The present invention relates generally to an improved flux focusing magnetic gear assembly using ferrite magnets or the like. The present invention also relates generally to an improved flux focusing magnetic gear assembly using ferrite magnets or the like that incorporates an outer stator assembly that converts a variable input to a constant output. The present invention further relates generally to an improved axially aligned flux focusing magnetic gear assembly using ferrite magnets or the like. The improved flux focusing magnetic gear assemblies of the present invention find applicability in traction, wind, and ocean power generation, among other applications.
Magnetic gear assemblies offer numerous advantages over counterpart mechanical gear assemblies. Magnetic gear assemblies provide a contactless mechanism for speed amplification (i.e. acoustic noises, vibrations, and wear and tear are all reduced), do not require lubrication (i.e. maintenance costs and pollution are both reduced), have inherent overload protection (i.e. slippage inherently replaces mechanical breakage), and have the potential for high conversion efficiency. Numerous conventional magnetic gear assemblies are known to those of ordinary skill in the art, typically including a plurality of permanent magnets arranged one directly next to another in adjacent or concentric rings or rotors around one or more axes, with steel poles or the like interspersed between the adjacent or concentric rings in an intermediate ring or rotor, for example. The result is selectively actuated relative rotation of the adjacent or concentric rings or rotors, as well as the intermediate ring or rotor, and speed amplification results. Typically, the flux fields of the magnets are purposefully magnetized in a radial direction.
For example, referring specifically to
P1=|P3−n2|, (1)
then the inner rotor 10 and the outer rotor 14 interact with the middle rotor 12, via flux linkage, to create space harmonics. The angular velocities of the rotors are related by:
ω1=[P3/(P3−n2)]ω3+[n2/(n2−P3)]ω2. (2)
If the outer rotor 14 is stationary (i.e. ω3=0), then:
ω1=[n2/n2−P3)]ω2=Gω2, (3)
where G is the gear ratio. The above referenced flux linkage, and flux focusing, is illustrated specifically in
Invariably, a rare earth material, such as a neodymium iron boron (Nd—Fe—B) alloy, is used as the permanent magnet material. This can become prohibitively expense, and the use of a less expensive ferrite material is certainly preferred, although the inferior performance of the ferrite material must be compensated for via a superior magnetic gear assembly design.
As alluded to above, magnetic gear assemblies are ideally suited for use in traction, wind, and ocean power generation applications, among others, where, for example, wave energy converters (WECs) or the like produce very low speed translational motions (e.g. 0.1-2 m/s) or rotational motions (5-20 rpm). Generally, given such low speeds, extremely large or extremely high force density devices are required to generate significant power. Exemplary devices include rotary turbo generators—typically driven by an oscillating airflow, hydraulic motor generators—typically driven by a pressurized fluid, and direct drive linear generators—typically driven by sea motion. It is in conjunction with such devices that magnetic gear assemblies prove to be most valuable at present, although the potential applications are virtually limitless.
Thus, what are still needed in the art are improved low cost magnetic gear assemblies using ferrite magnets or the like, that can provide increased angular velocities and gear ratios, while still providing a contactless mechanism for speed amplification, not requiring lubrication, having inherent overload protection, and having the potential for high conversion efficiency.
