The present invention relates to electromagnetic devices using rotating elements in a magnetic field, in particular to the variations of current carrying bars/windings placed in a magnetic field and the application of electrical current through these current carrying bars/windings.
It is a well understood aspect of electrometric theory that as current passes through a simple bar conductor, it induces a magnetic field perpendicular to the direction of current flow. As a result of the induced magnetic field, each of the moving charges comprising the current, experiences a force. The force exerted on each of the moving charges generates torque. It is this principle that underpins devices such as electric motors and generators.
Most typical DC motors consist of three main components namely a stator, armature/rotor and commutator. The stator typically provides a magnetic field which interacts with the field induced in the armature to create motion. The commutator acts to reverse the current flowing in the armature every half revolution thereby reversing the field in the armature to maintain its rotation within the field in the one direction. A DC motor in its simplest form can be described by the following three relationships:
e
a
=KΦω
V=e
a
+R
a
i
a
T=KΦi
a
Where ea is the back emf, V the voltage applied to the motor, T the torque, K the motor constant, Φ the magnetic flux, ω the rotational speed of the motor, Ra the armature resistance and ia the armature current.
The magnetic field in a typical motor is stationary (on the stator) and is created by permanent magnets or by coils. As current is applied to the armature/rotor, the force on each conductor in the armature is given by F=ia×B×1. Back emf is generated due to a relative rate of flux change as a result of the conductors within the armature rotating through the stationary field. The armature voltage loop therefore contains the back emf plus the resistive losses in the windings. Thus, speed control of the DC motor is primarily through the voltage V applied to the armature while torque scales with the product of magnetic flux and current.
Thus, in order to maximise torque in a DC motor, one would presume that it is simply a matter of increasing either the magnetic field or the current supplied. In practice, however, there are limitations. For instance, the size of the magnetic field which can be generated via permanent magnets is limited by a number of factors. In order to produce a significantly large field from a permanent magnet, the physical size of the magnet is relatively large (e.g. a 230 mm N35 magnet is capable of producing a field of a few Kilogauss (kG)). Significantly, larger fields can be produced utilising a plurality of magnets, the size and number of magnets again adds to the overall size and weight of the system. Both size and weight of the motor are critical design considerations in applications such as electric propulsion systems. Generation of larger magnetic fields is possible utilising standard wire coils but the size, weight and heating effects make the use of standard coils impractical.
Another factor which has an effect on torque that needs consideration is the production of drag caused by eddy currents created within the armature/rotor. Eddy currents occur where there is a temporal variation in the magnetic field, a change in the magnetic field through a conductor or change due to the relative motion of a source of magnetic field and a conducting material. The eddy currents induce magnetic fields that oppose the change of the original magnetic field per Lenz's law, causing repulsive or drag forces between the conductor and the magnet. The power loss (P) caused by eddy currents for the case of a simple conductor assuming a uniform a material and field, and neglecting skin effect can be calculated by:
where Bp is peak flux density, d—thickness or diameter of the wire, ρ—resistivity, σ—electrical conductivity, μ magnetic permeability, f frequency (change in field) and penetration depth (D).
As can be seen from the above equation, as the magnetic field increases the size and effects of eddy currents increase i.e. the higher the magnetic field, the greater the drag produced as a result of eddy currents. In addition to the field strength, the resistivity of and thickness of the conductive elements in the armature are also a factor. Selection of the material of the conductive elements in the armature can greatly affect the amount of current that can be applied to the armature.
These basic properties and functions are the focus of continuing developments in the search for improved devices having better efficiencies.
Reference to any prior art in this specification is not, and should not be taken as an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.
Aspects of the present invention are directed to electromagnetic devices, such as electromagnetic motors or generators, which may at least partially overcome at least one of the abovementioned disadvantages or provide the consumer with a useful or commercial choice.
