Patent Application
20160294236
The subject matter disclosed herein relates to electric motors, and more specifically, to supporting laminations of synchronous reluctance motors.
Electric motors typically have a stationary stator with poles that generate a rotating magnetic field to drive poles of a rotor. The rotor rotates relative to the stator, thereby rotating a shaft coupled to the rotor. The stator may generate the rotating magnetic field from a supplied current, such as an alternating current. The rotor of a reluctance motor does not receive an electric current. Rather, the magnetic field of the stator induces a magnetic field on the poles of the rotor, generating torque via magnetic reluctance. A synchronous reluctance motor is an alternating current motor for which the rotation of the shaft is synchronized with the frequency of the alternating current. Channels of the rotor poles carry magnetic flux to generate the torque. Large connections between channels of each rotor pole increases leakage flux between the channels. Additionally, radial stresses during rotor operation at high speeds or with large rotor radii may reduce an airgap between the rotor and the stator when the rotor has small connections between channels of each rotor pole.
Certain embodiments commensurate in scope with the originally claimed subject matter are summarized below. These embodiments are not intended to limit the scope of the claimed subject matter, but rather these embodiments are intended only to provide a brief summary of possible forms of the disclosed subject matter. Indeed, the disclosed subject matter may encompass a variety of forms that may be similar to or different from the embodiments set forth below.
In one embodiment, a synchronous reluctance machine includes a rotor having a first plate, a second plate, a first set of rotor poles, and a first set of axial stiffeners. Each rotor pole of the first set of rotor poles includes a first plurality of laminations axially stacked between the first plate and the second plate, and each lamination of the first plurality of laminations includes first channels configured to carry magnetic flux and a first plurality of passages spaced between the first channels. Each axial stiffener of the first set of axial stiffeners is disposed within a respective passage of the first plurality of passages. A first end of each axial stiffener of the first set of axial stiffeners interfaces with the first plate, and a second end of each axial stiffener of the first set of axial stiffeners interfaces with the second plate.
In another embodiment, a synchronous reluctance machine includes a rotor having a first plate, a second plate, a plurality of rotor poles, a first axial stiffener, and a second axial stiffener. Each rotor pole of the plurality of rotor poles includes a plurality of laminations axially stacked between the first plate and the second plate. Each lamination of the plurality of laminations includes a first channel configured to carry magnetic flux, a second channel configured to carry magnetic flux, and a body. The first channel defines a first passage, the first channel and the second channel define a second passage, and the second channel and the body define a third passage. The first axial stiffener is disposed within the first passage, coupled to the first end plate, and coupled to the second end plate. The first axial stiffener includes a hollow member. The second axial stiffener is disposed within the second passage, coupled to the first end plate, and coupled to the second end plate.
In another embodiment, a method of manufacturing a synchronous reluctance machine includes forming a plurality of laminations of a rotor pole, coupling a first end of a first axial stiffener to a first plate of a rotor, stacking the plurality of laminations in an axial direction, and coupling a second plate of the rotor to a second axial end of the first axial stiffener opposite the first end. Each lamination is a unitary piece having a plurality of channels and enclosed passages. The first axial stiffener extends in the axial direction perpendicular to a face of the first plate, and the first axial stiffener is configured to interface with a first enclosed passage of each lamination.
These and other features, aspects, and advantages of the present disclosed subject matter will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
One or more specific embodiments of the presently disclosed subject matter will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
When introducing elements of various embodiments of the presently disclosed subject matter, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
Synchronous reluctance machines (e.g., motors) have a plurality of rotor poles that rotate relative to stator poles, thereby generating torque on a shaft coupled to the synchronous reluctance machine. Stator poles of a reluctance motor may induce magnetic fields on ferromagnetic (e.g., steel) rotor poles, and the changing magnetic field of the stator poles drives the rotation of the rotor poles. Each rotor pole may be formed from a stack of laminations. Channels of the laminations carry the magnetic fields of the rotor poles, and passages separate the channels of each lamination. Connections between channels may reduce the flux carried by each channel based at least in part on the thickness of the connections. In some embodiments, bridge sections connecting channels may enable the lamination to be formed of a unitary piece of material (e.g., sheet steel). A unitary lamination piece may reduce the time and costs associated with forming the lamination and assembling the rotor pole with other laminations by reducing the quantity of parts of each rotor pole. As described in detail below, axial stiffeners coupled to one or more channels of the laminations enable rotor laminations to have narrow bridge sections that reduce leakage flux from each channel, which may increase the power density and/or improve the power factor of the synchronous reluctance machine. For example, the axial stiffeners may enable a rotor with a given radius (e.g., approximately 100 mm) configured to operate at a first speed (e.g., 10,000 rpm) to operate at a higher second speed (e.g., 14,000 rpm), thereby increasing the power output of the synchronous reluctance machine. Additionally, or in the alternative, the axial stiffeners may enable a rotor with a first radius configured to operate at a given speed (e.g., 10,000 rpm) to operate with a greater second radius, thereby increasing the power output of the synchronous reluctance machine. The axial stiffeners provide radial support to the laminations, thereby reducing stresses on the laminations during operation and maintaining an air gap between the rotor and the stator.
