Axial-flux motor/generator 18 may include a housing 22, a rotor 24, and a rotor 26. Rotors 24, 26 may each be supported from housing 22 in a manner allowing each rotor 24, 26 to rotate about a common axis 28. Housing 22 may support rotors 24, 26 directly and/or one or more components supported by housing 22, such as bearings, may support rotors 24, 26. Rotors 24, 26 may be mechanically decoupled from one another. Rotor 24 may be drivingly connected to mechanical power source 16, and rotor 26 may be drivingly connected to propulsion devices 14.
Axial-flux motor/generator 18 may also include a power-conversion system 27 configured to convert between mechanical power at rotors 24, 26 and electrical power in electrical power-transfer network 19. Power-conversion system 27 may include various sources of magnetic flux, such as electrical coils (not shown in
Electrical power-transfer network 19 may electrically connect power-conversion system 27 and various other electrical components of power system 12. Electrical power-transfer network 19 may include a power regulator 30, a power regulator 32, and various electrical conductors connecting power regulators 30, 32 to power-conversion system 27 and various other electrical components. Power regulators 30, 32 may be configured to regulate one or more aspects of the operation of axial-flux motor/generator 18 by regulating electrical activity in one or more components of power-conversion system 27. This may include regulating various timing aspects of electrical activity, such as the phase and/or frequency of alternating current, in one or more components of power-conversion system 27. Power regulators 30, 32 may also be configured to regulate power transfer between different components of power-conversion system 27 and/or to regulate power transfer between power-conversion system 27 and other electrical components of power system 12. Additionally, one or both of power regulators 30, 32 may be configured to convert power between different forms, such as alternating current and direct current, as the power flows between power-conversion system 27 and other electrical components.
Electrical power sources and/or loads connected to electrical power-transfer network 19 may include a battery 34, accessories 36, 38, 40, an operator interface 42, and controllers 44, 46. Accessories 36, 38, 40 may include devices such as lights, windshield wipers, power windows, power seats, radios, blowers, heaters, and/or various other types of electrical components for facilitating operation of machine 10.
Power-system controls 20 may include power regulator 30, power regulator 32, operator interface 42, controller 44, and controller 46. Operator interface 42 may include any types of components configured to transmit operator inputs to other components of machine 10. For example, operator interface 42 may include an accelerator pedal 47 and various associated components for receiving acceleration requests from an operator and transmitting such acceleration requests to other components of machine 10. Similarly, operator interface 42 may include a brake pedal 49 and various associated components for receiving braking requests from an operator and transmitting such braking requests to other components of machine 10. Additionally, operator interface 42 may include a starter switch 51 and various associated components for receiving from an operator a request to start mechanical power source 16 and transmitting that request to other components of machine 10.
Each controller 44, 46 may be any type of device configured to control one or more aspects of the operation of machine 10. Each controller 44, 46 may include one or more processors (not shown) and one or more memory devices (not shown). Controller 44 may be operatively connected to mechanical power source 16, operator interface 42, controller 46, and various other sources of information (not shown). Controller 44 may control one or more aspects of the operation of mechanical power source 16 dependent upon inputs from operator interface 42, controller 46, and other sources of information. Controller 46 may be operatively connected to power regulators 30, 32, operator interface 42, and controller 44. Additionally, information channels 48 may supply controller 46 with information regarding the state of electrification in components of power-conversion system 27. Similarly, information channels 50 may supply controller 46 with information relating to the state of electrification in electrical power-transfer network 19. Based on information received from operator interface 42, controller 44, information channels 48, information channels 50, and/or various other sources of information, controller 46 may control power regulators 30, 32 to control one or more aspects of the operation of axial-flux motor/generator 18.
Propulsion devices 14 may be any type of device configured to receive power from power system 12 and propel machine 10 by applying that power to the environment surrounding machine 10. For example, as
Machine 10 is not limited to the configuration shown in
Additionally, power-system controls 20 may include other controllers in addition to controllers 44, 46. Alternatively, power-system controls 20 may replace controllers 44, 46 with a single controller that controls mechanical power source 16 and power regulators 30, 32. In some embodiments, power-system controls 20 may replace controllers 44, 46 with hard-wired control circuits or other similar control components.