According to an aspect of the present invention, an electromagnetic device is provided. The electromagnetic device comprises: a stator; a gap comprising multiple gap regions; and a rotor arranged in the gap to move relative to the stator. One of the stator and the rotor comprises a conductor array having one or more conductors each configured to carry current in a respective current flow direction, the other of the stator and the rotor comprises a flux directing assembly having multiple flux directing sections, each arranged adjacent to at least one other flux directing section and each configured to facilitate a circulating magnetic flux path about the respective flux directing section. Each pair of adjacent flux directing sections are arranged about a common gap region of the multiple gap regions and configured to direct at least part of the respective circulating magnetic flux paths across the common gap region in a substantially similar flux direction substantially perpendicular to the current flow direction.
The adjacent flux directing sections are further configured to redirect the respective circulating magnetic flux paths from (or to) other gap regions of the multiple gap regions to (or from) the common gap region.
The adjacent flux directing sections include a common working element configured to direct magnetic flux into and out of the common gap region.
Each of the adjacent flux directing sections include a redirecting element configured to receive (or forward) the magnetic flux from (or to) the common gap region and redirect the magnetic flux to (or from) a respective one of the other gap regions.
The strength of the magnetic flux directed by the common working element may be reinforced compared to strength of the magnetic flux directed by the redirecting element.
In some embodiments, the common working element includes two electromagnetic coils placed on opposite sides of the common gap region.
In some embodiments, the redirecting element includes a single electromagnetic coil configured to direct the magnetic flux through the single electromagnetic coil in a direction tangential to the rotation of the rotor. In other embodiments, the redirecting element includes two electromagnetic coils, each placed on an opposite side of the gap. In yet other embodiments, the redirecting element includes one or more additional electromagnetic coils configured to direct the magnetic flux to (or from) the single electromagnetic coil.
The opposite sides of the gap or the common gap region represent an inner portion and an outer portion of the flux directing assembly. In some embodiments, the inner portion may include a flux guide and the outer portion may include one or more electromagnetic coils. In other embodiments, the inner portion may include one or more electromagnetic coils and the outer portion may include a flux guide.
The electromagnetic coil(s) may include one or more racetrack coils.
In some embodiments, the common working element includes one or more permanent magnets placed on each of opposite sides of the common gap region and oriented in a substantially radial direction. In such embodiments, the redirecting element may include one or more permanent magnets placed on each of the opposite sides of the common gap region and oriented in a substantially non-radial direction.
In some embodiments, the common working element may include a flux guide on a first side of the common gap region and one or more permanent magnets placed on a second, opposite side of the common gap region and oriented in a substantially radial direction. In these embodiments, the redirecting element may include an additional flux guide on the first side of the common gap region and one or more additional permanent magnets placed on the second, opposite side of the common gap region and oriented in a substantially non-radial direction.
The permanent magnets of the working and/or redirecting elements may be oriented to form one or more Halbach arrays or partial Halbach arrays.
The respective circulating magnetic flux paths of the adjacent flux directing sections circulate in opposite directions. For example, the magnetic flux path of one of the adjacent flux directing sections may circulate in a clockwise direction and the magnetic flux path of the other of the adjacent flux directing sections may circulate in an anticlockwise direction.
The number of the circulating magnetic flux paths may equal the number of magnetic flux traversals across the gap. Further, the number of flux directing sections may equal the number of gap regions.
Also disclosed is a magnetic gearbox that includes a rotating crown and pinion rotors. The crown and pinions may each include a magnetic array. In an arrangement, the magnetic array may be sequentially radially magnetised. For example, the magnetic array may form one or more Halbach magnetic array or partial array.
While the term ‘magnetic field’ is generally a vector quantity to represent directional magnetic field strength and the term ‘magnetic flux’ is generally a scalar quantity to represent non-directional magnetic energy flow, where the context requires, however, both terms in this specification are used interchangeably and their meanings are not limited by such strict use. For a non-limiting example, description of magnetic flux with corresponding static illustrations of magnetic field should be read with the magnetic flux associating with a directional context and the magnetic field associated with a flowing context.