In one exemplary embodiment, the present invention provides a flux focusing magnetic gear assembly, comprising: an inner rotor comprising a plurality of concentrically disposed inner magnets separated by a plurality of concentrically disposed inner interstitial members, wherein the magnetic fields within the plurality of inner magnets are magnetized azimuthally through their thicknesses such that their opposite poles are at their opposite major planar faces; a middle rotor disposed about the inner rotor and comprising a plurality of concentrically disposed poles separated by one of a plurality of concentrically disposed gaps and plurality of concentrically disposed middle interstitial members; and an outer rotor disposed about the middle rotor and comprising a plurality of concentrically disposed outer magnets separated by a plurality of concentrically disposed outer interstitial members, wherein the magnetic fields within the plurality of outer magnets are magnetized azimuthally through their thicknesses such that their opposite poles are at their opposite major planar faces. The inner interstitial members, the poles, and the outer interstitial members are comprised of a magnetic material, while the middle interstitial members are comprised of air or a nonmagnetic material. The inner rotor is disposed about one of a gap and a nonmagnetic shaft. Optionally, the middle rotor comprises the plurality of concentrically disposed poles separated by and interlocked with the plurality of concentrically disposed middle interstitial members. A performance characteristic of the flux focusing magnetic gear assembly is maximized by optimizing a length of each of the plurality of magnets and a width of each of the plurality of interstitial members.
In another exemplary embodiment, the present invention provides a flux focusing magnetic gear assembly, comprising: an inner rotor comprising a plurality of concentrically disposed inner magnets separated by a plurality of concentrically disposed inner interstitial members, wherein the magnetic fields within the plurality of inner magnets are magnetized azimuthally through their thicknesses such that their opposite poles are at their opposite major planar faces; a middle rotor disposed about the inner rotor and comprising a plurality of concentrically disposed poles separated by one of a plurality of concentrically disposed gaps and plurality of concentrically disposed middle interstitial members; and an outer stator disposed about the middle rotor and comprising one or more concentrated or distributed windings. The inner interstitial members and the poles are comprised of a magnetic material, while the middle interstitial members are comprised of air or a nonmagnetic material. The inner rotor is disposed about one of a gap and a nonmagnetic shaft. Optionally, the middle rotor comprises the plurality of concentrically disposed poles separated by and interlocked with the plurality of concentrically disposed middle interstitial members. A performance characteristic of the flux focusing magnetic gear assembly is maximized by optimizing a length of each of the plurality of magnets and a width of each of the plurality of interstitial members.
In a further exemplary embodiment, the present invention provides an axial flux focusing magnetic gear assembly, comprising: a high speed rotor comprising a plurality of concentrically disposed high speed magnets separated by a plurality of concentrically disposed high speed interstitial members, wherein the magnetic fields within the plurality of high speed magnets are magnetized azimuthally through their thicknesses such that their opposite poles are at their opposite major planar faces; an intermediate rotor disposed axially adjacent to the high speed rotor and comprising a plurality of concentrically disposed poles separated by one of a plurality of concentrically disposed gaps and plurality of concentrically disposed intermediate interstitial members; and a low speed rotor disposed axially adjacent to the intermediate rotor and comprising a plurality of concentrically disposed low speed magnets separated by a plurality of concentrically disposed low speed interstitial members, wherein the magnetic fields within the plurality of low speed magnets are magnetized azimuthally through their thicknesses such that their opposite poles are at their opposite major planar faces. The high speed interstitial members, the poles, and the low speed interstitial members are comprised of a magnetic material, while the intermediate interstitial members are comprised of air or a nonmagnetic material. The high speed rotor, the intermediate rotor, and the low speed rotor are disposed about one of a gap and a nonmagnetic shaft and rotate independently. Optionally, the intermediate rotor comprises the plurality of concentrically disposed poles separated by and interlocked with the plurality of concentrically disposed intermediate interstitial members. A performance characteristic of the axial flux focusing magnetic gear assembly is maximized by optimizing a length of each of the plurality of magnets and a width of each of the plurality of interstitial members.