Plurality of permanent magnets 56 may be disposed adjacent a side of electrical coil 54 opposite plurality of permanent magnets 52. Plurality of permanent magnets 56 may be attached to rotor 24 with an axial interface 66 disposed between plurality of permanent magnets 56 and electrical coil 54. Plurality of permanent magnets 56 may have magnetic poles facing generally toward axial interface 66 so that plurality of permanent magnets 56 transmits axial flux across axial interface 66 to electrical coil 54. Additionally, electrical coil 54 may be configured in a manner such that supplying electrical coil 54 with electricity causes electrical coil 54 to generate magnetic flux that flows across axial interface 66 to plurality of permanent magnets 56.
Plurality of permanent magnets 58 and electrical coil 60 may electromagnetically couple rotor 24 and rotor 26. Plurality of permanent magnets 58 may be mounted to rotor 24. Electrical coil 60 may be mounted to rotor 26 with an axial interface 68 disposed between plurality of permanent magnets 58 and electrical coil 60. Plurality of permanent magnets 58 may have magnetic poles facing generally toward axial interface 68 so that plurality of permanent magnets 58 may transmit magnetic flux across axial interface 68. Additionally, electrical coil 60 may be configured such that supplying electricity to electrical coil 60 causes electrical coil 60 to generate magnetic flux that flows across axial interface 68 to plurality of permanent magnets 58. Electrical coil 60 may be any of various types of electrical coils that may function in this manner, including, but not limited to, a slot-wound electrical coil and a Gramme-type electrical coil. Electrical coil 60 may electrically connect to power regulator 32 through brushes 61 that contact rotor 26.
Paired sources of magnetic flux may have equal numbers of magnetic poles. For example, plurality of permanent magnets 52 and electrical coil 54 may have equal numbers of poles. Similarly, plurality of permanent magnets 56 may have the same number of poles as electrical coil 54. Additionally, plurality of permanent magnets 58 and electrical coil 60 may have equal numbers of poles.
In some embodiments, the sources of magnetic flux associated with rotor 24 may have a different number of magnetic poles than the sources of magnetic flux associated with rotor 26. For example, in some embodiments, plurality of permanent magnets 52, electrical coil 54, and plurality of permanent magnets 56 may each have a greater number of poles than plurality of permanent magnets 58 and electrical coil 60.
Axial-flux motor/generator 18 is not limited to the configuration shown in
Additionally, in some embodiments, axial-flux motor/generator 18 may include different numbers of rotor discs and/or different numbers of stators than shown in
In the embodiment shown in
Power-conversion system 27 of axial-flux motor/generator 18 is not limited to the configurations shown in
Additionally, in some embodiments, axial-flux motor/generator 18 may include different numbers of rotor discs and/or different numbers of stators than shown in
Machine 10 and power system 12 may have application wherever power is required to perform one or more tasks. Power-system controls 20 may cause power system 12 to generate electricity with axial-flux motor/generator 18. For example, power-system controls 20 may cause mechanical power source 16 to drive rotor 24 while axial-flux motor/generator 18 generates electricity with mechanical power received from mechanical power source 16. As mechanical power source 16 rotates rotor 24 about rotation axis 28, magnetic flux flowing from plurality of permanent magnets 52 across axial interface 62 and magnetic flux flowing from plurality of permanent magnets 56 across axial interface 66 may induce electric current in electrical coil 54.
In addition to causing power system 12 to generate electricity with axial-flux motor/generator 18, power-system controls 20 may cause axial-flux motor/generator 18 to operate as an electric motor to drive rotor 26 in some circumstances. For example, when an operator of machine 10 makes an acceleration request with accelerator pedal 47, power-system controls 20 may respond by causing axial-flux motor/generator 18 to operate as an electric motor driving rotor 26, thereby driving propulsion devices 14 and propelling machine 10. In some circumstances, power-system controls 20 may cause axial-flux motor/generator 18 to operate as an electric motor to drive rotor 26 while simultaneously causing mechanical power source 16 to drive rotor 24 and axial-flux motor/generator 18 to generate electricity with rotor 24.
