The present invention relates to electric motors and in particular to an induction motor having an independently rotating permanent magnet rotor variably coupled to an inductive rotor to reconfigure the motor from asynchronous induction operation at startup to synchronous operation after startup for efficient operation.
A preferred form of electric motors are brushless AC induction motors. The rotors of induction motors include a cage (or squirrel cage resembling a “hamster wheel”) rotating inside a stator. The cage comprises axially running bars angularly spaced apart on the outer perimeter of the rotor. An AC current provided to the stator introduces a rotating stator magnetic field inside the rotor, and the rotating field inductively induces current in the bars. The current induced in the bars creates an induced magnetic field which cooperates with the stator magnetic field to produce torque and thus rotation of the rotor.
The introduction of current into the bars requires that the bars are not moving (or rotating) synchronously with the rotating stator magnetic field because electromagnetic induction requires relative motion (called slipping) between a magnetic field and a conductor in the field. As a result, the rotor must slip with respect to the rotating stator magnetic field to induce current in the bars to produce torque, and the induction motors are therefore called asynchronous motors.
Unfortunately, low power induction motors are not highly efficient at designed operating speed, and are even less efficient under reduced loads because the amount of power consumed by the stator remains constant at such reduced loads.
One approach to improving induction motor efficiency has been to add permanent magnets to the rotor. The motor initially starts in the same manner as a typical induction motor, but as the motor reached its operating speed, the stator magnetic field cooperates with the permanent magnets to enter synchronous operation. Unfortunately, the permanent magnets are limited in size because if the permanent magnets are too large, they prevent the motor from starting. Such size limitation limits the benefit obtained from the addition of the permanent magnets.
The present invention addresses the above and other needs by providing a hybrid induction motor which includes a fixed stator, an independently rotating hybrid permanent magnet/squirrel cage (HPMSC) outer rotor, and a Squirrel Cage (SC) inner rotor fixed to a motor shaft. The HPMSC rotor has N angularly spaced part permanent magnets and N sets of a plurality of first bars angularly spaced apart between consecutive permanent magnets. The SC rotor has N groups of angularly spaced apart second bars, and slots in an outer surface of the SC rotor between consecutive groups of the second bars. The HPMSC rotor is initially accelerated by cooperation of the stator with the first bars. The permanent magnets create a rotating magnetic field in the SC rotor cooperating with the second bars to accelerate the SC rotor. As the HPMSC rotor accelerates towards synchronous RPM, the stator field reaches into the HPMSC rotor and cooperates with the permanent magnets to transition to synchronous operation. Salient poles are created by cooperation of the permanent magnets with the slots in the SC rotor to lock the two rotors at synchronous RPM.
In accordance with one aspect of the invention, there is provided an inner Squirrel Cage (SC) rotor having angularly spaced apart axially extending slots on an outer surface of the inner SC rotor. The spacing of the slots matching the spacing of permanent magnets in an independently rotating hybrid permanent magnet/squirrel cage (HPMSC) outer rotor. At synchronous speed the slots and permanent magnets cooperate to form salient poles coupling the rotation of the SC inner rotor with the HPMSC outer rotor, eliminating a need for mechanical coupling of the HPMSC outer rotor with the SC inner rotor.
In accordance with another aspect of the invention, there is provided a motor having an improved sequence of inductive startup and transition to efficient synchronous operation. The design of the first bars of the HPMSC outer rotor produces sufficient torque to over come the drag of the SC inner rotor created by the permanent magnets. As a result, the HPMSC outer rotor reaches synchronous RPM quickly. As the HPMSC outer rotor accelerates faster than the SC inner rotor, the cooperation of the permanent magnets and the second bars of the SC inner rotor create more torque on SC inner rotor to accelerate the SC inner rotor. When first rotor reaches near synchronous rpm, the stator flux penetrates to second bars of the SC inner rotor applying additional torque to further accelerate the SC inner rotor toward synchronous RPM.
In accordance with still another aspect of the invention, there is provided a motor having an HPMSC outer rotor and SC inner rotor coupled by the cooperation of permanent magnets in the HPMSC outer rotor and axially extending slots in the surface of the SC inner rotor. The depth of the slots may be altered based on the purpose of the motor to optimize locking of the SC inner rotor to the HPMSC outer rotor.
The above and other aspects, features and advantages of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings wherein:
Corresponding reference characters indicate corresponding components throughout the several views of the drawings.
The following description is of the best mode presently contemplated for carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of describing one or more preferred embodiments of the invention. The scope of the invention should be determined with reference to the claims.
An end view of an electric motor 10 having an independently rotating Hybrid Permanent Magnet/squirrel Cage (HPMSC) outer rotor 20 and a Squirrel Cage (SC) inner rotor 30 fixedly coupled to a motor shaft 14, according to the present invention is shown in
A cross-sectional view of the housing 12 and fixed stator portion 16 of the electric motor 10 taken along line 2-2 of
A cross-sectional view of the independently rotating HPMSC outer rotor 20 taken along line 2-2 of
Rotor end caps 28 are attached to opposite ends of the HPMSC outer rotor 20 and include bearings 29 allowing the HPMSC outer rotor 20 to rotate freely on the motor shaft 14. The bearings 29 are preferably low friction bearings (for example, ball bearings), but may be simple bushings (for example, bronze bushings or oilite bushings).
A cross-sectional view of the SC inner rotor 30 of the electric motor 10 taken along line 2-2 of
Angularly spaced apart, axially extending slots 34 are formed in a cylindrical outer face 36a of the rotor core 36. The number and spacing of the slots 34 are matched to the number and spacing of the magnets 22 in the HPMSC outer rotor 20. The size, and particularly, the depth, of the slots 34 substantially determine the coupling of the HPMSC outer rotor 20 to the SC inner rotor 30 by affecting the salient poles 50 (see
A cross-sectional view of the electric motor 10 at startup, taken along line 2-2 of
The slots 34 in the SC inner rotor 30 do not align with the magnets 22 at start up because the HPMSC outer rotor 20 accelerates first, causing the magnets 22 (and thus the magnet magnetic field) the skip over the salient poles 50, but still inductively cooperating with second bars 32 of the SC inner rotor 30 until the SC inner rotor 30 reaches near synchronous rpm where the attraction of the salient poles 50 to the magnets 22 is sufficient to hold the SC inner rotor 30 at the same RPM as the HPMSC outer rotor 20. The design of salient poles 50 determines the coupling torque. The coupling torque is designed to be slightly higher than the rated torque of motor to hold the SC inner rotor 30 at the same RPM as the HPMSC outer rotor 20 during normal operation. This design is also advantageous because the design prevents the motor 10 from completely stalling during overload because when the load on the motor shaft 14, and thus on the SC inner rotor 30, exceeds the motor design torque, the SC inner rotor 30 can break away from the HPMSC outer rotor 20 leaving the HPMSC outer rotor 20 at synchronous RPM.
As the HPMSC outer rotor 20 increases in RPM, the rotor frequency decreases, as this occurs the rotating stator magnetic field reaches deeper into HPMSC outer rotor 20 and into the SC inner rotor 30, creating a duel cage rotor effect of a bar section at the surface of rotor and larger section bars deeper into rotor, producing more starting resistance reducing current spikes.
A cross-sectional view of the electric motor 10 at synchronous speed, taken along line 2-2 of
While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims.
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102868268CNA.tran Translation of Yu H CN102868268. |
USPTO Translation of CN102868268. |
JP 11341757 English Translation. |
EIC STIC 2800 Search Report 548636. |
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20150194866 A1 | Jul 2015 | US |