Aspects of the present invention in one form, reside broadly in an electromagnetic device including a flux directing assembly to generate a magnetic field, a gap having multiple gap regions, and a conductor array located within the gap to allow interaction between a current flow in the conductor array and the relative movement of the conductor array to the flux directing assembly in the presence of the magnetic field. In some configurations, as exemplified in
The flux directing assembly includes one or more working elements (also referred to as primary elements/coil or pole elements/coils in this disclosure) configured to direct magnetic flux across the corresponding gap regions and redirecting elements (also referred to as interstitial elements or coils in this disclosure) configured to redirect the magnetic flux back towards the working elements. At least a portion of a working element and a redirecting element form a flux directing section. The flux directing assembly may include multiple such flux directing sections. Each flux directing section is arranged adjacent to at least one other flux directing section, such that the adjacent flux directing sections share a common working element. Each flux directing section is configured to facilitate a circulating magnetic flux path about itself.
Furthermore, each pair of adjacent flux directing sections is arranged about a common gap region of the multiple gap regions and configured to direct at least part of the respective circulating magnetic flux paths across the common gap region in a substantially similar flux direction substantially perpendicular to the current flow direction.
The working elements and the redirecting elements may each be formed of one or more electromagnetic coils or permanent magnets. According to a particular embodiment, each common working element about adjacent flux directions sections is formed of a single working coil or permanent magnet, positioned either on the inner or outer side of the corresponding gap region. In another embodiment, each common working element is formed of two working coils or permanent magnets, one positioned on the outer side of the gap region and another positioned on the inner side of the gap region. In either embodiment, each working coil/permanent magnet therefore forms one half of the common working element shared by two adjacent flux directing sections. The working coils/permanent magnets are spaced from one another allowing the mounting for the conductive element to extend into the magnetic field generated by the common working elements.
Similarly, in some embodiments, a redirecting element may have a single redirecting coil/permanent magnet positioned on either the outer or inner side of the gap. In some other embodiments, the redirecting element may have two redirecting coils/permanent magnets—one positioned on the outer side of the gap and another placed on the inner side of the gap. In yet other embodiments, the number of inner and outer redirecting coils/permanent magnets can be increased to two, three, four, five, six, or more positioned on either side of a the gap and between two working elements on each side.
In other embodiments, the outer and/or inner working coils/permanent magnets may each or collectively be interchanged with one or more flux guides, for example, in the form of multiple pole pieces or a single cylinder having a hollow centre. The flux guides may be formed of any suitable material, such as ferromagnetic or paramagnetic materials without departing from the scope of the present disclosure.
When the flux guides are in the form of multiple pole pieces, the pole pieces may be substantially aligned with the working coils or permanent magnets on the opposite side of the gap regions and function as part of the working elements. Air gaps between the pole pieces may allow passage of magnetic flux between adjacent pole pieces.
Alternatively, when the flux guide is in the form of a hollow cylinder, the portions of the cylinder that are substantially aligned with the working coils/permanent magnets on the opposite side of the gap regions function as part of the working elements whereas the remainder of the hollow cylinder functions as part of the redirecting elements.
Each of the working coils and redirecting coils may be substantially rectangular in shape.
In some embodiments, the coils may be formed of superconductor material. In these embodiments, the portion of the electromagnetic device that is formed of superconductor material is at least partially enclosed within a cryogenic envelope or cryostat in order to cool the superconducting coils. When the flux directing assembly and the conductive element are both formed of superconductor material, the magnetic flux assembly may be positioned in a first cryostat and the conductive element may be provided in a second cryostat which is movable relative to the first cryostat. Typically, the first cryostat is fixed and the second cryostat rotates within at least a portion of the first cryostat with the conductive element fixed within the second cryostat.
The superconducting coils of the flux directing assembly may be formed by winding superconducting tape or wire to form a coil. These types of coils may be preferred due to their near zero electrical resistance when cooled below the critical temperature. They also allow high current density and hence, allow creation of a large (and dense) magnetic field.
The magnetic field generated by the flux directing assembly may be permanent or changing. In some instances, the magnetic field is a permanent field with the field of the at least one conductive element being the changing field in order to provide the motive force for moving the at least one conductive element through interaction with the magnetic field.
In some instances, where a changing field is provided, this is achieved through a physically or electronically commutated direct current supply or an alternating current supply.
It should be appreciated that the characteristics of the flux directing assembly and the at least one conductive element will be determined according to the application.
The coils can be provided in any number of layers, with some example embodiments using multiple layers.
