KR20060022654A - Modular transverse flux motor with integrated brake - Google Patents

Abstract

An elevator machine (12) has a plurality of identical transverse flux rotor/stator modules (28-30) of a generally cylindrical configuration arranged contiguously on a common shaft (21) to provide torque to the shaft equal to the torque capability of the modules times the number of modules. A disc brake (49) is integrated with the motor; a two-sided brake disc (49) has friction pads (92, 93) on both sides, braking force being applied to motor end plate (14) and through the brake disc to a stator (60) of one phase (30) of the motor. A process (113) forms variously-sized motors from identically sized modular components, in various configurations (12, 100, 110).

Description

MODULAR TRANSVERSE FLUX MOTOR WITH INTEGRATED BRAKE}

The present invention relates to a transverse flux type motor having an integrated brake, in which the output torque can be adjusted by stacking rotor / stator modules to suit the needs of applications such as elevators.

As an example of the present invention, elevator machines account for a major part of the material cost of the elevator. Elevator machines require low rotational speeds and provide free maintenance service for ten years. For low noise, smooth operation, low cost and small drive systems, gearing can be avoided if possible. An important factor in motor selection is the amount of output torque per unit of mass or volume of active material, including core steel, conductive wires and permanent magnets. The maximum torque demand of the elevator machine is determined by the maximum imbalance, which is about half of the rated load and maximum cable mass mismatch with the sheave diameter and the roping device (1: 1, 2: 1, etc.)

Rotating field electric machines typically have a phase winding integrated into one core structure. For large torque capacities, stacked laminations of longer cores are required, which in turn have a variety of phase windings that require various winding fixtures and other manufacturing equipment. The stator of a conventional motor has end turns that extend beyond the flux generator of the useful motor. The coil extension makes it difficult to achieve a compact motor / sieve combination and to integrate the brake or other auxiliary structure by the motor.

In order to reduce the number of motor models required for the production line, some elevator models sharing the motor type with other elevator models are largely dimensioned for their torque requirements. By having a large number of motors without common parts, the extra cost of material, setup, manufacturing and storage is increased.

It is an object of the present invention to provide an improved, low speed, high torque for the elevator, and by simply adding a module phase, the torque can be increased simply, the torque can be increased without requiring a full change of the windings, and high volume torque With a relatively short assembly with a density, low loss by having a coil-free end turn, a simple stator winding, and smaller than a similarly rated permanent magnet brushless motor using significantly less copper It is a motor that can be formed by the same module which requires manufacturing labor and allows small steps in torque rating using the same parts.

According to the invention, an electric motor suitable for driving an elevator sheave consists of a rotor / stator module having one module per phase of the drive current, the motor comprising one or more modules per phase to select the appropriate torque rating of the motor. It is formed of the same rotor / stator module having a.

In addition, according to the invention, the brake is arranged integrally on the same shaft and in close contact with the rotor / stator module of the transverse flux type motor.

The motor according to the invention provides higher torque per unit volume than a conventional motor, has a substantially constant effect for constant stator torque and speed, and improves the power factor (due to the absence of the end turning leakage flux). With this, increasing power factor by multiple poles is possible. The motor according to the invention has a substantially constant effect in the range of about 50% to about 120% of rated shaft torque at rated operating speed. The present invention has shorter ferromagnetic cores and shafts, uses up to 30% copper in conductor and ferromagnetic core volumes than permanent magnet brushless motors, and has a coil-free end turn, which results in shorter and lighter motors. The present invention provides a motor having only a single annular coil per phase regardless of the number of poles.

Other objects, features and advantages of the present invention will become more apparent in light of the following detailed description of exemplary embodiments shown in the accompanying drawings.

1 is an external perspective view of a motor according to the present invention that may be attached to an elevator sheave.

2 is an enlarged perspective view of an integrated brake and three phase motor in accordance with the present invention.

3 is a perspective view of the assembled rotor / stator module.

4 is an enlarged perspective view of the module of FIG.

5 is a partial view taken along line 5-5 of FIG.

