The present disclosure relates to rotors with segmented magnet configurations and related dynamoelectric machines and compressors.
This section provides background information related to the present disclosure which is not necessarily prior art.
Permanent magnet motors commonly include rotors having buried or embedded magnets of various shapes and/or configurations. These shapes and configurations can present challenges when magnetizing the magnets. If the magnets are not properly shaped, arranged and magnetized, the magnetic flux of the rotor and, thus, the efficiency of the rotor, may be less than optimal.
This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
According to one aspect of the present disclosure, a rotor for a dynamoelectric machine includes a rotor core having an outer periphery and at least a first set of magnets positioned within the outer periphery of the rotor core. The first set of magnets includes at least two block magnets and a magnet having an arc portion. The block magnets have a substantially parallel magnetization pattern and the magnet having an arc portion has a substantially radial magnetization pattern. The arc portion has a concave surface facing the outer periphery of the rotor core. The first set of magnets defines a pole of the rotor.
Accordingly to another aspect of the present disclosure, a rotor for a dynamoelectric machine includes a rotor core having an outer periphery and at least a first set of magnets positioned within the outer periphery of the rotor core. The first set of magnets including at least two magnets. Each magnet includes a straight portion and an arc portion. The arc portion has a concave surface facing the outer periphery of the rotor core. The first set of magnets define a pole of the rotor.
Further aspects and areas of applicability will become apparent from the description provided herein. It should be understood that various aspects of this disclosure may be implemented individually or in combination with one or more other aspects. It should also be understood that the description and specific examples herein are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
Example embodiments will now be described more fully with reference to the accompanying drawings.
Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.
Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
A rotor according to one example embodiment of the present disclosure is illustrated in
As shown in
Because the rotor 100 of
As further shown in
In the example of
As shown in
The bridge 114 may be any suitable thickness including, for example, 1 mm for a 5 hp motor, 2 mm for a 10 hp motor, 5 mm for a 50 hp motor, etc. In other embodiments, the bridge thickness may be relative to an air gap between a stator and the rotor 100. For example, the bridge thickness may be about 0.5 to 3 times the size of the air gap. Thus, if the air gap is about 0.5 mm, the bridge 114 thickness may be from about 0.25 mm to about 1.5 mm.
Additionally, the rotor core 102 may include a bridge 118 positioned between each block magnet 104 and the periphery 116 of the rotor core 102. The bridge 118 may have the same or different thickness as the bridge 114 described above.
By employing the bridge 114 and/or the bridge 118, the rotor 100 may exhibit increased mechanical strength. Therefore, the rotor 100 may be operable at higher speeds including, for example, 7200 rpm, 8500 rpm, 9000 rpm, etc.
The rotor core 102 may include slots for the block magnets 104 (e.g., block magnet slots) and slots for the arc magnets 106 (e.g., arc magnet slots). These slots may be defined, at least in part, by the bridges 114. In some embodiments, the block magnet 104 and the arc magnet 106 may not completely fill their respective slots. For example, as shown in
Alternatively, the arc magnets 106 and the block magnets 104 may completely fill their respective slots so no portion of the slot includes a non-magnetic material (e.g., air, etc.).
Further, one or more block magnets 104 and/or one or more arc magnets 106 may be positioned in the same slot of the rotor core 102. That is, one or more block magnets 104 and/or one or more arc magnets 106 may be adjacent to one another with no bridge(s) therebetween.
Various changes can be made to the magnet configuration of
Additionally, although all the slits 112 are elongated and have the same size and shape, any suitable size and/or shape may be employed. For example, one or more of the slits 112 may have a different size than one or more other slits 112, and/or may be tear-shaped, S-shaped, etc.
As shown in
Additionally, as shown in
By employing the slits 112, iron loss and inductance of a motor including the rotor 100 may be reduced. This is beneficial because lower iron losses improve the motor's efficiency. Additionally, because inductance consumes voltage, a lower inductance consumes less voltage. If less voltage is consumed, the torque of the motor may be increased and in some cases maximized.