Power-system controls 20 may cause axial-flux motor/generator 18 to operate as an electric motor by supplying electricity to electrical coil 60 in a manner to cause electrical coil 60 to generate a rotating field of magnetic flux. In the case of the embodiment shown in
Additionally, in some circumstances, power-system controls 20 may also cause axial-flux motor/generator 18 to generate electricity with mechanical power from rotor 26. For example, when machine 10 is in motion and an operator transmits a braking request with brake pedal 49, power-system controls 20 may cause axial-flux motor/generator 18 to generate electricity in electrical coil 60 with power transmitted to rotor 26 by propulsion devices 14, thereby braking machine 10. Power-system controls 20 may do so by regulating electrical activity in electrical coil 60 in such a manner that magnetic flux from plurality of permanent magnets 58 or from plurality of permanent magnets 72 induces electric current in electrical coil 60.
Furthermore, in some circumstances, power-system controls 20 may cause axial-flux motor/generator 18 to operate as an electric motor to rotate rotor 24. For example, when mechanical power source 16 is not running and an operator manipulates starter switch 51 to request starting of mechanical power source 16, power-system controls 20 may cause axial-flux motor/generator 18 to operate as an electric motor to drive rotor 24 and, thus, mechanical power source 16.
The disclosed embodiments may allow power-system controls 20 to control rotors 24, 26 completely independently, thereby utilizing axial-flux motor/generator 18 to effectively perform the roles of two axial-flux motor/generators. Because rotors 24, 26 are mechanically decoupled, power-system controls 20 may control the speed and direction of rotation of each of rotors 24, 26 independently. Power-system controls 20 may control whether axial-flux motor/generator 18 generates electricity with rotor 24 or drives rotor 24 independently of whether axial-flux motor/generator 18 generates electricity with rotor 26 or drives rotor 26. Additionally, by providing a stationary source of reaction torque for rotor 24, stator 64 may allow power-system controls 20 to control the torque on rotor 24 independently of the torque on rotor 26.
The disclosed embodiments of power system 12 may be energy efficient, space efficient, and inexpensive. The ability to control the speed and torque at rotors 24, 26 independently may enable power system 12 to supply mechanical power in an energy efficient manner across a wide range of speeds and torques. When mechanical power source 16 drives rotor 24 and axial-flux motor/generator 18 uses rotor 24 to generate electricity, power-system controls 20 may control the speed and torque at rotor 24 in a manner to generate electricity with maximum energy efficiency. Simultaneously, using the efficiently generated electricity, axial-flux motor/generator 18 may operate as an electric motor to drive rotor 26 through a wide range of speeds and torques. Using a single axial-flux motor/generator 18 to simultaneously generate electricity and drive a mechanical power load may conserve space for other components of power system 12 and machine 10. Similarly, using a single axial-flux motor/generator 18 for these purposes may help keep component costs of power system 12 low.
Additionally, configuring the sources of magnetic flux associated with rotor 26 with fewer poles than the sources of magnetic flux associated with rotor 24 may enhance the energy efficiency of power system 12 in some applications and/or circumstances. In some cases, when operating as an electric motor driving rotor 26, axial-flux motor/generator 18 may convert electricity to mechanical power most efficiently by driving rotor 26 at a relatively high speed. Configuring the sources of magnetic flux associated with rotor 26 with a relatively low number of poles may enable axial-flux motor/generator 18 to drive rotor 26 at relatively high speeds. Conversely, when generating electricity with rotor 24, axial-flux motor/generator 18 may convert mechanical power to electricity most efficiently if the sources of magnetic flux associated with rotor 24 have a relatively greater number of poles and rotor 24 rotates relatively slowly.
It will be apparent to those skilled in the art that various modifications and variations can be made in the power system and methods without departing from the scope of the disclosure. Other embodiments of the disclosed power system and methods will be apparent to those skilled in the art from consideration of the specification and practice of the power system and methods disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope of the disclosure being indicated by the following claims and their equivalents.