature is lower than or equal to 20° C.), it is needed to use the heating element 122 to heat the ferrite magnet according to the working condition of the electric motor. The heating current may be any suitable heating current, as long as an eddy current can be generated in the heating element 122.
According to an exemplary implementation manner of the present invention, before the electric motor is started, the drive is used to apply a pulse current to the windings of the stator, so as to generate a pulsating magnetic field which generates an eddy current in the heating element so as to generate heat; and/or, when the electric motor is started or running, the drive applies a pulse current component or a high-frequency sine current component to the windings of the stator (that is, a current applied to the windings of the stator in the electric motor includes a pulse current component or a high-frequency sine current component), in order to generate a pulsating magnetic field or a high-frequency rotating magnetic field which generates an eddy current in the heating element so as to generate heat. Preferably, the pulse current or the pulse current component or the high-frequency sine current component applied to the windings of the stator makes a magnetic axis of the magnetic field generated by the windings of the stator substantially coincide with a magnetic axis of the rotor.
For example, before the electric motor is started at a low temperature, the ferrite motor is in an “off” state in a low-temperature environment. In such a situation, a large start current is generally needed in order to start the electric motor. In this case, before the electric motor is started, it is needed to heat the ferrite magnet of the electric motor by the heating element 122 so as to increase the temperature of the ferrite magnet and to avoid the demagnetization during the start. The drive or an inverter in the drive may be used to generate a pulse current shown in
In some situations, due to a large resistance on the rotor, the rotor of the electric motor does not swing even if the pulse current applied to the windings such as three-phase windings of the stator does not make the magnetic axis of the magnetic field generated by the windings such as three-phase windings coincide with the magnetic axis 125 of the rotor. As an example, a pulse current may be applied to the windings of the stator to drive the rotor to rotate, so that the axis of windings at one phase among the three-phase windings substantially coincides with the magnetic axis 125 of the rotor; then, a pulse current is applied to the three-phase windings of the stator, the amplitude of the pulse current applied to the windings at one phase is twice the amplitude of the pulse current applied to windings of the other two phases, and the phase of the pulse current applied to the windings at one phase has a 180-degree phase difference with the phase of the pulse current applied to the windings of the other two phases. For example, as shown in
When the ferrite motor 10 runs with a heavy load in a low-temperature environment, a pulse current, a sine current, a high-frequency pulse current or a high-frequency sine current may be added to an output current of the drive or the inverter in the drive so that more eddy currents are generated in the heating element 122, thereby heating the ferrite magnet. Consequently, an operating capacity of the electric motor can be further improved and the electric motor can output a larger torque and can be protected from the demagnetization. The added current may be applied continuously or intermittently. The introduction of the pulse current or sine current may increase a torque fluctuation, and if the increased torque fluctuation is greater than a corresponding standard for the electric motor, the electric motor may be designed in order to reduce the torque fluctuation, for example, an auxiliary slot or non-uniform air gaps may be configured on the stator.
A temperature of the electric motor is obtained. The temperature of the electric motor is determined according to at least one of a winding temperature, a rotor temperature and an ambient temperature of the electric motor. For example, a temperature of the low-pressure chamber in the compressor may be detected and used or a temperature of the electric motor may be detected and used. According to a relationship table between maximum allowable working currents and temperatures of the electric motor, a maximum allowable working current of the electric motor corresponding to the temperature of the electric motor may be found; and the electric motor may be controlled according to the maximum allowable working current of the electric motor found.
A working current of the electric motor under the temperature of the electric motor obtained is compared with the maximum allowable working current of the electric motor so as to determine whether the working current of the electric motor is greater than the maximum allowable working current. If the working current of the electric motor is greater than the maximum allowable working current, a power supply of the compressor is turned off and the electric motor is stopped. If the working current of the electric motor is not greater than the maximum allowable working current, it is determined whether a ratio of the working current to the maximum allowable working current is greater than a predetermined value (such as 80-90% or 90%). If the ratio of the working current to the maximum allowable working current is greater than the predetermined value, an alarm is generated but the electric motor is kept running normally. If the ratio of the working current to the maximum allowable working current is not greater than the predetermined value, the electric motor is kept running normally. The predetermined value may be selected according to a specific condition and is not limited to any specific numerical value.