Moreover, the electromagnetic device can have a reciprocating or rotating configuration with the at least one conductive element mounted for movement according to either (or both) of these principles. According to the rotating embodiment, the flux directing assembly may include a set of coils in order to produce the magnetic field. Typically, the at least one conductive element is located within a gap in the flux directing assembly and rotates about an axis substantially perpendicular to the dominant direction of the magnetic field created by the flux directing assembly in the gap.
In another broad form, the present invention resides in an electromagnetic machine having a number of magnetic elements, each having a north magnetic pole and/or field and a south magnetic pole and/or field positioned relative to one another to create an interstitial magnetic pole between adjacent magnetic elements and at least one conductor element located relative to the magnetic elements such that the conductor interacts with the magnetic poles and/or fields of the magnetic elements to produce electrical current or mechanical work.
A basis of operation of at least some disclosed devices is the interaction between a current carrying conductor and a magnetic field. This interaction results in an output torque developed in the device (in the case of a motor) or an output voltage and current (in the case of a generator). Some disclosed devices include one static or stationary magnetic field and one alternating field.
The magnetic field consists, at a fundamental level, of a magnetic pole created by either an electromagnetic coil or by a permanent magnet. The pole has a North and South orientation of the magnetic field.
In at least some disclosed devices, the generated magnetic field is used more than once, that is—that multiple paths are described through the magnetic field by the current carrying conductors in order to greatly increase the power density of the electrical machines.
The rotating machines (motors and generators) of some embodiments each have:
In an embodiment, the driving or generating path remains stationary while the flux directing assembly rotates. The reverse scenario with moving driving or generating windings and stationary flux directing assembly is also workable, one characteristic of the first embodiment is that the higher currents that are constantly reversing polarity in the driving or generating coils do not have to be transmitted via a sliding contact or brush, reducing electrical losses in the device.
On the other hand, if there is application requirement that the spinning mass of the device be reduced to allow for rapid stopping, starting, acceleration and deceleration, there may well be an advantage in spinning the driving or generating path instead of the flux directing assembly. In this case, the design of the machine should favour a larger number of windings in the flux directing assembly. The operating direction of the machines presented in this document can be reversed by a reversal of the current direction in the background field coils or driving/generating path windings.
While the images and descriptions in this document present the embodiments in terms of rotating electrical machinery, it would be clear to anyone skilled in the art that the principles presented could be applied to linear machines as well as rotating devices.
The devices disclosed in this document also concern the production of mechanical work from an input of electrical voltage and current (motors) or the production of electrical voltage and current from the application of mechanical work (generators).
The motors/generators of the disclosed embodiments comprise a rotating part (rotor) and a stationary part (stator). In at least some devices disclosed, the primary function of the stator is to provide a high strength magnetic field in which the rotor rotates. The rotor can be powered with a current that changes direction in concert with the relative change in direction of the magnetic field (that is, as the rotor moves from one magnetic pole to the next) in the case of a motor. In the case of a generator, the movement of the rotor generally results in the generation of an alternating voltage and current.
In at least some devices disclosed herein, electrical energy is converted into mechanical work or mechanical work is used to create electrical energy through the action of a current carrying conductor moving within a magnetic field.
In some disclosed configurations, the magnetic field may be created by a series of adjoining electromagnetic coils that are wound in the form of toroids or sections of toroids in order to direct the magnetic field into a working region or a series of working regions through which a current carrying conductor moves. These toroidal sections both direct the magnetic field such that it is substantially perpendicular to the direction of current flow in the current carrying conductors/windings and contain the magnetic field largely within the device itself. In this manner, a high power device can be constructed limiting or eliminating the need for steel or ferromagnetic flux guides.
A gap region may exist between toroidal winding sections to allow for the mechanical placement and operation of the current carrying conductors.
Some disclosed configurations show the toroidal winding sections and arrangements built from superconducting wire and current carrying conductors from normal conducting material such as copper. It would be clear to a person skilled in the art that either part of the device could be readily constructed from either superconducting or normal conducting material.
In light of this disclosure, some features include (either separately or in one or more combinations):
Any of the features described herein can be combined in any combination with any one or more of the other features described herein within the scope of the invention.
