TW202034607A - Stator and rotor design for periodic torque requirements - Google Patents

Abstract

Disclosed is a motor or generator comprises a rotor and a stator, wherein the rotor has an axis of rotation and is configured to generate first magnetic flux parallel to the axis of rotation, the stator is configured to generate second magnetic flux parallel to the axis of rotation, and at least one of the rotor or the stator is configured to generate a magnetic flux profile that is non-uniformly distributed about the axis of rotation. Also disclosed is a method that involves arranging one or more magnetic flux producing windings of a stator non-uniformly about an axis of rotation of a rotor of an axial flux motor or generator.

Description

Stator and rotor design that meets periodic torque requirements

The embodiments of the present invention are related to stator and rotor designs that meet periodic torque requirements.

The permanent magnet axial flux motor and generator described in certain patents including U.S. Patent No. 7,109,625 (the "'625 Patent" are inserted between magnets with alternating north and south magnetic poles). A substantially flat printed circuit board stator (PCS ) Is a feature. These printed circuit board stators have a hole through which the shaft connecting the rotor passes when supported from the outer edge of the stator to the fixed frame. An alternative embodiment is to interchange the roles of the inner radius and the outer radius to cause A situation in which the inner radius of the stator is supported and the rotor encloses the stator. In this configuration, the shaft effectively moves to the outer radius, sometimes called an "out-runner."

This [Summary of the Invention] is provided to introduce a selection of concepts that will be further described in the following [Embodiments] in a simplified form. This [Summary of the Invention] does not intend to identify key features or basic features, nor does it intend to limit the scope of the patent application included in this article. In some disclosed embodiments, a motor or generator includes a rotor and a stator, wherein the rotor has a rotation axis and is configured to generate a first magnetic flux parallel to the rotation axis, and the stator is configured To generate a second magnetic flux parallel to the rotation axis, and at least one of the rotor or the stator is configured to generate a magnetic flux shape that is unevenly distributed around the rotation axis. In other disclosed embodiments, a method involves unevenly arranging one or more magnetic flux generating windings of stators around a rotation axis of an axial flux motor or a rotor of a generator. In other disclosed embodiments, a rotor used in a motor or generator includes a support structure and one or more magnet segments. The one or more magnet segments are supported by the support structure and generated parallel to A first magnetic flux of a rotating shaft, the support structure rotates around the rotating shaft when assembled with a stator that generates a second magnetic flux parallel to the rotating shaft, wherein the one or more magnet segments are configured and arranged To produce a magnetic flux profile that is unevenly distributed around the axis of rotation.

Cross reference of related applications This application claims the rights of the U.S. Provisional Application No. 62/754,051 named "planar stator and rotor design for periodic torque requirements" filed on November 1, 2018 under 35 U.S.C. § 119(e). This application is also a part of the continuation and claims the rights of U.S. Patent Application No. 16/378,294 filed on April 8, 2019 under the name "STRUCTURES AND METHODS FOR CONTROLLING LOSSES IN PRINTED CIRCUIT BOARDS" under 35 USC § 120, U.S. Patent Application No. 16/378,294 is one of U.S. Patent Application No. 16/165,745 and current U.S. Patent No. 10,256,690 filed on October 19, 2018 under the title ``STRUCTURES AND METHODS FOR CONTROLLING LOSSES IN PRINTED CIRCUIT BOARDS'' A continuation of the case and claiming its rights under 35 USC § 120, U.S. Patent No. 10,256,690 is a U.S. patent application filed on December 22, 2017 entitled "PLANAR COMPOSITE STRUCTURES AND ASSEMBLIES FOR AXIAL FLUX MOTORS AND GENERATORS" No. 15/ No. 852,972 and one of the current U.S. Patent No. 10,170,953 and claims its rights under 35 USC § 120, U.S. Patent No. 10,170,953 claims under 35 USC § 119(e) that the name of the application on July 10, 2017 is "Structures and Methods of Stacking Subassemblies in Planar Composite Stators to Obtain Higher Working Voltages" in the United States Provisional Application No. 62/530,552 rights, and U.S. Patent No. 10,170,953 is also filed on June 1, 2017 under the title "STRUCTURES AND METHODS FOR CONTROLLING LOSSES IN PRINTED CIRCUIT BOARDS" U.S. Patent Application No. 15/611,359 and a partial continuation of the current U.S. Patent No. 9,859,763 and its rights are claimed under 35 USC § 120, U.S. Patent No. 9,859,763: (A) is 2016 U.S. Patent Application No. 15/283,088 and Xianmei filed on September 30 named "STRUCTURES AND METHODS FOR CONTROLLING LOSSES IN PRINTED CIRCUIT BOARDS" National Patent No. 9,800,109 is a partial continuation case and its rights are claimed under 35 USC § 120. US Patent No. 9,800,109 is a partial continuation case and is claimed under 35 USC § 120 that the name of the application on June 30, 2016 is "STRUCTURES AND METHODS FOR THERMAL MANAGEMENT IN PRINTED CIRCUIT BOARD STATORS" U.S. Patent Application No. 15/199,527 and current U.S. Patent No. 9,673,684, and U.S. Patent No. 9,800,109 is also claimed under 35 USC § 119(e) (1) October 2015 U.S. Provisional Patent Application No. 62/236,407 filed on 2nd October 2015 entitled "STRUCTURES TO REDUCE LOSSES IN PRINTED CIRCUIT BOARD WINDINGS" and (2) The title filed on 2nd October 2015 is STRUCTURES FOR THERMAL MANAGEMENT IN PRINTED CIRCUIT BOARD STATORS" U.S. Provisional Patent Application No. 62/236,422; and (B) is a U.S. patent application filed on July 12, 2016 entitled "APPARATUS AND METHOD FOR FORMING A MAGNET ASSEMBLY" No. 15/208,452 and a partial continuation of the current US Patent No. 9,673,688 and claiming its rights under 35 USC § 120, US Patent No. 9,673,688 claims the name filed on January 6, 2016 under 35 USC § 119(e) "ALIGNMNET OF MAGNETIC COMPONENTS IN AXIAL FLUX MACHINES WITH GENERALLY PLANAR WINDINGS" US Provisional Patent Application No. 62/275,653. This application is also a part of the continuation and it is claimed under 35 USC § 120 that it was filed on May 18, 2018 and published as U.S. Patent Publication Application No. US 2018/0351441. The name is ``PRE-WARPED ROTORS FOR CONTROL OF MAGNET-STATOR GAP IN AXIAL FLUX MACHINES" U.S. Patent Application No. 15/983,985 rights, U.S. Patent Publication Application No. US 2018/0351441 claims under 35 USC § 119(e) (1) Filed on June 5, 2017 U.S. Provisional Patent Application No. 62/515,251 and (2) filed on June 5, 2017 named "Pre-Warped Rotors for Control of Magnet-Stator Gap in Axial Flux Machines" named "AIR CIRCULATION IN AXIAL FLUX MACHINES" The rights of each of the US Provisional Patent Application No. 62/515,256. The entire contents of each of the above-mentioned applications, publications and patents are incorporated herein by reference for all purposes.