Turning to the drawings,
The synchronous reluctance machine 12 includes a stator 24 and a rotor 26. The rotor 26 may be disposed within the stator 24, offset by an airgap 28 between an interior surface 30 of the stator 24 and an exterior surface 32 of the rotor 26. As may be appreciated, the interior surface 30 of the stator 24 may be cylindrical. Stator poles 34 receiving power from the power source 20 are configured to generate magnetic fields to drive the rotor 26 and shaft 18 about the axis 22. The stator poles 34 may be powered so that the generated magnetic fields rotate about the axis 22. In some embodiments, the stator poles 34 are axially spaced along the stator 24, opposite laminations 36 of the rotor 26. The stator poles 34 are circumferentially spaced about the rotor 24. While
The laminations 36 of the rotor 26 are stacked between the end plates 42 of the rotor 26. The laminations 36 reduce eddy currents from the induced magnetic field from the stator poles 34, thereby reducing inductive heating and energy loss of the rotor 26. In some embodiments, the rotor 26 has approximately 10, 20, 50, 100, 500, 1000, or more laminations 36 axially stacked between the end plates 42. The end plates 42 and the laminations 36 may extend approximately the same radial distance 47 from the shaft 18, thereby forming the exterior surface 32 offset from the interior surface 30 of the stator 24 by the airgap 28. The term “approximately” as utilized herein with respect to the radial distance 47 may include distances within 10 percent. That is, the laminations 36 may extend radially beyond the end plates 42 by up to 10 percent in some embodiments, and the end plates 42 may extend radially beyond the end plates 42 by 10 percent in other embodiments. In some embodiments, an outer diameter 49 of the rotor 26 is between approximately 150 to 300 mm, 175 to 250 mm, or 200 to 225 mm.
The material of the laminations 36 may include, but is not limited to laminated silicon steel, a carbonyl iron, or a ferrite ceramic, or any combination thereof. In some embodiments, each lamination 36 may be cut (e.g., mechanically cut, electrically cut, laser cut) or stamped from a sheet, such as a laminated silicon steel sheet. Channels of each lamination 36 form rotor poles that carry the induced magnetic field. The rotor poles are circumferentially spaced about the axis 22. The quantity of rotor poles of the rotor 26 may be the same or less than the quantity of stator poles 34 of the stator 24. In some embodiments, each lamination 36 is substantially circular, and each lamination 36 has multiple (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 16, 24, 36, or more) rotor poles. In some embodiments, each rotor pole is formed of separate stacks of laminations 36.