The embodiments shown in
The embodiments shown in
The device shown in
In a further embodiment of the star toroidal device
A further variation involves the use of additional steel flux guides in and around the toroidal windings themselves in order to contain magnetic field and direct it across the working gap region.
The applicant's prior publication, such as PCT application no. PCT/AU2015/050333 published as WO2015192181 disclosed a magnetic gearbox that included a rotating crown and pinion rotors wherein the crown and pinions were sequentially radially magnetised North, South, North, South . . . etc. The relative number of poles between the crown and pinion was a function of the relative working diameters of the crown and pinions and ultimately the desired gear ratio of the final magnetic gearbox.
In further variation of that embodiment, the magnetisation of the magnetic material of the crown and pinions is arranged so as to form a Halbach magnetic array. The Halbach array consists of functionally magnetised sub-components that produce a strong magnetic field on one side of the array and very little magnetic field on the other side of the array. In a round form the magnetic gear consists of an internal Halbach cylinder (crown) and an external Halbach cylinder (pinion). The direction of magnetisation in a Halbach cylinder is functional and governed by:
M=M
r[cos(kϕ){circumflex over (ρ)}+sin(kϕ){circumflex over (ϕ)}]
Where M is the magnetisation vector and k is the order of the Halbach cylinder. Positive values for k produce internal Halbach cylinders and negative k values produce external Halbach cylinders. The number of poles in the Halbach cylinder is equal to (k−1)*2.
In further variation the elements that make up the magnetic gears are shaped such that they interlock. In normal operation the force at a distance provided by the magnets transmit torque with a gap between the interlocking elements. When subjected to overload the interlocking elements physically engage and transmit torque as a normal non-magnetic gear. This variation is shown in
The device shown in
A further axial magnetic gearbox variation is shown in
Any of the magnetic gearbox geometries disclosed could be magnetised in a number of ways while still transmitting torque between the magnetic gear elements. In addition to the alternating North-South and Halbach style magnetisations, the gear elements could also be magnetised in an All-North or All-South arrangement or any combination thereof.
In a further variation of the Star Toroidal devices that feature an internal flux guide, instead of internal flux directing coils, this flux guide can be made from laminated ferrite based material that has low hysteresis and eddy current loss. If the flux guide is constructed as a complete cylinder then the flux guide could rotate with the current carrying windings, resulting in a simpler construction of the rotor. A device featuring this unified current carrying winding and flux guide structure is shown in
In another embodiment of the toroidal style devices the creation and direction of the magnetic flux between successive poles around a cylindrical stator is accomplished using a smaller number of discrete coils. The arrangement of the smaller number of discrete coils produces a similar effect to that produced by a cylindrical Halbach array of permanent magnet material. This ‘Flux Directed’ coil construction achieves a similar effect to the arrangement of a larger number of coils in a set of toroidal sectors, in terms of containing and directing the magnetic field between successive poles, but uses a smaller amount of superconducting material.
The conductor array 4506 has a substantially cylindrical shape. It includes one or more conductors 4510 each configured to carry current in a respective current flow direction. The gap 4504 may also be in the form of a cylindrical space. The shape of the gap 4504 may correspond with the shape of the conductor array 4506. In some embodiments, the conductor array 4506 is wound on a rotor assembly (not shown) that consists of a cylindrical structure that supports and locates the conductor array 4506. This cylindrical structure connects to a shaft (not shown) and bearing assembly (not shown) that allows the rotor to spin and for power to be delivered or taken off from the shaft and rotor assembly. The rotor windings might be supported from both ends or from one end.
As seen in
In other embodiments, the working element may include one coil on one side of the gap region and a corresponding portion of a flux guide on the opposite side of the gap region. Example flux guides include multiple pole pieces or a hollow cylinder.
Similarly, the redirecting element may include a single redirecting coil on one side of the gap or multiple redirecting coils on one or both sides of the gap (as shown in later embodiments). When redirecting coils are present on one side of the gap, and not the other, portions of a flux guide on the other side may function as redirecting coils as described in detail with reference to
In some embodiments, the coils of the flux directing assembly 4502 are mechanically retained in a cryostat structure, comprising first and second cryostats for the two portions of the flux directing assembly (such as the inner portion and the outer portion). The cryostat structure secures the relative locations of the inner and outer portions of the flux directing assembly and provides cooling to the superconducting coils. The conductor array may be outside the cryostats, at room temperature, in the gap 4504 between the first and second cryostats.