6 is a partial perspective view of the interface between the rotor and stator of the rotor / stator module.

7 is a partially enlarged view of the cross section of FIG.

8 is a partial view of the integrated brake and motor shown in FIGS.

FIG. 9 is a partially enlarged view of the integral brake shown in FIG. 8 with the brake released. FIG.

10 is an enlarged view of the integral brake of FIG. 8 with the brake engaged.

11 and 12 are simplified side cross-sectional views illustrating the modular scheme of the present invention.

13 is a macrofunction diagram of a method of manufacturing a modular motor.

Referring to Figure 1, the motor 12 with integral brake of the present invention has a left end plate 13 fixed to the enclosure 15 by suitable fasteners such as radial screws 16 in low torque applications. And a right end plate 14. In large motors, the end plates can be fixed by axial bolts screwed into the thicker enclosure. The motor rotates the driven member, which may for example be an elevator sheave 17. The motor enclosure has a mounting base 19. Enclosure 15 is omitted in FIG. 2 for clarity.

Referring to Fig. 2, the end plates 13 and 14 have bearings therein, and only the bearing 41 for the right end plate is shown in Fig. 2. Although not shown here, the bearing may have a cover to support lubrication and prevent the ingress of impurities, as is known. The shaft 21 has a slot for receiving a key 24 that engages a plurality of rotor / stator modules 28 to 30, each module corresponding in the rotor to transfer torque from the rotor to the shaft. Has a slot 22. The spacer 33 (also shown in FIG. 8) prevents the rotor of the module 28 from engaging the outer race of the bearing 20. The spring clip 34 in the notch 35 of the shaft 21 engages with the rotor of the module 30 to prevent relative axial movement between the modules 28 to 30 and the shaft 21 and thereby adjacent each other. The modules 28 to 30 are held in contact with the spacer 33. Similarly, to prevent movement to the right of the shaft 21, the spring clip 36 (also shown in FIG. 8) in the notch 37 has an inner race 40 of the bearing 41 on the right end of the shaft. , Which is shown only in FIGS. 8 to 10.

The brake disc 43 is engaged with a hole 44 in the shaft 21 by a pin 46 on which the disc 43 can slide through the long slot 37. The brake assembly 49 includes an annular frame 50 having an annular groove 51 for the brake release coil, and the lands 52 on which the wave springs 53 are stacked oppositely allow the brake release coil to stop energizing. When pressed, it will be pressed to engage the brake. The return spring 56 allows the brake disc to assume a neutral position that does not contact the right end plate 14 and the frame 50 when energized to the brake release coil. This is explained below in connection with FIGS. 9 and 10.

3 to 7, each rotor / stator module 28 to 30 is a pair of soft magnetic flux stator plates 60 separated by a soft magnetic annular portion 63 including an annular coil 64. 61). The stators 60, 61 have opposite supported poles and become north pole on the stator plate 61 as shown in FIG. 6 (at this time, south pole on the stator plate 60), but the polarity of the coil 64 It is changed by the current inside. The pole 67 is separated by an air gap 68.

The rotor of each rotor / stator module 28 to 30 consists of an annular soft magnet base 71 having holes 72 for the shaft 21. At the surface of the base 71, two rows of rigid permanent magnets 74 to 77, which may be NdFeb, are separated by a non-magnetic spacer 78 (but air between the two rows of magnets 74 to 77) May be). The south pole 74 in one magnet row is axially aligned with the north pole 76 in the other magnet row, and the north pole 75 in one magnet row is axially aligned with the south pole 77 in the other magnet row. Thus, there is a pair of magnets 74, 75 for each pole 67. Other configurations can have a variety of magnet positions, sizes, shapes, and consistency. Alternating fields, multiple magnets or multiple pole segments are required. Magnets 75-77 are shown spaced from adjacent magnets in FIGS. 4 and 6, but may be in contact. In fact, it may include an extension of the magnet material of the polarized base 71 or a solid ring of ash material to provide proper polarization. Base 71 has a polarity created therein as shown in FIG. 6, which opposes the air gap polarity of each magnet 74-77, and provides an effective return path for the magnetic field.