In existing axial flux motors or generators (such as U.S. Patent Nos. 7,109,625, 9,673,688, 9,800,109, 9,673,684 and 10,170,953, and U.S. Patent Publication No. 2018-0351441 A1 (``'441 The axial flux motor or generator disclosed in the “publication case”), the entire contents of each of these cases are incorporated herein by reference), the stator’s magnetic flux generation component (whether by a single continuous printing The circuit board or multiple printed circuit board segments are configured so that at any given time when the windings of the stator are excited by current, the position of the peak magnetic flux generated by the stator is evenly distributed with respect to the angle around the axis of rotation of the rotor. Similarly, in these machines, the rotor's magnetic flux generating components (whether composed of a ring magnet or individual magnets placed in a cavity) are also configured so that at any given point in time, the peak magnetic flux generated by the rotor The position is also evenly distributed with respect to the angle around the axis of rotation of the rotor. Therefore, in all these machines, at any given time during the operation of the machine, the position of the peak magnetic flux generated by each of the rotor and the stator is evenly distributed according to the angle around the rotation axis of the machine. In other words, for each of the rotor and stator in these machines, the positions of the peak magnetic flux around the rotating shaft are separated by the same angle from an adjacent position below the peak magnetic flux, so that the magnetic flux profile of each of the rotor and stator Evenly distributed around the axis of rotation.

An alternative design is disclosed herein, which has a cost advantage relative to the conventional design of a specific load and machine configuration, where the stator and/or the rotor can be configured to have a magnetic flux that is unevenly distributed around the axis of rotation of the rotor. shape. For example, in some embodiments, the stator may be configured such that it describes an arc portion surrounding the main shaft of the machine. If this stator segment can be positioned, it is due to the integration of the machine and the attached load. At a radius larger than a stator of equal area evenly distributed around the same axis, the torque generated can be the same as the stator segment placed in it. The increase in radius is proportional to the assumption that the equivalent magnetic flux and current density in the gap limit the stator. However, the cost of maintaining the equivalent magnetic flux in the gap of an "off-center" stator segment is to increase the volume of the magnet inversely proportional to the angle subtended by the segment. In most cases, this trade-off is not expected. However, in an application where peak torque at a specific angle or range of shaft angles is desired, the magnet material may be unevenly distributed relative to the rotor, so that the stator is exposed to the peak magnetic flux density at the shaft angle at the desired peak torque. For generator applications where the power source has periodic torque production capacity, a machine designed based on this principle can provide similar advantages.

The design of the stator and magnet system used to generate the peak torque at a specific angle is not limited to a stator segment and/or a concentration of magnet material on the rotor, but this is the simplest embodiment. Embodiments that include one or more non-uniformly distributed stator segments and/or one or more non-uniformly distributed magnet segments can provide a useful combination of angle-dependent torque capabilities. It should be understood that different combinations of one or more non-uniformly distributed stator segments and one or more non-uniformly distributed magnet segments can be used to achieve the same or similar torque capabilities that vary depending on the angle. For example, the same or similar torque capacity can be achieved by changing the stator segment distribution and the rotor magnet position. This allows the designer to achieve a trade-off between the cost of the magnet material and the area of the stator, while achieving the same or similar torque capacity that varies depending on the angle.