The axial stiffeners 46 couple to the end plates 42 of the rotor 26 and interface with channels of each lamination 36 disposed between the end plates 42. The axial stiffeners 46 are configured to provide radial support for the laminations 36 during operation of the synchronous reluctance machine 12. As the rotor 26 rotates about the axis 22, a centrifugal force in a radial direction 48 out from the axis 22 generates stress on components (e.g., laminations 36, axial stiffeners 46) of the rotor 26. The axial stiffeners 46 are configured to interface with the laminations 36 to enable the axial stiffeners 46 to carry the radial stress generated by the centrifugal force, thereby reducing deformation of the laminations 36 and maintaining the airgap 28 between the exterior surface 32 of the rotor 26 and the inner surface 30 of the stator 24. In some embodiments, each rotor pole has one or more axial stiffeners 46. Recessed portions (e.g., pockets) 51 of the end plates 42 may receive the axial stiffeners 46, such as via an interference or friction fit. Additionally, or in the alternative, the axial stiffeners 46 may be mounted (e.g., welded, bolted, brazed, adhered) to the end plates 42. In some embodiments, the axial stiffeners 46 may be integrally cast with one of the end plates 42. Moreover, the rotor 26 may have two or more sections 50 of laminations 36 separated by an end plate 52 (e.g., midplate), where opposite faces of the end plate 52 couple to axial stiffeners 46. In some embodiments, the axial stiffeners may be formed of a non-magnetic steel, such as A286 stainless steel. Additionally, or in the alternative, the materials of the axial stiffeners 46 may include, but are not limited to sheet steel, aluminum, copper, composites, resins, carbon fiber, or any combination thereof. As may be appreciated, the materials of the axial stiffeners 46 may be non-magnetic, thereby reducing the effect of the axial stiffeners on the magnetic field through the channels. It may be appreciated that some of the laminations 36 of the right section 50 of the rotor 26 of
In some embodiments, a cooling system 54 is coupled to the synchronous reluctance machine 12. The cooling system 54 may direct a coolant flow 56 (e.g., air, carbon dioxide, nitrogen) to the stator 24 and/or to the rotor 26, which may utilize the coolant flow 56 to reduce the temperature of heat generating components. For example, resistance heating based on electric current flow and/or induction heating based on magnetic fields may generate heat in the stator poles 34, the rotor poles, or any combination thereof. In some embodiments, the cooling system 54 directs the coolant flow 56 to passages of the stator 24 and/or the rotor 26. The coolant flow 56 directed to the synchronous reluctance machine 12 may be directed from the cooling system 54 in an open or closed loop.
In some embodiments, each rotor pole has one or more axial stiffeners 46. The rotor 26 of
The channels 90 of the lamination 36 carry the magnetic fields induced by the stator poles 34 of the stator 24, and the passages 92 separate the channels 90. The channels 90 may have radial portions 95 that extend towards the outer surface 32 of the lamination 36 in substantially the radial direction 48. Bridge sections 96 couple the channels 90 at ends of the radial portions 95 and enable the lamination 36 to be formed (e.g., cut, stamped) as a unitary piece such that each of the channels 90 is formed with the body 86. Additionally, the bridge sections 96 enable the channels 90 of the lamination 36 to be assembled (e.g., stacked) as one piece. Moreover, the bridge sections 96 support the channels 90 to maintain the separation via the passages 92. For example, a first channel 98 is supported by a first bridge section 100 coupled to a second channel 102, and the second channel 102 is supported by a second bridge section 104 coupled to a third channel 106. However, a thickness 108 of the bridge sections 96 affects the quantity of the magnetic field carried by each respective channel 90. That is, increasing the thickness 108 may decrease the magnetic field carried by the channels 90, thereby decreasing the power density of the synchronous reluctance machine 12. Likewise, decreasing the thickness 108 may increase the magnetic field carried by the channels 90, thereby increasing the power density of the synchronous reluctance machine 12.
The axial stiffeners 46 provide radial support to the channels 90 of the laminations 36. During operation of the rotor 26, centrifugal forces on the lamination 36 would generate radial stresses on the bridge sections 96 unless otherwise supported by the axial stiffeners 46 as described herein. Accordingly, radial stresses on the bridge sections 96 without axial stiffeners 46 may limit how narrow the bridge section 96 may be and/or may limit the rotational speed of the rotor 26 to maintain the airgap 28 between the outer surface 32 and the stator 24. The axial stiffeners 46 are configured to radially support the laminations 36 to enable the thickness 108 of the bridge sections 96 to be reduced and/or enable the rotational speed of the rotor 26 to be increased while maintaining the airgap 28. The axial stiffeners 46 are arranged within the rotor 26 to receive more radial stress from the centrifugal forces during operation than the bridge sections 96, and more radial stress than the channels 90. That is, the axial stiffeners 46 are arranged to receive non-zero radial stresses from the centrifugal forces during operation. For example, the axial stiffeners 46 may receive approximately 50, 75, 80, 90, or 95 percent or more of the radial stress on the rotor 26 during operation. The axial stiffeners 46 are disposed within passages 92 of the laminations 36. In some embodiments, the axial stiffeners 46 interface with interior faces 110 and/or exterior faces 112 of the channels 90. For example, the first stiffener 64 interfaces with an interior face 110 of a first passage 114, and the second stiffener 66 interfaces with an interior face 110 of a second passage 116. In some embodiments, the second stiffener 66 only interfaces with the interior face 110 of the second passage 116 and does not interface with the exterior face 112, thereby reducing leakage flux between the first and second channels 98, 102 through the second stiffener 46.