As seen in
Each pair of adjacent flux directing sections (for example, see flux directing sections 4514a and 4514b) is arranged about a common gap region (see gap region 4505a). Furthermore, the flux directing sections 4514 each facilitate their own circulating flux paths such that at least a part of the respective circulating magnetic flux paths cross the common gap region 4505 in a substantially similar flux direction. For example, the flux directing sections 4514a and 4514b that share the common working element 4518a (i.e., outer working coil 4518ao and inner working coil 4518ai) direct at least part of the respective circulating magnetic flux paths across the common gap region 4505a in a substantially similar inward direction (see the magnetic flux paths of the flux directing sections 4514a and 4514b in the common gap region 4505a). Similarly, the magnetic flux paths of both the flux directing sections 4514b and 4514c are directed outwards in the common gap region 4505b, by the working element 4518b (i.e., outer working element 4518bo and inner working element 4518bi).
In this embodiment, during operation, the flux directing assembly 4502 facilitates eight circulating flux directing paths. It will be appreciated that the number of flux directing paths is equal to the number of gap regions and flux directing sections. The magnetic flux paths of three of the flux directing sections (i.e., sections 4514a, 4514b and 4514c) will be described in detail next to illustrate how the magnetic field is directed.
As mentioned previously, the working elements are configured to direct magnetic flux into the gap regions 4505. The redirecting elements are each configured to receive magnetic flux from a working element and/or forward the magnetic flux to another working element. For example, during operation, the outer working coil 4518ao is configured to receive magnetic flux from outer redirecting elements 4520ao and 4520bo (dashed arrows 1 in
The inner redirecting coils 4520ai and 4520bi direct (forward) the magnetic flux to the inner working coils 4518hi and 4518bi (dashed arrows 4 in
The conductor array is arranged in the gap, where the one or more conductors allow current to flow in a direction substantially perpendicular to the magnetic field in the gap. In the case of a motor, application of such current enables relative movement of the one or more conductors around the annular gap with respect of the flux directing assembly, facilitating rotational movement. In the case of a generator, such rotational movement around the annular gap enables generation of current or voltage along the one or more conductors.
In some embodiments, the strength of the magnetic flux directed by the working elements is reinforced compared to the strength of the magnetic flux directed by the redirecting element.
By using redirecting elements to provide multiple paths for the magnetic flux to return towards common working elements, the electromagnetic devices disclosed herein can be compact by, for example, positioning adjacent flux directing sections close to each other. Furthermore, the redirecting elements aid in shaping the field profile in the gap region to improve the smoothness of the power delivery and/or reduce torque ripple. To shape the field profile for smoothness, the position, number, angle, size and/or shape of the redirecting coils can be adjusted, for example by way of trial and error and/or simulation/optimization. As in a permanent magnetic Halbach array, the perpendicular magnetic field in the gap regions can be made more sinusoidal, that is, the back-emf can have lower harmonic content or total harmonic distortion.
In some embodiments, the working elements and the redirecting elements are formed of racetrack coils. Each working element produces the bulk of the magnetic field for each magnetic pole and each redirecting element directs and reinforces the magnetic field between each of the magnetic pole. Furthermore, the redirecting element racetrack coil is configured to direct the magnetic flux through the coil in a direction that is tangential to the rotation of the rotor 4506.
It will be appreciated that in this embodiment, the flux directing assembly is illustrated with eight poles. However, in other embodiments, the flux directing assembly 4502 may have more or fewer poles without departing from the scope of the present disclosure.
In this embodiment, the end windings of the conductor array 4906 are ‘diamond shaped’ rather than bedstead shaped such that they do not extend beyond the inner and outer radial constraints of the rotor body. This allows the rotor to fit cleanly through the clear bore of the device. However, it will be appreciated that bedstead shaped end windings may also be utilized with this embodiment without departing from the scope of the present disclosure.