Referring to Fig. 7, the magnetic flux path shown by arrow 79 is reversed by the current. The pin 81 (FIG. 4) is forced into an annular portion 63 that engages the holes 82 in the stator plates 60, 61 to maintain module alignment.

9 and 10, the frame 50 of the disc brake 49 includes a pair of alignment holes 83 in which the alignment pins 84 freely slide, and the pins 84 It is forced into a hole in the stator 60 of the rotor / stator module 30. This secures the frame to the stationary part of the motor to prevent the disc brake assembly 50 from rotating against the force of the brake disc 43 when the brake is applied. Alternatively, the frame may be secured to an appropriate fixture of a motor, such as enclosure 15. A pair of brake coils 86 and 87 are disposed inside the groove 51 adjacent thereto. Each coil has sufficient strength to release the brakes, and both coils are provided for redundant safety. When the brake is released such that the return spring 56 is moved away from the end plate 14, the pin 46 engages the shoulder 90 (FIG. 9) and acts on the shoulder 90 (FIG. 9). The pin 46 will prevent the brake disc 43 from being dragged on the disc brake assembly 50 by the spring 56.

Wave spring 53 may have dimensions and numbers that are essentially determined to provide a predetermined brake torque. For example, the springs include a crest-to-crest spring, as shown on the website www.smalley.com/spring, and the Smalley Steel, Lake Zurich, Illinois, USA. Provided by the Ring Company.

As shown in Fig. 10, the brake friction pad 92 on the brake disc engages with the end plate 14 of the motor when the brake is actuated by a spring 53 that does not energize the coils 86, 87. will be. Similarly, brake friction pad 93 will engage frame 50, which in turn is secured to stator 60 by pin 84 when the brake is engaged, as shown in FIG. 10. . Thus, the brake is integral with the motor assembly, reducing space, mass and part count, thereby providing more effective and economical units.

Instead of using the rotor / stator device described with respect to FIGS. 1-7 of the present application, the present invention is directed to the ICEM '98 Vol. Using a transverse flux permanent magnet machine employing a variety of topography, as disclosed in Harris M. R., pages 1110-1122, "Comparison of Surface Magnetic Configurations of Flux-Centered and VRPM Machines." Can be executed. The only important requirement is that the torque direction be perpendicular to the flux line.

The module design scheme of the present invention that can be used to properly dimension a motor for various configurations using the same rotor / stator module is shown in FIGS. 8, 11, and 12. Each module includes a single phase. The motors of FIGS. 1 to 10 have three modules 28 to 30, for example, by four phase AC power provided by various known variable voltage, variable frequency power converters (VVVF drives). Can work. Assuming each module is distributed to provide a 5 ton motor, the motors of FIGS. 1-10 may include a 20 ton machine.

11 shows three phases of a 15 ton machine 100 as shown in FIGS. The VVVF driver 102 provides the phases associated with the individual drive currents across the associated lines 104, 105, 106 for the corresponding modules 28-30. Alternatively, for a fully modular approach, each module can have its own individual drive.

In Figure 12, the elevator machine 110 may include six modules 28-30, 28a-30a operating on a common shaft 21, the modules being separated by six different phases of AC power. The modules 28-30 and 28a-30a can be driven in parallel with the same three phases of AC power. However, six phase powers provide smoother operation and lower losses, as is known.

Similarly, modules that can generate more or less torque per module are placed as few as the number of pairs of modules driven by two phase powers or six driven by three or six or more phase powers. As few as three or more phases can be arranged. For example, the three phase drive can drive a motor comprised of a 3N stator module, where N can be 1 to 7 or a positive integer, and similar modules share power from the three phase drive.

