The disclosure relates to laminations that may be used for rotors in interior pole magnet (IPM) motors, and with subsequent operations to form rotor bar slots, the same laminations may be used for line-start, IPM motors. In other words, a lamination which has been optimized for use in a non-line start IPM motor for low cogging, minimal usage of magnet material, and maximum torque per ampere, may be further processed to include rotor bars slots to allow the lamination's use in connection with an LSIPM motor. This provides manufacturing flexibility in that the same lamination may be used in both applications (albeit modified through further processing in the LSIPM motor application) to provide efficient, power dense, and economical motors over previous designs.
Turning to the drawings,
To induce rotation of the rotor, current is routed through stator windings disposed in the stator. (See
As will be become apparent from the discussion that follows, the stator and rotor may be designed to limit cogging torque of motor and optimize steady state performance of the motor. Generally speaking, the stator teeth 37 (and winding slots 34) may alternate in a rotationally symmetric fashion about the center axis 28. The stator slots and teeth 34,37 may have a generally constant cross-sectional profile and may be evenly spaced circumferentially about the axis of rotation 28 as measured by a line passing through a line passing through a longitudinal axis of the slots or teeth. There may be as many teeth as slots (for instance, 24), and this may be an integer multiple of the number of poles (e.g., two, four, six, eight, or more) of the rotor. The number of teeth (and/or slots) may also be an integer multiple of the number of phases of power the motor. The stator windings may also be arranged according to the number of poles and the number of phases of power delivered to the motor.
The rotor assembly 40 resides within the rotor chamber 34, and similar to the stator core 32, the rotor assembly 40 comprises a plurality of rotor laminations 42 aligned and adjacently placed with respect to one another to form a contiguous rotor core 44 with an outer diameter “Dr”. End members 46 are disposed on opposite ends of the rotor core 44 and may be generally circular in cross-section with an outer diameter that generally approximates the diameter of the rotor laminations 42. Each rotor lamination 42 has a generally circular cross-section and is formed of a magnetic material, such as electrical steel. Extending from end-to-end, i.e., transverse to the cross-section, each lamination 42 includes features that, when aligned with adjacent laminations 42, form cumulative features that extend axially through the rotor core 44. For example, when assembled, the rotor laminations 42 cooperate to form a shaft chamber 47 located in the center of the lamination 42 that extends through the center of the rotor core 44 and that is configured to receive the rotor shaft 26 therethrough. The rotor shaft 26 is secured with respect to the rotor core 44 such that the rotor core and the rotor shaft rotate as a single entity about the rotor center axis 28. As described below in greater detail, in each lamination, magnet slots, and in the case of the LSIPM, rotor bar slots, may also cooperate to form passages extending through the rotor core 44. While
To support the rotor assembly 40, the exemplary motor 10 includes drive and opposite drive bearing sets 50,52, respectively, that are secured to the rotor shaft 26 and that facilitate rotation of the rotor assembly 40 within the stationary stator core 32. During operation of the motor 10, the bearing sets 50,52 transfer the radial and thrust loads produced by the rotor assembly 40 to the motor housing. Each bearing set 50,52 includes an inner race 54 disposed circumferentially about the rotor shaft 26. The tight fit between the inner race 54 and the rotor shaft 26 causes the inner race 54 to rotate in conjunction with the rotor shaft 26. Each bearing set 50,52 also includes an outer race 56 and rotational elements 58, which are disposed between the inner and outer races 54,56. The rotational elements 58 facilitate rotation of the inner races 54 while the outer races 56 remain stationary and mounted with respect to the drive and opposite drive end caps 14,16. Thus, the bearing sets 50,52 facilitate rotation of the rotor assembly 40 while supporting the rotor assembly 40 within the motor housing, i.e., the frame 12 and the drive and opposite drive end caps 14,16. To reduce the coefficient of friction between the races 54, 56 and the rotational elements 58, the bearing sets 50,52 are coated with a lubricant. Although the drawings show the bearing sets 50, 52 with balls as rotational elements, the bearing sets may be other constructions, such as sleeve bearings, pin bearings, roller bearings, etc.