In other words, controlling of the electric motor may include: when the working current of the electric motor is lower than a specified threshold, keeping the electric motor running normally; when the working current of the electric motor is greater than the specified threshold and lower than the maximum allowable working current, generating an alarm but keeping the electric motor running normally; and when the working current of the electric motor is greater than the maximum allowable working current, stopping the electric motor. The temperature of the electric motor may be determined according to at least one of the winding temperature, the rotor temperature, and the ambient temperature of the electric motor.
A method for controlling the compressor includes: acquiring a temperature of an electric motor in the compressor; searching for a maximum allowable working current of the electric motor corresponding to the temperature of the electric motor according to a relationship table between maximum allowable working currents and temperatures of the electric motor; and controlling the compressor according to the maximum allowable working current of the electric motor. The controlling the compressor may include: when a working current of the electric motor is lower than a specified threshold, keeping the electric motor running normally, thereby keeping the compressor running normally; when the working current of the electric motor is greater than the specified threshold and lower than the maximum allowable working current, generating an alarm but keeping the electric motor running normally, thereby keeping the compressor running normally; and when the working current of the electric motor is greater than the maximum allowable working current, stopping the electric motor, thereby stopping the compressor. The specified threshold may be 90% of the maximum allowable working current. The temperature of the electric motor may be determined according to at least one of a winding temperature, a rotor temperature and an ambient temperature of the electric motor.
The method according to an embodiment of the present invention may further include: heating a ferrite magnet. According to an implementation manner of the present invention, any suitable heating manner may be used, for example, resistance heating or chemical heating.
According to an exemplary embodiment of the present invention, a heating current is applied to windings of a stator in order to generate an eddy current in the heating element so that the heating element can generate heat. For example, a pulse current or a sine current is applied to the windings of the stator in order to generate an eddy current in the heating element so as to generate heat.
Exemplarily, during an operation period, the windings of the stator in the electric motor generate an alternating magnetic field so that the heating element generates heat used for heating the ferrite magnet. In other words, the alternating magnetic field generated by the windings of the stator in the electric motor during normal operation enables the heating element to generate heat used for heating the ferrite magnet. Before the electric motor is started or when the electric motor is started or is running, a pulse current, or a pulse current component or high-frequency sine current component (that is, a current applied to the windings of the stator of the electric motor includes a pulse current component or a high-frequency sine current component) is applied to the windings of the stator in the electric motor, in order to generate a pulsating magnetic field or a high-frequency rotating magnetic field which generates an eddy current in the heating element to generate heat. Preferably, the pulse current, the pulse current component or the high-frequency sine current component applied to the windings of the stator makes a magnetic axis of the magnetic field generated by the stator substantially coincide with a magnetic axis of the rotor.
According to an embodiment of the present invention, for example, a ferrite permanent magnet synchronous motor is used in the variable-speed compressor, and in this way, costs of the variable-speed compressor are significantly reduced and the performance thereof is basically the same as a compressor using a rare-earth permanent magnet synchronous motor. Moreover, by controlling an input current of the electric motor or the compressor, the ferrite magnet in the electric motor is protected from irreversible demagnetization at a low temperature, thereby improving the reliability of the compressor.
Besides, embodiments of the present invention are applicable to any electric motor having a permanent magnet formed by a ferrite material, and any compressor having such electric motor. The electric motor may be disposed in a low-pressure chamber of the compressor or any low-temperature environment.
Although some embodiments of the general inventive concept have been shown and illustrated, persons of ordinary skill in the art shall understand that changes may be made to these embodiments without departing from the principle and spirit of the general inventive concept, and the scope of the present invention is defined by the claims and their equivalents.
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