The design of a machine for generating peak torque at a specific angle does not preclude continuous rotation. When continuous rotation is desired, a machine designed according to the principles disclosed herein can supply torque in a series of pulses (at the peak torque angle) that are smoothed by the moment of inertia of the attached load to provide a substantially constant speed. One advantage of this design is that when the stator does not overlap the magnet, the stator loss due to eddy current can be zero. Another possibility for continuous rotation is to distribute the magnets so that the stator segment always sees the magnetic flux, but at a value smaller than the "peak torque" angle.

Some of the embodiments described herein can be particularly advantageous for applications in which the radius of the machine can be significantly increased relative to a conventional design. In these applications, placing a flat circuit board stator (PCS) segment with a radius larger than a uniform flat circuit board stator can achieve higher peak torque per unit stator area. In addition, compared to a thin ring-shaped stator with a large radius, the stator segments can be "assembled" or arranged on a printed circuit board "panel" of a standard size. This can allow more efficient use of printed circuit board materials and reduce the cost of associated machinery.

Examples of application areas include reciprocating piston or diaphragm pumps that may have a periodic torque requirement. In addition, for balance, these machines usually contain an eccentric mass that can be replaced by an asymmetrically designed rotor. Similarly, a generator coupled to a single-piston engine can benefit from the co-design of the balance mass and the magnetic materials in the stator segmented generator. Other potential applications include washing machines or other applications where a motor or generator moves through a restricted angle and periodic or "reverse" type loads.

One of the basic observations of the novel concept disclosed in this article can be reduced to a "zoom" parameter of the originally equidistant stator or stator segment based on the basic design considerations, which is not related to the internal organization and connection of the stator. In one of the conventional annular PCS described in the '625 patent, the torque can be expressed as follows:

係一微分面積元素，且

係對應於方程式

之扭矩密度量值。力密度歸因於軸向磁通及徑向電流密度而θ定向，即：

The components of this expression include the integral from a first radius r1 to a second radius r2, which includes the effective area of the stator. The integral covers the entire ring by limiting the integral of θ. item

Is a differential area element, and

Corresponds to the equation

The torque density value. The force density is θ-oriented due to the axial magnetic flux and radial current density, namely:

Here, the force density is the product of the current density supported by the stator and the magnetic flux density caused by the rotor magnet circuit and the stator reaction at the current density. For illustration, assume that B is radial. In the stator designed according to the '625 patent, divergent radial traces are effectively introduced from the inner radius r1 to reduce one of the current densities 1/r. One model system to extract this effect:

係符合內半徑處之大小及間隙要求之基於一給定銅重量處之特徵干擾的最大支援電流密度。就此模型而言，

由定子支援之電流密度取決於可安置於r1處之內通路之數目(其取決於特徵大小及相關聯間隙)及r1處之圓周，且取決於該圓周是否適應接近製造限制之一間距處之特徵。因此，不能將

嚴格視作常數。例如，若r1=0，則無法容納通路，且

。然而，針對實際關注之馬達，

將接近主要取決於熱考量及間隙要求之一值。為了比較原本等距定子而將

視作一常數傾向於使圍繞中心軸件定位之一習知定子具有一較小r1，表現得比依一較大半徑之一定子更有競爭力。among them

The maximum supported current density based on characteristic interference at a given copper weight that meets the size and gap requirements at the inner radius. For this model,

The current density supported by the stator depends on the number of internal paths that can be placed at r1 (which depends on the feature size and associated gap) and the circumference at r1, and depends on whether the circumference is suitable for a distance close to the manufacturing limit feature. Therefore,

Strictly regarded as a constant. For example, if r1=0, the passage cannot be accommodated, and

. However, for the motor of actual concern,

Will be close mainly depends on one of thermal considerations and gap requirements. In order to compare the original equidistant stator

Treating as a constant tends to make a conventional stator positioned around a central shaft member have a smaller r1, behaving more competitively than a stator with a larger radius.

The area A of the stator or stator segment with angular range δ:

。針對一定子分段，δ理想地對應於整數個磁極對。為比較定子分段與基於成本之習知設計，可合理比較等面積定子與磁體總成。隨著內半徑

增大，任何

存在δ及

之多個解，且在此將δ及

之多個解視作獨立變數。特定言之，當考量δ時，一分段上之磁極間距亦無需如同一習知定子般符合在2π rad上均勻安置磁極之通常約束。此暗示習知定子不享有之分段之相當大設計靈活性及達成相等面積A之能力。使用較小δ來將定子面積位移至較大

之優點之實例包含：(1)具有較大

之定子分段提供每單位面積之較高峰值扭矩；(2)當定子分段及磁性材料在特定轉子角(或角範圍)處完全重疊時，可使用峰值扭矩；(3)當磁性材料及定子不重疊時，機器中無渦電流損耗；(4)可在