Claims (9)

Modular transverse flux rotary electric machine series, each machine 12 The rotary shaft 21, A plurality of generally cylindrical transverse flux rotor / stator modules 28 to 30 disposed on the shaft; A rotary driven member 17 arranged for rotation by the shaft, A plurality of end plates 13, 14 on the side of one of the modules 28, 30 which are not in close contact with the other module, A magnetic flux line 79 between the rotor and stator of the module 68 is perpendicular to the torque, at least one of the modules is in close contact with at least one of the adjacent modules, and each module is substantially in contact with the shaft. The same rated torque can be distributed, whereby the rated torque of the motor is equal to the rated torque of each module multiplied by the number of the modules. Each of the machines is formed to be compatible with the module and has at least one brake 49 disposed between one of the corresponding end plates 14 and one of the sides that are not in close contact with the other side of the module. Including, At least one said machine has a different number of modules than at least one of said machines, And the length of the shaft is selected to adapt at least the number of the module, the brake and the driven member. Modular transverse flux rotary electric machine series, each machine 12 The rotary shaft 21, A plurality of generally cylindrical transverse flux rotor / stator modules 28 to 30 disposed on the shaft; A rotatable driven member 17 arranged to rotate with the shaft, A magnetic flux line 79 between the rotor and stator of the module 68 is perpendicular to the torque, at least one of the modules is in close contact with at least one of the adjacent modules, and each module is substantially in contact with the shaft. The same rated torque can be distributed, whereby the rated torque of the motor is equal to the rated torque of each module multiplied by the number of the modules. At least one said machine has a different number of modules than at least one other machine of said machine, A length of said shaft is selected to adapt at least the number of said driven member and said module, said module mounted on at least one side of said driven member. 3. The machine family of claim 2 wherein at least one of said machines has all said modules disposed on only one side of said driven member. 3. The machine family of claim 2, wherein at least one of the machines has at least one module disposed on one side of the driven member. Modular transverse flux rotary electric machine 12, The rotary shaft 21, A plurality of generally cylindrical transverse flux rotor / stator modules 28 to 30 disposed on the shaft; A rotary driven member 17 arranged for rotation by the shaft, A plurality of end plates 13, 14 on the side of one of the modules 28, 30 which are not in close contact with the other module, A magnetic flux line 79 between the rotor and stator of the module 68 is perpendicular to the torque, at least one of the modules is in close contact with at least one of the adjacent modules, and each module is substantially in contact with the shaft. The same rated torque can be distributed, whereby the rated torque of the motor is equal to the rated torque of each module multiplied by the number of the modules. Each of the machines is formed to be compatible with the module and has at least one brake 49 disposed between one of the corresponding end plates 14 and one of the sides that are not in close contact with the other side of the module. Modular transverse flux rotary electric machine characterized by an improvement comprising a. 6. The brake according to claim 5, wherein the brake comprises one or more coils (86, 87) for disengaging the brake when energized; A brake disc 43 having friction brake pads 92 and 93 on each major surface, arranged to rotate with the shaft and axially slidable 46 and 47 on the shaft, A frame 50 which is not rotated but is secured to the fixing part 60 of the machine (83) so as to slide axially (83) and having an annular groove for at least one coil, At least one spring 53 for urging the frame towards the end plate when no energy is supplied to one or more coils, whereby at least one of the pads is engaged with the end plate and the other pad is A machine that engages the pad and thereby provides brake torque. To provide a modular transverse flux rotary electric machine (12), (a) selecting a torque increment, (b) A cylindrical flux line 79 between the rotor and stator of the module 68 perpendicular to the axis of the module, to provide torque equal to the increment. ) Design, (c) for each machine, (Iii) select the shaft 21 to mount the required number of modules N to reach or exceed the torque required for the machine and driven member 17, and (Ii) mounting said driven member on said shaft and mounting said module mounted on at least one side of said driven member on said shaft; (d) at least one machine having a different number of modules than at least one other machine. 8. The method of claim 7, further comprising the steps of: designing a brake module 49 having a generally cylindrical configuration of a diameter no greater than the module; Mounting the brake member on a shaft in close contact with one of the modules (30). 8. The method of claim 7, further comprising selecting a number of phases (P) of drive current for the module, wherein P = NX, X = small integer, whole integer, positive integer. (positive integer), Said step (ii) comprises mounting said module by an appropriate mutual orientation with respect to said phase number.

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