As shown in
As shown in
The block magnets 404a, 404b and the arc magnets 406 include similar magnetization patterns as described above with reference to
In some embodiments, two block magnets and two arc magnets may together define a pole of the rotor. One example of this configuration is shown in
As shown in
Similar to arc magnets described above, the arc magnets 806a, 806b each include a concave surface 807 facing the outer periphery 818 of the rotor core 802. Further, each block magnet 804a, 804b has a substantially parallel magnetization pattern and each arc magnet 806a, 806b has a substantially radial magnetization pattern (similar to the embodiment of
In the example of
In other embodiments, only two magnets may be used to define each pole of the rotor. An example of this configuration is shown in
As shown in
As shown in the example of
The rotor 900 includes six alternating poles, each defined by a pair of magnets 904a, 904b arranged in a U-shape. Alternatively, the rotor 900 may include more or less poles (and thus more or less magnets).
As shown in
Although not shown in
The rotor 1000 includes slits 1012 extending through the rotor core 1002. Although the slits 1012 are different in size and orientation than the slits 112 of
Although not shown in
Although not shown in
Preferably, the various magnets described herein are premagnetized magnets. That is, each magnet is magnetized before the magnet is positioned within a rotor. Alternatively, the magnets may be magnetized after they are positioned in a rotor (e.g., by a magnetizer, by energizing stator windings, etc.).
Each magnet described herein may be formed of any suitable magnetic material(s) including, for example, rare earth materials (e.g., neodymium, etc.), ferrite, etc. Further, each rotor described herein may include magnets all formed of the same magnetic material(s) and having the same or different grades. For example, one or more block magnets may include a first grade of a magnetic material while one or more arc magnets may include a second grade (different than the first grade) of the same magnetic material. Alternatively, each rotor described herein may include a plurality of different magnet types (i.e., comprised or different materials and/or different grades). In some embodiments, a given rotor may employ only rare earth magnets (neodymium, etc.), only ferrite magnets, etc. Thus, the magnets may have different coercivities (i.e., the resistance of a material to becoming demagnetized) and/or BR (sometimes referred to as residual induction or residual flux density). In some preferred embodiments, the block magnets include a material having a higher coercivity and a lower BR, while the arc magnets include a material having a lower coercivity and a higher BR (relative to the block magnets).
Further, each magnet described herein may have any suitable thickness, which may be the same or different thickness than another magnet. For example, in
In some embodiments, the block magnets have a thickness greater than the thickness of the arc magnets. This configuration may alleviate demagnetizing concerns. Further, decreasing the thickness of an arc magnet (or an arc portion of a magnet) will increase the area of its concave surface. Because a magnet surface generally includes a constant magnetic flux density, the increased surface area of the arc magnet (and thus increased magnetic flux density) may produce more magnetic flux in the rotor.
Although the embodiments described herein refer to arc magnets, any magnet having an arc portion may be employed, including for example a C-shaped magnet, a U-shaped magnet, etc.
Testing, however, has shown that the rotors 100, 400, 800 including the block magnets 104, 404a, 404b, 804 and the arc magnets 106, 406, 806 produce a higher magnetic flux compared to other rotors employing different magnet configurations (e.g., C-shaped magnets and/or U-shaped magnets). Specifically, testing has shown that the rotors (e.g., the rotors 100, 400) having the block magnets and the arc magnets produce a magnetic flux of about 1.419 mWb, while a magnetic flux of a rotor having a C-shaped magnet configuration was about 1.262 mWb. Thus, the magnetic flux of the rotors described herein may be 12-15% higher than the magnetic flux of rotors including C-shaped magnet configurations.
Additionally, the rotor 1000 including the block magnets 1004 and the arc magnets 1006 produces a magnetic flux about 10% higher than the magnetic flux produced in the rotors 100, 400.
In addition, testing has shown that the efficiency of the rotors (e.g., the rotors 100, 400, 800) including the block magnets and the arc magnets is higher than the efficiency of rotors including a C-shaped magnet configuration. Specifically, the efficiency of the rotors including the block magnets and the arc magnets is about 93.6%, while the efficiency of a rotor having a C-shaped magnet configuration was about 92.8%.
Further, by increasing magnetic flux of the rotor as explained above, the drive efficiency of the rotor may be increased. That is, by increasing magnetic flux, the inductance in the rotor is reduced. This reduces the amount of current consumed by the inductance. Thus, less current may be used to produce the same amount of torque. This in turn increases the drive efficiency of the rotor.
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
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PCT/CN2012/001335 | 9/29/2012 | WO | 00 |
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WO2014/047748 | 4/3/2014 | WO | A |
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