The subject matter disclosed herein relates generally to electric machines. More specifically, the subject disclosure relates to permanent magnet rotor construction for electric machines.
Typical permanent magnet rotors used in electric machines, such as hybrid motors, include slots extending through a rotor lamination stack to receive the permanent magnets. The slots are typically oval in shape, and receive rectangular magnets, so there are gaps between each slot and each magnet. This gap is then injected molded with nylon or filled with an epoxy or varnish material to fill the gap.
Cooling the permanent magnets in such a rotor is a challenge. Operation of the rotor at elevated temperatures causes degradation in magnet performance, and even demagnetization of the magnets resulting in failure of the motor.
A permanent magnet rotor assembly for an electric machine includes a rotor core including one or more axially-extending openings and one or more permanent magnets located in the one or more axially-extending openings defining one or more gaps between the one or more permanent magnets and the one or more axially-extending openings. One or more thermally-conductive bars are located in the one or more gaps to transfer thermal energy from an interior of the rotor assembly toward an axial end of the rotor assembly.
An electric machine for a motor vehicle includes a stator, and a rotor assembly located at a central axis of the electric machine and interactive with the stator. The rotor assembly includes a rotor core having one or more axially-extending openings and one or more permanent magnets located in the one or more axially-extending openings defining one or more gaps between the one or more permanent magnets and the one or more axially-extending openings. One or more thermally-conductive bars are located in the one or more gaps to transfer thermal energy from an interior of the rotor assembly toward an axial end of the rotor assembly.
A method of cooling a rotor of a permanent magnet electric machine includes locating one or more thermally conductive bars in one or more axially-extending openings in a rotor core. Thermal energy is transferred to the one or more thermally conductive bars from the rotor and is transferred along a length of the one or more conductive bars to an axial end of the rotor. The thermal energy is dissipated from the axial end of the rotor.
The detailed description explains embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.
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A thermally conductive bar 36 extending a length of the magnet opening 22 is installed in the gap 30. In some embodiments, the conductive bar 36 is formed from an aluminum or copper based material. An aluminum based conductive bar 36 has a thermal conductivity about 4 times that of the steel rotor laminations 20, while a copper based conductive bar 36 has a thermal conductivity about 8 times that of the rotor laminations 20. In some embodiments, the conductive bar 36 is a single, solid piece of material, while in other embodiments, the conductive bar 36 may be a tubular form or other hollow shape. Further the conductive bar 36 may comprise more than one piece of material, or may be formed of more than one type of material. For example, the conductive bar 36 may be a layered structure including layers of conductive materials arranged to form the conductive bar 36. It is to be appreciated that the conductive bar 36 structures described herein are merely exemplary, and that other conductive bar 36 structures are contemplated by the present disclosure. During operation of the electric machine 10, the rotor 12, and particularly the rotor magnets 26 increase in temperature, with the greatest temperature occurring at or near an axial midpoint of the rotor 12. The conductive bars 36 are utilized to transfer thermal energy from the interior of the rotor 12 toward the axial ends 28, 50 of the rotor 12 where the thermal energy can be dissipated by the cooling system (either fluid or air cooled) of the electric machine 10. Locating the conductive bars 36 in the magnet opening 22 with the rotor magnet 26, closest to the accumulated thermal energy, increases effectiveness of the thermal energy removal by the conductive bars 36 over locating the conductive bars elsewhere in the rotor 12.
In some electric machines 10, eddy current within the conductive bars 36 may cause operability problems for the electric machine 10. In such cases, the conductive bars 36 may be formed from a powdered metal, such as aluminum or copper. The flakes or particles of powdered metal are individually coated with a magnetically and electrically insulative material, such that a magnetic and electrical barrier is formed to prevent the eddy current problems, while the conductive bar 36 retains its thermal conductivity.
While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.
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