With these considerations in mind the rotor laminations 42A, 42B may be formed with magnet slots 70 and magnets 72 arranged in V configuration at a magnet angle 74 to form a pole width 76 defined by leading and trailing edges 77, 78 that provides a sufficient area in the lamination for the rotor bars between the magnets while providing magnet alignment to accommodate low cogging. The magnet angle may correspond to the angle formed between the edges of adjacent magnet slots. The magnet angle may also correspond to an angle between reference lines passing through points on adjacent magnets where the pole of each magnet changes direction. For instance, adjacent magnets may have a north pole on one side of each of the magnets and a south pole on another side of each of the magnets. The magnet angle may correspond to the angle between a first reference line passing through a center plane of one magnet where the poles switch direction and a second reference line passing through a center plane of an adjacent magnet where the poles switch direction. The magnets 72 may be rotationally symmetrically disposed about the axis of rotation and generally define the poles of the motor. Depending on the number of poles, the magnets 72 may be disposed in different repetition patterns, such as at intervals of 180 degrees, 60 degrees, 45 degrees, etc, for example. The magnets may be magnetized in a generally radial direction to establish inwardly and outwardly disposed north and south poles on the magnets. This means that adjacent magnets cooperate to establish alternate north and south poles on the periphery of the rotor. The rotor may be constructed with any even number of poles. An exemplary lamination for a four pole motor non-LS, IPM motor is shown in
As shown in the drawings by example and not in any limiting sense, the magnets may establish a direct axis 80 and a quadrature axis 82. The magnets define a general axis of magnetization (north or south pole) on the periphery of the rotor. The edges of the magnet slots facing the general axis of magnetization, which are radially outward from the magnets, establish a generally arcuate saturation boundary area as indicated by reference characters 84a,84b. The saturation boundary area may correspond to the pole width 74 depending upon the lamination design. The saturation boundary area may also be different from the pole width depending upon the lamination design. Generally speaking, the edges of the magnet slots and the edges of the magnets both face the general axis of magnetization.
In each of the designs of the laminations shown in
As explained below, the shape of the poles and the size of the pole width relative to the size of the stator tooth pitch may be arranged to limit adverse cogging. The poles may be configured so that when the leading edges are between teeth, the trailing edge is aligned with a tooth. In other words, the magnets (and other aspects of the lamination) are arranged so that both edges 84a,84b of the pole (air gap flux density changes) do no align with stator teeth at the same time. That is, the poles are spatially desynchronized with the stator teeth. For purposes of illustration,
With this general configuration, the lamination may be used directly in a non-line start IPM or further processed for use in a rotor of a LSIPM. In a LSPIM, the lamination 42 may be further processed to include a series of rotor bar slots 100 that are arranged at positions about the lamination such that when assembled, the rotor bar slots cooperate to form channels for the rotor bars that extend through the rotor core 44. The rotor bar slots 100 are spaced radially inward from the rotor outer diameter Dr. As shown in the drawings, each of the rotor bar slots may extend radially outward to generally the same radial position relative to the rotor outer diameter Dr, or one or more rotor bar slots may extend radially outward and terminate at different radial distances relative to the outer diameter Dr, depending upon the application. The rotor bars 48 may present the same shape as the rotor bar slots 100 to provide a tight fit for the rotor bars 48 within the rotor bar slots. The rotor bars 48 may be manufactured with tight tolerances between the rotor bars and the rotor bar slots 100. The rotor bar slots may also be configured to receive electrically conductive material to form the rotor bars 48 for the starting cage of the motor. The conductive material may comprise a molten material introduced into the slots to form cast rotor bars. The end members may also be cast.
The rotor bars slots 100,102 forming the starting cage may have a different size, shape, and spacing about the center axis 28. The rotor bar slots 100 may be distributed about the rotor in a manner that is asymmetric rather than evenly distributed, i.e., asymmetric rather than equiangularly spaced, around the outer edge of the lamination surface. Additionally, the rotor bar slots may have an arbitrary shape. The rotor bar slots 100 that are disposed in the saturation boundary area 84a,84b form a cluster. At least two of the rotor bar slots of the cluster may vary in cross-sectional area by at least 10 percent. At least two of the rotor bar slots of the cluster may also vary dimensionally by at least 5 percent. The laminations may be stacked off-set to one another such that the rotor bar in the slot has a helix relative to the rotor axis of rotation. Additionally, a rotor bar slot 102 may be provided to align with the quadrature axis 82. The rotor bar slot 102 of the quadrature axis 82 may have a geometry which matches at least one of the rotor bar slots 100 aligned with the direct axis 80. Although some of the drawings show a plurality of rotor bar slots in the direct axis and one rotor bar slot in the quadrature axis, other variations may be used.
The lamination designs shown in
In the lamination design shown in
While certain embodiments have been described in detail in the foregoing detailed description and illustrated in the accompanying drawings, those with ordinary skill in the art will appreciate that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Particularly, the figures and exemplar embodiments of the rotor laminations are intended to show illustrative examples and not to be considered limiting in any sense. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the appended claims and any and all equivalents thereof.
This application is a continuation in part of application Ser. No. 13/329,814 filed Dec. 19, 2011, currently pending, the disclosure of which is incorporated by reference herein.
This invention was made with Government support under agreement no. DE-FG36-08GO180132 awarded by the Department of Energy. The Government has certain rights in this invention.
Number | Date | Country | |
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Parent | 13329814 | Dec 2011 | US |
Child | 14271922 | US |