、

及δ使得分段可「巢套」於一印刷電路板面板上時獲得定子分段以最小化浪費材料及成本；及(5)每單位面積(或每單位成本)之峰值扭矩隨定子分段之半徑而增大。Aiming at one of the conventionally designed stators,

. For a certain sub-segment, δ ideally corresponds to an integer number of magnetic pole pairs. In order to compare stator segments with conventional cost-based designs, a reasonable comparison of equal area stator and magnet assemblies can be made. With inner radius

Increase, any

There is δ and

Multiple solutions, and here δ and

The multiple solutions are treated as independent variables. In particular, when considering δ, the pitch of the magnetic poles on a segment does not need to conform to the usual constraint of uniformly arranging magnetic poles on 2π rad as in the same conventional stator. This implies considerable design flexibility and the ability to achieve the same area A of the segments that conventional stators do not enjoy. Use smaller δ to displace the stator area to larger

Examples of its advantages include: (1) It has greater

The stator segment provides a higher peak torque per unit area; (2) When the stator segment and the magnetic material completely overlap at a specific rotor angle (or angle range), the peak torque can be used; (3) When the magnetic material and When the stators do not overlap, there is no eddy current loss in the machine; (4)

,

And δ enable the segments to be "nested" on a printed circuit board panel to obtain stator segments to minimize wasted material and cost; and (5) the peak torque per unit area (or per unit cost) follows the stator segment The radius increases.

之一原型習知定子之一設計程序滿足一特定扭矩

，當分段與磁性材料完全重疊時，可推斷對向跨越一角度δ之原型設計中之磁極之一子集的定子分段之設計產生角範圍內之

之一峰值扭矩。因此，分段之一實際設計程序係設計習知定子原型，其中扭矩要求增大習知定子中之磁極相對於意欲留在分段中之磁極的比率。此程序儘管有利，但無法利用分段設計之自由，因為磁極間距同時受約束於分段之角範圍及習知設計之2π範圍。分段角δ無需為2π之一除數且可因此經最佳化以滿足設計約束。Suppose to have

A prototype conventional stator A design program to meet a specific torque

, When the segment is completely overlapped with the magnetic material, it can be inferred that the stator segment of a subset of the magnetic poles in the prototype design that crosses an angle δ produces an angle within the range

One of peak torque. Therefore, one of the actual design procedures for the segment is to design a conventional stator prototype, in which the torque requirement increases the ratio of the poles in the conventional stator to the poles intended to stay in the segment. Although this procedure is advantageous, it cannot take advantage of the freedom of segmented design, because the magnetic pole pitch is constrained by both the angle range of the segment and the 2π range of the conventional design. The segment angle δ does not need to be a divisor of 2π and can therefore be optimized to meet design constraints.

The combination of stator segments and magnetic materials concentrated on the fixed frame and the rotor at a specific angle can achieve various torque capabilities that vary depending on the angle. One or more areas on the rotor can carry magnetic materials (one or more magnetic pole pairs) with different magnetic flux densities, and can be distributed at various angles. There may be one or more stator segments positioned at various angles in the fixed frame.

U.S. Patent Nos. 7,109,625, 9,673,688, 9,800,109, 9,673,684, and 10,170,953 and U.S. Patent Publication No. 2018-0351441 A1 (``'441 Publication'') (these cases are incorporated by reference) The above) describes examples of motors and/or generators in which non-uniformly distributed stators and/or rotors (such as the stators and/or rotors disclosed herein) can be used. First, illustrative examples of these machines will be described in conjunction with FIGS. 1A and 1B. Next, examples of stators and rotors with magnetic flux profiles that are unevenly distributed around a rotor axis and can be used in these machines will be described with reference to FIGS. 2 to 8.

FIG. 1A shows an example of using a flat composite stator 110 for a system 100 in an assembly having rotor components 104a and 104b, shaft 108, wires 114, and controller 112. An expanded view is shown in Figure 1B, which shows these components and their assembly components. The pattern of the magnetic poles in the permanent magnetized parts 106a, 106b of the rotor assembly is also clearly seen in the expanded view of FIG. 1B. FIG. 1A is an example of an embodiment in which the electrical connector 114 is taken at the outer radius of the PCS 110 and the stator is mounted to a frame or housing at the outer periphery. Another useful configuration ("outer wheel" configuration) involves mounting the stator at the inner radius so that the electrical connection 114 is located at the inner radius and the shaft 108 is replaced by a ring that separates the rotor halves. It is also possible to configure the system with only one magnet 106a or 106b or to insert multiple stators between consecutive magnet assemblies. The wire 114 can also transmit information about the position of the rotor based on the readings of the Hall effect or similar sensors installed on the stator. Although not shown in the figure, for a similar purpose, an encoder attached to the shaft 108 can provide position information to the controller 112.