As noted previously, the portions of the cylindrical flux guide that are directly opposite the outer working coils function as part of the corresponding working element, whereas the remaining portions of the cylindrical flux guide function as part of the redirecting elements.
The embodiments disclosed concern devices that use flux directing assemblies having arrays of permanent magnets that are magnetised in such a manner so as to direct magnetic field in a succession of working elements around a gap or region. Within this gap region a set of current carrying windings are placed such that energising the current carrying windings results in the relative rotation between the magnetic array and the current carrying windings, thereby resulting in the conversion of electrical power to mechanical power. The reverse scenario, where the application of mechanical power to the permanent magnet array results in the generation of electrical current and power in the current carrying windings, is also applicable.
Other features of this embodiment include a set of multi-phase current carrying windings and an internal steel flux guide that draws the magnetic field created by the outer magnetic array across the working gap. In one embodiment the flux guide is constructed from laminated, low core loss material and is attached to the current carrying windings. In this embodiment the windings and internal flux guide remain stationary and the outer magnet array rotates.
It will be appreciated that in other embodiments the device may have an inner array of permanent magnets and an external steel flux guide that draws the magnetic field created by the inner magnetic array across the working gap.
In an alternative embodiment of the device shown in
In this embodiment, the windings 7008 remain stationary whereas the flux directing assembly rotates. It will be appreciated that the alternative (i.e., stationary flux directing assembly and rotating conductive windings) is also considered within the scope of the present disclosure.
The elements of the inner and outer Halbach arrays are magnetized such that the two permanent magnet cylinders are aligned to create a strong magnetic field in the gap region where the current carrying windings sit.
As seen in
It should be appreciated by the skilled person in the art that, while the “radial” embodiments illustrated in
Furthermore, as described below for arrangements involving Halbach arrays,
A further variation on the disclosed embodiments involves the use of a layer of backing steel on the outer side of the external permanent magnet array (or additionally on the inner layer of the internal flux directed permanent magnet array). This backing steel helps to contain and strengthen the magnetic field within the devices thereby increasing the power level of the device.
It will be clear to a person skilled in the art that the torque coupling described wherein the predominant direction of the interacting magnetic fields is along the radial direction of the device, that an equivalent device could be constructed wherein the predominant direction of the interacting magnetic fields is along the axial direction of the device. Such an axial flux device is shown in
In a further variation to the previously disclosed magnetic gearbox that featured multiple input/output shafts feeding torque to or from a single secondary shaft, the externally magnetized ‘planet’ gears can further transmit torque to a central ‘sun’ magnetic gear that is also constructed as an externally magnetized Halbach cylinder. The device effectively becomes a magnetic epicyclical gearbox that has no physical contact between the different torque transmitting faces of the device. Similar to a traditional toothed contact epicyclical gearbox there is a central ‘sun’ gear formed from an externally magnetized Halbach cylinder, several externally magnetized ‘carrier’ gears similar to the previously disclosed planetary magnetic gears and an internally magnetized annulus gear that surrounds the entire assembly. An embodiment of this type of epicyclical magnetic gearbox is shown in
The ratio of the device is a function of the radius and number of magnetic poles (magnetic teeth) of each of the element in the gear and is also dependant on which elements (sun, annulus and carrier assembly) form the input and output of the gear and which element is held stationary. In a typical embodiment the sun and annulus gears form the input and output with the carrier gear assembly held stationary allowing for a relative step-up or step down of the speed or torque. This particular embodiment should not be seen as limiting potential applications and choice of inputs or outputs. The calculation of ratios for epicyclical gearboxes is well known to persons skilled in the art.
The limitation of the torque that can be transmitted is principally determined by the first interaction between the sun gear and the carrier gears. In order to make the most effective use of the magnetic material the annulus should be sized such that it's slipping point or maximum available torque is similar to that of the interaction between the sun and carrier gears.
In all of the permanent magnet devices shown where the background field is created by flux directing or Halbach style arrays of permanent magnets—these arrays are constructed from a number of discretely magnetized elements. The embodiments disclosed typically use 2 or 4 elements or discrete directions of magnetization per pole for clarity. It would be obvious to a person skilled in the art that a larger number of constituent elements could be employed and that as a larger number of discrete magnetization directions are employed, the more that the array approaches ‘ideal’ Halbach functional magnetization. These embodiments should not been seen as limiting the number of constituent elements of the flux directed array or the directions of magnetization of these constituent elements that are employed.