The present invention is illustrated and described herein with reference to the various drawings, in which like reference numbers are used to denote like assembly components/method steps, as appropriate, and in which:
Referring specifically to
Related to the inner rotor 20, the plurality of magnets 26 are separated by a plurality of rectangular, wedge shaped, or annular steel teeth 28 or the like for enhancing flux focusing functionality. The performance of the magnetic gear assembly 15 is, in part, optimized by adjusting the length of the magnets 26, L1, relative to the available angular span, θs1, provided by each of the steel teeth 28 or the like. Similarly, related to the outer rotor 24, the plurality of magnets 26 are separated by a plurality of rectangular, wedge shaped, or annular steel teeth 28 or the like for enhancing flux focusing functionality. Again, the performance of the magnetic gear assembly 15 is, in part, optimized by adjusting the length of the magnets 26, L3, relative to the available angular span, θs3, provided by each of the steel teeth 28 or the like. The middle rotor 22 includes a plurality of steel poles 32 or the like, separated by air gaps or the like, in this exemplary embodiment. It should be noted that the inner rotor 20, the middle rotor 22, and the outer rotor 24 are disposed about a common central axis 40 and are separated by small air gaps 42 concentrically, such that they may freely rotate with respect to one another in a frictionless manner. As is described in greater detail herein below, a large number of characteristics and parameters can be, and are, optimized for enhanced performance.
In order to take advantage of flux focusing, the inner rotor 20 should have more than 4 poles. For example, the flux focusing magnetic gear assembly 15 can have P1=4 pole pairs, n2=17 steel poles, P3=13 pole pairs on the outer rotor 24. If the outer rotor 24 is stationary, then ω3=0, and the gear ratio is:
ω1=[n2/(n2−P3)]ω2Gω2, (4)
where G=4.25 ω2. This combination of poles was chosen for illustration purposes because it has a low cogging factor, Cf=1. The cogging factor is defined by:
Cf=(2P1n2)/[LCM(2P1,n2)], (5)
where LCM is the lowest common multiple.
Referring specifically to
Referring specifically to
Exemplary specifications are provided in Table 1 below, for the purpose of providing relative characteristics and dimensions only.
Flux focusing is achieved by first changing the area with which the flux flows through the width of the steel pole 28 relative to the length of the magnets 26. The relation between air gap flux density and magnet flux density is given by:
BgWsd=Bm2L1d, (6)
where Bg is the air gap flux density, Bm is the magnet flux density, L1=ro1−ri1, d is the active stack length, and Ws=ro1 θs1 is the angular span of the inner rotor steel poles 28. The flux concentration ratio is then given by:
Cφ1=Bg/Bm=(2/θs1)[1−(ri1/ro1)]. (7)
Cφ1=3.06 is obtained for the inner rotor 20 in the present example.
The flux concentration ratio, Cφ3, can also be varied to determine the optimum length for the outer rotor magnets 26, using:
Cφ3=Bg3/Bm3=(2/θs3)[ro3/r−3)−1]. (9)
Cφ3=6.77, which corresponds to L3=15 mm, gives the highest torque density, as an example.
The cage rotor steel pole length, L2, can further be varied, from 3 to 24 mm in the present example, by way of illustration.
L2=ro2−ri2. (10)
It is observed that L2=6 mm provides the highest torque density and lowest torque ripple.
The cage rotor steel pole span, θs2, can still further be varied, keeping other parameters constant.
Ws23=θs2/θs3. (11)
θs2=14 degrees and Ws23=2.36 provides the maximum torque density, by way of illustration.
As a result, a final flux focusing magnetic gear assembly design is achieved, after parametric optimization (which is example specific), including the design parameters provided in Table 2, for the purpose of providing relative characteristics and dimensions only.
It should be noted that the common central shaft portion of the flux focusing magnetic gear assembly 15 of the present invention can be open, nonmagnetic, or complex, as is illustrated in
Referring specifically to
Referring specifically to
ω1=[1/(P3−n2)]ωc+[n2/(n2−P3)]ω2. (12)
Therefore, the use of windings results in the gear ratio being continuously variable. With P1=4, P3=13, and n2=17, the speed relationship is:
ω1=−0.25ωc+4.25ω2. (13)
It is then noted that, if the input speed, ω2, from a turbine, for example, is varying, then the output mechanical speed, ω1, can be made constant by controlling the frequency, ωc. At the same time, the mechanical speed is amplified. The windings 75 shown are concentrated windings, however, distributed windings or the like can also be used. A surface mounted rotor, rather than a spoke type rotor, can also be used in this embodiment.