The system 100 in FIGS. 1A and 1B can act as a motor or a generator, depending on the operation of the controller 112 and the components connected to the shaft 108. As a motor system, the controller 112 operates the switch so that the current in the stator 110 is due to the magnetic flux originating from the gap between the magnets 104a, 104b connected to the shaft 108 to generate a torque around the shaft. Depending on the design of the controller 112, the magnetic flux in the gap and/or the position of the rotor can be measured or estimated to operate the switch to achieve the torque at the shaft 108. As a generator system, a mechanical rotating power source connected to the shaft 108 generates a voltage waveform at the terminal 112 of the stator. These voltages can be directly applied to a load, or they can be rectified by a three-phase (or multi-phase) rectifier in the controller 112. The rectifier implementation 112 can use diodes in the generator mode to "self-commutate", or can be constructed using the control switch of the motor controller, but the shaft torque is opposite to the torque provided by the mechanical wave source after operation, and Mechanical energy is converted into electrical energy. Therefore, the same configuration in FIG. 1A can serve as both a generator and a motor, depending on how the controller 112 is operated. In addition, the controller 112 may include filter components that mitigate switching effects, reduce EMI/RFI from the wires 114, reduce losses, and provide additional flexibility for power supplied to or delivered from the controller.

Figure 2 shows the geometry of three stators 202, 204, and 206 with different angular and radial extents but equal areas. The stators 204 and 206 have different inner radii. The stator 206 shows the typical relative dimensions of the stator described by the '625 patent. The stator 204 has a thin ring design. In the stator 204, the inner radius is increased, but a stator having such a relative size cannot efficiently use one of the printed circuit board materials "panel". As proposed herein, the stator 202 exhibits a stator segment 208 having an area and radius equal to the stator 204. All other equal larger radius stators 202 and 204 will produce a peak torque higher than stator 206 because the radius increases the torque arm.

FIG. 3 shows the "pieces" or filling of the stator segment (the segment 208 shown in FIG. 2) on a standard size printed circuit board panel 302. Use the illustrated configuration to efficiently utilize the panel 302. The cost of the stator segment 208 is inversely proportional to the utilization rate of the panel 302.

FIG. 4 shows an invalid configuration of the segment 208 on the panel 302 with the same size as that of FIG. 3. Although this configuration is not practical, it demonstrates the effective panel utilization achieved by a conventional stator having inner and outer radii that are the same as those achieved by the segment 208.

FIG. 5 shows an exemplary configuration of a stator segment 208 with respect to a magnet 502 on a rotor 504. In the illustrated example, a dense angular range 506 of the magnets 502 on the rotor 504 (also referred to herein as a "dense magnet area" is provided to achieve the peak torque at the overlap angle with the stator segment 208. The magnet 502 The non-dense angular range 508 (also referred to herein as the "non-dense magnet area" is configured to provide a lower torque capability that is independent of angle. Although not shown in the figure, it should be understood that in some embodiments, it may be nearby Or add non-magnetic elements in the non-dense magnet area 508 to balance the weight of the entire rotor 504. In addition, it should be understood that in some embodiments, there is an additional rotor part (not shown) with a corresponding but opposite magnet configuration. Can be positioned above the illustrated part of the rotor 504, so that the stator segment 208 can be positioned in a gap between the two rotor parts, wherein the magnetic flux lines extend in a direction parallel to the axis of rotation of the rotor to opposite polarities In addition, although not shown in FIG. 5, it should be understood that the stator segment 208 may include, for example, conductive traces and/or vias disposed on one or more dielectric layers, which pass through It is configured to form windings that generate magnetic flux in a direction parallel to the axis of rotation of the rotor when excited by current. These windings can be configured to receive one or more from a power supply (not shown in Figure 5) The current phase can be configured into one or more spirals, one or more serpentine patterns or other to generate this magnetic flux.

As shown in Figure 5, in some embodiments, the stator segment 208 may be attached via an arcuate attachment member 510 (one or more fasteners 512 may be used to attach the stator segment 208 to the arcuate attachment member 510) To be held in place, and one or more windings of the stator segment 208 (not shown in the figure) can be connected to the terminal 514 associated with the attachment part 510, and these terminals can be connected to a controller (Figure Not shown in 5) (such as the controller 112 discussed above in connection with FIGS. 1A and 1B) to supply the excitation current(s) to the winding(s).

Figure 6 shows the same configuration as Figure 5, but where the rotor 504 is positioned at an angle at which the stator segment 208 overlaps the dense magnet segment 506 that provides peak torque.

Figure 7 shows an alternative configuration of Figures 4 and 5. As shown in the figure, in addition to using a non-dense magnet area 508 (not shown in FIG. 7) and a dense angle range 506 or instead of using a non-dense magnet area 508 and a dense angle range 506, the stator segments 208a to 208g can be It is configured such that it completely or almost describes an annular stator with constant available torque at any angle. In some embodiments, a subset of the stator segments 208a to 208g may be smaller, may be arranged at a larger pitch, may contain fewer winding "turns", and/or may be supplied with more than one or more other The low power of the stator segment 208 allows a machine with concentrated magnets to provide angular specific peak torque while still providing torque capability at any angle. For example, in some embodiments, the stator segment 208a may be configured, configured, and/or excited differently from the other stator segments 208b to 208g for this purpose.