Many of the devices (motors, generators, couplings and gearboxes) disclosed have been shown as radial flux machines. It will also be clear to a person skilled in the art that conceptually, these devices could readily be constructed as axial flux machines and that such axial flux machines may have benefit in particular applications.
A further variation on the previously disclosed Flux Directed permanent magnet motors and generators employs an externally magnetised inner Halbach array of permanent magnetic material as the rotor that is surrounded by a set of current carrying windings and an outer laminated steel shroud or flux guide. The primary benefit of having an internal permanent magnet rotor is that the torque to and from the generator/motor can be readily delivered/extracted to or from the device via a central shaft. It is also easier to extract or deliver this torque at both ends of the device rather than at one end.
An important variation is highlighted in
It is important to note that the use of this additional backing steel on the opposite side of the permanent magnet array to the side where the current carrying windings are located has previously been disclosed for devices that employ an internally magnetised external permanent magnet array. A 16 Pole embodiment that uses an external permanent magnet rotor with backing steel is shown in
For both embodiments shown in
Based on the present disclosure, it would be obvious to a person skilled in the art that the superconducting coils from any of previously disclosed superconducting flux directed or star toroidal machines could be contained within a rotating cryostat and be made to rotate in relation to a set of stationary current carrying windings thereby removing the need for slip-rings or brushes to transfer power to or from these current carrying windings. This approach could be readily applied to devices that employ inner and outer star toroidal/flux directing coils as well as those that employ steel pole pieces that would rotate in concert with the rotating cryostat.
In yet a further embodiment of the Flux Directed Superconducting machines the inner flux directing coils can be simplified to a single racetrack coil per pole of the device. This variation is well suited to smaller devices where space in the internal bore for a cryostat is at a premium. An example of this embodiment is illustrated in
In a further addition to the previously disclosed Flux Directed magnetic coupling, an additional mechanism is included that allows the coupling to be braked. In one embodiment this brake consists of a stationary cylinder of conductive material that is introduced into the gap region between the inner and outer magnetic cylinders. If the cylinder is made from an electrically conductive material then the changing magnet field seen by the cylinder induces eddy currents in the cylinder that oppose this change in magnetic field. This results in a drag torque or braking effect on the rotating members of the coupling. The arrangement and operation of the braking assembly is illustrated in
In an alternative embodiment, the braking cylinder could also be made from a material that is both ferromagnetic and electrically conductive. In this embodiment the braking effect would occur due to eddy current generation and hysteretic losses generated in the ferromagnetic material. The ferromagnetic material would also act as a magnetic shield between the two halves of coupling, thereby decreasing or removing the magnetic interaction between the two halves.
In yet a further variation the device can be constructed as purely an eddy current brake with a single internal or external flux directed permanent magnet cylinder and a conductive braking element. In this variant there is no torque transfer during normal operation—it simply acts as a brake when engaged.
A further improvement to the flux directed magnetic coupling concerns the location and alignment of the two rotating torque elements of the magnetic coupling. Correct axial alignment of the inner and outer flux directed permanent magnet arrays is crucial to obtaining the best performance of the coupling in terms of torque output and vibration. In the embodiments shown in
In the present specification and claims (if any), the word ‘comprising’ and its derivatives including ‘comprises’ and ‘comprise’ include each of the stated integers but does not exclude the inclusion of one or more further integers.
Reference throughout this specification to ‘one embodiment’ or ‘an embodiment’ means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases ‘in one embodiment’ or ‘in an embodiment’ in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.
In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.
Number | Date | Country | Kind |
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2015902759 | Jul 2015 | AU | national |
2015903808 | Sep 2015 | AU | national |
2015904119 | Oct 2015 | AU | national |
2015904164 | Oct 2015 | AU | national |
Filing Document | Filing Date | Country | Kind |
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PCT/AU2016/050610 | 7/13/2016 | WO | 00 |