In some embodiments, each passage 92 has a substantially uniform width 109. Additionally, or in the alternative, the passage width 109 may vary among the passages 92. For example, a second width 117 of the second passage 116 may be different than (e.g., less than, greater than) a third width 119 of a third passage 122. Moreover, the passage width 109 may vary along a length of each passage 92. For example, a leg width 121 of the second passage 116 may be greater than a base width 123 of the second passage 116, or vice versa. The passage width 109 may be based at least in part on the magnetic field to be carried by each channel 90, the geometry of the axial stiffeners 46, the quantity of channels 90 and passages 92 of the lamination 36, and/or stress concentrations of the channels 90 during operation, among other factors.
The geometries of the axial stiffeners 46 are configured to provide radial support to the channels 90. A low cross-sectional moment of inertia of the axial stiffeners 46 facilitates the radial support of the channels 90 of the laminations 36 and increases the resistance of the axial stiffeners 46 to deformation (e.g., bending) along an axis perpendicular to the axis 22 through the shaft 18. For example, ribs 118 of the axial stiffeners 46 that extend in substantially the radial direction 48 may increase the radial support. In some embodiments, the axial stiffeners 46 have hollow regions 120. In some embodiments, the hollow regions 120 and/or the passages 92 increase the convection potential to transfer heat among the components of the rotor 26, thereby reducing the likelihood of overheating a portion of the rotor 26. For example, the coolant flow 56 from the cooling system 54 may be directed to the hollow regions 120 and/or to the passages 92 of the rotor 26. As may be appreciated, the radial stresses of a rotating body (e.g., rotor 26) increase with the radial distance from the axis of rotation and/or the rotational speed of the rotating body. Accordingly, the first stiffener 64 in the first passage 114 may be configured to resist greater radial stresses than the second stiffener 66 in the second passage 116. In some embodiments, the third channel 106 may be sufficiently supported in the radial direction 48 by the body 86 of the lamination 36 that a third passage 122 radially inside the first and second passages 114, 116 does not have an axial stiffener 46. However, other embodiments of the lamination 36 may have a third axial stiffener 124 disposed within the third passage 122, as illustrated with the dashed line. Moreover, while the embodiments discussed above with respect to
A first axial end 132 of each axial stiffener 46 couples with an inner face 134 of a first end plate 136, and a second axial end 138 of each axial stiffener 46 couples with an opposing inner face 140 of a second end plate 142 (e.g., mid plate 52). Recessed portions (e.g., pockets) 51 of the inner face 134 and/or the opposing inner face 140 of the respective end plates 136, 142 may receive the axial stiffeners 46, such as via an interference or friction fit. That is, at least a part of the first axial end 132 and the second axial end 138 may be inserted within the end plates 42. Additionally, or in the alternative, the axial fasteners 46 may be retained within the recessed portions 52 via axial compression of the end plates 42. In some embodiments, the first axial end 132 and/or the second axial end 138 of each axial stiffener 46 is coupled to the respective end plate 136, 142 via a weld connection, a braze connection, or a mechanically fastened connection (e.g., bolt, threaded connection), or any combination thereof. The end plates 42 are configured to provide radial support to the axial stiffeners 46, which in turn provide radial support to the laminations 36. In some embodiments, the axial stiffeners 46 do not extend through the mid plate 52 to support multiple sections 50 of the rotor 26. That is, each axial stiffener 46 may support the laminations 36 of only one section 50 of the rotor 26.
Technical effects of the presently disclosed subject matter include increased power density of a synchronous reluctance machine without the use of rare-earth magnets. Additionally, the axial stiffeners enable a synchronous reluctance machine to maintain an airgap between the stator and the rotor despite increased centrifugal forces due to increased rotor radius and/or to increased rotor speeds. Moreover, unitary laminations of the rotor with multiple channels to carry the magnetic field for rotor poles may reduce the time and/or costs associated with manufacturing the laminations.
This written description uses examples to disclose the subject matter, including the best mode, and also to enable any person skilled in the art to practice the disclosed subject matter, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosed subject matter is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