Regardless of the specific configuration of the magnet(s) 502 and the stator segment(s) 208 used, in at least some scenarios, care should be taken to ensure that at least certain sub-segments 208 are at each position during one revolution of the rotor 504 and at least A magnet 502 is at least partially overlapped so that the rotor 504 is not "stuck" at a position where no magnetic flux from the stator segment 208 interacts with the magnetic flux from a magnet 502.

In each of the above exemplary configurations, the stator segment(s) 208 and/or the magnet(s) 502 of the rotor 504 are configured to have a magnetic flux profile that is unevenly distributed around the main rotation axis of the machine. In particular, the stator segment(s) 208 are configured so that at any given point in time when the windings of the stator are excited by current, the position of the peak magnetic flux generated by the stator is unevenly distributed with respect to the angle around the axis of rotation of the rotor. Similarly, in these machines, the magnet 502 of a rotor 504 is also configured such that at any given point in time, the position of the peak magnetic flux generated by the rotor is also unevenly distributed with respect to the angle around the axis of rotation of the rotor. Therefore, for each of the rotor and stator in these machines, at least some positions of the peak magnetic flux around the axis of rotation and the adjacent positions of the peak magnetic flux are separated at different angles, so that the magnetic flux generated by the component rotates around The shafts are not evenly distributed.

8 shows a cross-section of an exemplary embodiment of an axial flux motor 802 according to some aspects of the present invention. The axial flux motor 802 is configured as shown in FIGS. 5 and 6 The components of the components are integrated with a washing machine load 804. As shown in the figure, a stator section 208 of the motor 802 can be fixed to a housing 806 that houses a washing machine tub 808 via an attachment part 510 and one or more fasteners 512, and the washing machine tub 808 can be via bearing elements 810 is rotatably coupled to the housing 806. A rotor 504 of the motor 802 can directly drive the washing machine tub 808 via a shaft 812 that can extend from the washing machine tub 808 and/or is fixedly attached to the washing machine tub 808. As far as the configuration shown is concerned, stator segment 208 and one set of magnets 502 arranged in a dense magnet area 506 and one or more non-dense magnet areas 508 can be used (as described above in conjunction with FIGS. 5 and 6 Described) to achieve continuous rotation at relatively high speed and low torque in the "spin" mode. During this spinning mode, the magnetic flux profile due to the rotor and the stator is unevenly distributed around the axis of rotation of the rotor. When the rotor 504 rotates through an angular range relative to the stator segment 208 at a substantially constant speed, the The periodicity of the torque generated by the interaction between the magnetic flux generated by the rotor and the stator is irregular. The reverse action required for the "washing" mode can be a relatively low-speed, high-torque operation mode in which torque can be supplied at a specific angle. In this case, the interaction of the stator segment 208 with the dense magnet area 506 can provide the peak torque requirement. Exemplary embodiments of the apparatus and method according to the present invention

The following paragraphs (A1) to (A14) describe examples of devices that can be implemented according to the present invention.

(A1) A motor or generator, which may include a rotor and a stator. The rotor has a rotation axis and is configured to generate a first magnetic flux parallel to the rotation axis. The stator is configured to generate a first magnetic flux parallel to the rotation axis. The second magnetic flux of the rotating shaft, wherein at least one of the rotor or the stator is configured to produce a magnetic flux profile that is unevenly distributed around the rotating shaft.

(A2) The motor or generator of paragraph (A1), wherein the rotor can be further configured to produce a first magnetic flux profile that is unevenly distributed around the axis of rotation.

(A3) The motor or generator of paragraph (A2), wherein the rotor may further include one or more magnet segments unevenly distributed around the rotation axis.

(A4) The motor or generator of paragraph (A3), wherein each of the one or more magnet segments may further have a respective surface position in which the first magnetic flux has a maximum density, and the respective surfaces The positions may be unevenly distributed around the axis of rotation.

(A5) The motor or generator of any of paragraphs (A2) to (A4), wherein the rotor can be further configured such that when the rotor rotates through an angular range relative to the stator at a substantially constant speed, A periodicity of the torque generated due to the interaction of the first magnetic flux and the second magnetic flux is irregular.

(A6) The motor or generator of any one of paragraphs (A2) to (A5), wherein the stator can be further configured to produce a second magnetic flux profile that is unevenly distributed around the axis of rotation.

(A7) The motor or generator of paragraph (A1), wherein the stator can be further configured to produce a magnetic flux profile that is unevenly distributed around the rotation axis.

(A8) The motor or generator of any one of paragraphs (A2) to (A7), wherein the stator may further include one or more printed circuit board segments unevenly distributed around the rotation axis.

(A9) The motor or generator according to any one of paragraphs (A2) to (A8), wherein the stator may further include a conductive layer disposed on at least one dielectric layer to generate the second magnetic flux when excited by a current Trace.

(A10) The motor or generator of any of paragraphs (A2) to (A9), wherein the stator can be further configured such that at any given time when the conductive traces are excited by current, the second magnetic Generally, one or more positions of the maximum density are unevenly distributed around the axis of rotation.

(A11) For the motor or generator of paragraph (A9) or paragraph (A10), the conductive traces are arranged on the at least one dielectric layer and are coupled to a power source to generate three corresponding to the current output by the power source Three phases of the second magnetic flux of two phases.