The torque magnitude, and therefore the power flow, can also be varied by varying the converter voltage level. This topology was studied by others for a traction motor. However, in this analysis, only the high speed rotor was rotating. A continuously variable magnetic gear (CVMG) with two rotors has not been studied by others. By combining this CVMG with a low cost permanent magnet synchronous generator (PMSG) or the like, the resultant system can act like a gearbox and doubly fed induction generator (DFIG), but without the need for brushes or a mechanical gearbox. Also, unlike a direct drive system, the PMSG can be sized to be relatively small because the input speed into the generator is high. In order to further increase the rotational speeds up to an acceptable level for the generator, a second and possibly third magnetic gear set can be used (wind turbines typically use multiple gearboxes, for example). This topology is particularly low cost because it requires minimal energy storage.
A further possibility that is available when using a magnetic gear with windings is the ability to create high speed unidirectional rotational motion from low speed oscillatory motion. This is an important characteristic for WECs, since the speed of the prime mover is typically oscillating. If the stator 70 is replaced by a dual winding and, as an example, winding one is designed to create P3=13 pole pairs, while winding two creates P3=21 pole pairs, then it is noted by looking at equation 12 that, if only the winding one is turned on, since n2=17, the speed relationship is ω1=−0.25ωc+4.25ω2, while if only the winding two is turned on, the speed relationship is, ω1=+0.25ωc−4.25ω2. Therefore, by choosing to turn on the correct stator winding, an oscillatory WEC rotation, ω2, can be converted to speed amplified unidirectional rotation by a noncontact means; the speed smoothing can be achieved by added or subtracting the electrical frequency, ωc.
Referring specifically to
Related to the high speed rotor 80, the plurality of magnets 26 are separated by a plurality of rectangular, wedge shaped, or annular steel teeth 28 or the like for enhancing flux focusing functionality. The performance of the magnetic gear assembly 85 is, in part, optimized by adjusting the depth of the magnets 26, lm1, relative to the available angular span, θ1s, provided by each of the steel teeth 28 or the like. Similarly, related to the low speed rotor 84, the plurality of magnets 26 are separated by a plurality of rectangular, wedge shaped, or annular steel teeth 28 or the like for enhancing flux focusing functionality. Again, the performance of the magnetic gear assembly 85 is, in part, optimized by adjusting the depth of the magnets 26, lm3, relative to the available angular span, θ3s, provided by each of the steel teeth 28 or the like. The intermediate rotor 82 includes a plurality of steel poles 28 or the like, separated by air gaps or the like, in this exemplary embodiment. The high speed rotor 80, the intermediate rotor 82, and the low speed rotor 84 are disposed substantially adjacent to one another about a common central axis and are separated by small air gaps axially, such that they may freely rotate with respect to one another in a frictionless manner. Again, a large number of characteristics and parameters can be, and are, optimized for enhanced performance. Exemplary configurations are provided in Table 3 below, for the purpose of providing relative characteristics and dimensions only.
Although the present invention has been illustrated and described herein with reference to preferred embodiments and specific examples thereof, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples may perform similar functions and/achieve like results. All such equivalent embodiments and examples are within the spirit and scope of the present invention, are contemplated thereby, and are intended to be covered by the following claims.
The present patent application/patent is a divisional of co-pending U.S. patent application Ser. No. 14/240,049, filed on Feb. 21, 2014, and entitled “FLUX FOCUSING MAGNETIC GEAR ASSEMBLY USING FERRITE MAGNETS OR THE LIKE,” the contents of which are incorporated in full by reference herein.
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Number | Date | Country | |
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20170005560 A1 | Jan 2017 | US |
Number | Date | Country | |
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Parent | 14240049 | Feb 2014 | US |
Child | 15265196 | US |