(A12) The motor or generator of any one of paragraphs (A1) to (A11), wherein the stator can be further configured such that when the rotor rotates through an angular range relative to the stator at a constant speed, attributable A periodicity of the torque generated by the interaction between the first magnetic flux and the second magnetic flux is irregular.

(A13) A rotor used in a motor or generator, which may include a support structure and one or more magnet segments, the one or more magnet segments are supported by the support structure and generated parallel to a rotation axis The first magnetic flux, the support structure rotates around the rotation axis when assembled with the stator, the stator generates a second magnetic flux parallel to the rotation axis, wherein the one or more magnet segments are configured and arranged to A magnetic flux profile that is unevenly distributed around the axis of rotation is produced.

(A14) The rotor of paragraph (A13), wherein the one or more magnet segments may further include at least one first magnet segment and a second magnet segment spaced apart from the first magnet segment, and the The first magnet segment may include one more number of adjacent magnets than the second magnet segment.

The following paragraphs (M1) to (M5) describe examples of methods that can be implemented according to the present invention.

(M1) A method which may include unevenly arranging one or more magnetic flux-generating windings of stators around a rotating shaft of an axial flux motor or a rotor of a generator.

(M2) The method of paragraph (M1), wherein arranging the one or more magnetic flux generating windings further includes unevenly arranging one or more printed circuit board segments including the windings around the rotation axis.

(M3) The method of paragraph (M1) or paragraph (M2), wherein arranging the one or more printed circuit board segments may further include arranging the one or more printed circuit board segments so that current flows in the windings At any given time of excitation, one or more positions of the maximum density of the second magnetic flux are unevenly distributed around the axis of rotation.

(M4) The method of any one of paragraphs (M1) to (M3), wherein the rotor may include magnets unevenly arranged around the rotation axis.

(M5) The method of any one of paragraphs (M1) to (M4), wherein configuring the one or more magnetic flux generating windings may further include configuring the one or more magnetic flux generating windings such that when the rotor is When the constant speed passes through an angular range with respect to the rotation of the stator, a periodicity of the torque due to the interaction of the magnetic flux generated by the rotor and the stator is irregular.

Therefore, although several aspects of at least one embodiment have been described, it should be understood that those skilled in the art will easily think of various alternatives, modifications and improvements. These substitutions, modifications and improvements are intended to be part of the present invention and are intended to be within the spirit and scope of the present invention. Therefore, the above description and drawings are for illustration only.

The various aspects of the present invention can be used alone, in combination, or in various configurations that are not specifically discussed in the above embodiments, and are therefore not limited to the details in this application and the components set forth in the above description or shown in the drawings The configuration. For example, the aspect described in one embodiment can be combined with the aspect described in other embodiments in any way.

In addition, the disclosed aspect can be embodied as one of the methods provided for its example. The actions that are part of the method can be sequenced in any suitable way. Therefore, embodiments can be constructed in which actions are performed in a sequence other than the sequence shown, which may include performing some actions at the same time, even if the actions are shown as sequential actions in the illustrative embodiment.

The ordinal number used to modify a claim element in the scope of the patent application (such as "first", "second", "third", etc.) itself does not imply the priority of one claim element compared to another claim element , Order or order, or the time sequence of the actions of a method, but only used to distinguish a claim element with a specific name from another element with the same name (but using an ordinal number) to distinguish the requested element .

In addition, the phrases and terms used herein are used for description and should not be considered as limiting. As used in this article, "include", "include" or "have", "include", "involved" and their variants mean the items listed thereafter and their equivalents and additional items.

100: System 104a: Rotor assembly/magnet 104b: Rotor assembly/magnet 106a: Permanently magnetized part/magnet 106b: Permanently magnetized part/magnet 108: Shaft 110: stator 112: Controller/terminal/rectifier implementation plan 114: Wire/electrical connection 202: Stator 204: Stator 206: Stator 208: stator segment 208a to 208g: stator segment 302: printed circuit board panel 502: Magnet 504: Rotor 506: dense magnet section / dense magnet area / dense angle range 508: Non-dense angular range/non-dense magnet area 510: attachment parts 512: Fastener 514: Terminal 802: Motor 804: washing machine load 806: shell 808: washing machine bucket 810: bearing element 812: Shaft

The purpose, aspect, features and advantages of the embodiments disclosed herein will be more fully understood from the following [Embodiments], the scope of the attached patent application and the accompanying drawings. In the accompanying drawings, the same component symbols identify similar or identical components. The reference element symbols introduced into this specification in conjunction with a figure may be repeated in one or more subsequent figures and are not otherwise described in this specification to provide a background for other features, and each element may not be labeled in each figure. The drawings are not necessarily drawn to scale, but the emphasis is placed on illustrating the embodiments, principles and concepts. The drawings are not intended to limit the scope of the patent application included in this article.

Figure 1A shows an example of an axial flux motor or generator in which some aspects of the present invention can be used;

Figure 1B is an exploded view showing the components of the axial flux motor or generator shown in Figure 1A and a component used to assemble one of these components;

Figure 2 is a conceptual diagram showing three printed circuit board stators with equal areas but different configurations;

Figure 3 is a diagram showing how multiple stator segments can be configured to be manufactured on a printed circuit board panel of a standard size;

Fig. 4 is a diagram showing how a subset of the stator segments shown in Fig. 3 is presented edge-to-edge arranged on the printed circuit board panel shown in Fig. 3;

Figure 5 shows an exemplary configuration of a stator segment relative to a magnet on a rotor according to some aspects of the present invention;

Figure 6 shows the same configuration as Figure 5, but in which the rotor is shown at an angle, and the stator segment overlaps with a magnet segment that provides peak torque at this angle;

Figure 7 shows an exemplary configuration of a plurality of stator segments with respect to magnets on a rotor according to some aspects of the present invention; and

FIG. 8 shows a cross-section of an exemplary embodiment of an axial flux motor with a washing machine load configuration and integration according to some aspects of the present invention.

208: stator segment

502: Magnet

504: Rotor

506: Dense magnet section / Dense angle range / Dense magnet area

508: Non-dense angular range/non-dense magnet area

510: attachment parts

512: Fastener

514: Terminal

Claims (20)

A motor or generator, which includes: A rotor having a rotating shaft and configured to generate a first magnetic flux parallel to the rotating shaft; and A stator, which is configured to generate a second magnetic flux parallel to the axis of rotation; At least one of the rotor or the stator is configured to produce a magnetic flux profile that is unevenly distributed around the rotation axis. Such as the motor or generator of claim 1, wherein the rotor is configured to produce a first magnetic flux profile that is unevenly distributed around the rotation axis. Such as the motor or generator of claim 2, wherein the rotor includes one or more magnet segments unevenly distributed around the rotation axis. Such as the motor or generator of claim 3, wherein each of the one or more magnet segments has a respective surface position in which the first magnetic flux has a maximum density, and the respective surface positions are not around the rotation axis Evenly distributed. Such as the motor or generator of claim 2, wherein the rotor is configured such that when the rotor rotates through an angular range relative to the stator at a substantially constant speed, it is due to the first magnetic flux and the second magnetic flux One of the periodicity of the torque produced by the interaction is irregular. Such as the motor or generator of claim 2, wherein the stator is configured to produce a second magnetic flux profile that is unevenly distributed around the rotation axis. Such as the motor or generator of claim 1, wherein the stator is configured to produce a magnetic flux profile that is unevenly distributed around the rotation axis. Such as the motor or generator of claim 7, wherein the stator includes one or more printed circuit board segments unevenly distributed around the rotation axis. The motor or generator of claim 1, wherein the stator includes conductive traces arranged on at least one dielectric layer to generate the second magnetic flux when excited by current. The motor or generator of claim 9, wherein the stator is configured such that at any given time when the conductive traces are excited by current, one or more positions of the maximum density of the second magnetic flux surround the axis of rotation Uneven distribution. The motor or generator of claim 10, wherein the conductive traces are arranged on the at least one dielectric layer and are coupled to a power source to generate the second magnetic flux corresponding to the three phases of the current output by the power source The three phases. Such as the motor or generator of claim 10, wherein the stator includes one or more printed circuit board segments unevenly distributed around the rotation axis. Such as the motor or generator of claim 1, wherein at least one of the rotor or the stator is configured such that when the rotor rotates through an angular range with respect to the stator at a constant speed, it is due to the first magnetic flux and The periodicity of the torque generated by the interaction of the second magnetic flux is irregular. A method including: One or more magnetic flux generating windings of stators are unevenly arranged around a rotating shaft of a rotor of an axial flux motor or a generator. Such as the method of claim 14, wherein configuring the one or more magnetic flux generating windings includes: The uneven configuration around the axis of rotation includes one or more printed circuit board segments of the windings. The method of claim 15, wherein the rotor includes magnets arranged unevenly around the rotation axis. Such as the method of claim 15, wherein configuring the one or more printed circuit board segments further includes: The one or more printed circuit board segments are configured such that at any given time when the windings are excited by current, one or more positions of the maximum density of the second magnetic flux are unevenly distributed around the axis of rotation. Such as the method of claim 14, wherein configuring the one or more magnetic flux generating windings includes: The one or more magnetic flux generating windings are arranged so that when the rotor rotates through an angular range with respect to the stator at a constant speed, the torque is due to the interaction of the magnetic flux generated by the rotor and the stator A periodicity is irregular. A rotor used in a motor or generator, which includes: A supporting structure; and One or more magnet segments, which are supported by the support structure and generate a first magnetic flux parallel to a rotation axis, the support structure rotates around the rotation axis when assembled with the stator, and the stator generates parallel to the rotation axis The second magnetic flux, wherein the one or more magnet segments are configured and arranged to produce a magnetic flux shape that is unevenly distributed around the rotation axis. Such as the rotor of claim 19, wherein the one or more magnet segments include at least one first magnet segment and a second magnet segment spaced apart from the first magnet segment, the first magnet segment including The second magnet segment has one more number of adjacent magnets.

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