TWI827721B - A motor or generator, a rotor for use in a motor or generator, and a method for arranging a motor or genenerator - 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

Motors or generators, rotors for use in motors or generators and methods for arranging motors or generators

Embodiments of the present invention relate to stator and rotor designs that meet cyclic torque requirements.

Permanent magnet axial flux motors and generators are described by several patents, including U.S. Patent No. 7,109,625 (the "'625 Patent"), with a generally flat printed circuit board stator (PCS) inserted between magnets having alternating north and south poles. ). 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 reverse the roles of the inner and outer radii to result in 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] is provided to introduce a selection of concepts in a simplified form that are further described below in [Description]. This Summary is not intended to identify key features or essential features, nor is it intended to limit the scope of the claims contained herein.

In some disclosed embodiments, a motor or generator includes a rotor and a stator, wherein the rotor has an axis of rotation and is configured to generate a first magnetic field parallel to the axis of rotation. Pass, 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 flux profile that is unevenly distributed around the rotation axis.

In other disclosed embodiments, a method involves unevenly arranging one or more flux-generating windings of a stator about an axis of rotation of a rotor of an axial flux motor or generator.

In other disclosed embodiments, a rotor for use in a motor or generator includes a support structure and one or more magnet segments supported by the support structure and generated parallel to A first flux of an axis of rotation about which the support structure rotates when assembled with a stator that generates a second flux parallel to the axis of rotation, wherein the one or more magnet segments are configured and arranged to produce a flux profile that is unevenly distributed around the axis of rotation.

100:System

104a:Rotor assembly/magnet

104b:Rotor assembly/magnet

106a: Permanently magnetized part/magnet

106b: Permanently magnetized part/magnet

108:Shaft parts

110:Stator

112:Controller/Terminal/Rectifier Implementation Plan

114: Wires/electrical connectors

202:Stator

204:Stator

206:Stator

208:Stator segmentation

208a to 208g: stator segments

302: Printed circuit board panel

502:Magnet

504:Rotor

506: dense magnet section/dense magnet area/dense angular range

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

510: Attachment parts

512: Fasteners

514:Terminal

802: Motor

804: Washing machine load

806: Shell

808:Washing machine barrel

810:Bearing components

812:Shaft parts

The purpose, aspects, features and advantages of the embodiments disclosed herein will be more fully understood from the following [Embodiments], the accompanying patent claims and the accompanying drawings, in which the same component numbers identify similar or identical components. Reference element numbers introduced into this specification in connection with a figure may be repeated in one or more subsequent figures and not otherwise described in this specification to provide context for other features, and each element may not be labeled in every figure. The drawings are not necessarily to scale, emphasis instead being placed on illustrating embodiments, principles and concepts. The drawings are not intended to limit the scope of the claims contained herein.

Figure 1A shows an example of an axial flux motor or generator in which aspects of the invention may be employed; Figure 1B shows the components of the axial flux motor or generator shown in Figure 1A and for assembly An expanded view of one of the components of these assemblies; Figure 2 is a conceptual diagram showing three printed circuit board stators of equal area but different configurations; Figure 3 is a diagram showing how multiple stator segments can be configured to be fabricated on a standard sized printed circuit board panel; Figure 4 is a diagram showing how a subset of the stator segments shown in Figure 3 can appear as A diagram of a printed circuit board panel arranged edge-to-edge as shown in Figure 3; Figure 5 shows an example arrangement of stator segments relative to magnets on a rotor in accordance with aspects of the invention; Figure 6 shows the same configuration as Figure 5, but showing the rotor at an angle at which the stator segments overlap a magnet section that provides peak torque; Figure 7 shows a plurality of stator segments according to some aspects of the invention. an example arrangement of segments relative to magnets on a rotor; and FIG. 8 illustrates one of an example embodiment of an axial flux motor configured and integrated with a washing machine load in accordance with aspects of the present invention. cross section.

Cross-references to related applications

This application asserts the rights under 35 U.S.C. § 119(e) in U.S. Provisional Application No. 62/754,051, titled "PLANAR STATOR AND ROTOR DESIGN FOR PERIODIC TORQUE REQUIREMENTS", filed on November 1, 2018. This application is also a continuation in part and asserts the rights under 35 U.S.C.§ 120 of U.S. Patent Application No. 16/378,294 titled "STRUCTURES AND METHODS FOR CONTROLLING LOSSES IN PRINTED CIRCUIT BOARDS" filed on April 8, 2019. U.S. Patent Application No. 16/378,294 was filed on October 19, 2018, titled "STRUCTURES AND METHODS FOR CONTROLLING LOSSES IN" PRINTED CIRCUIT BOARDS" is a continuation of U.S. Patent Application No. 16/165,745 and current U.S. Patent No. 10,256,690 and claims its rights under 35 U.S.C.§ 120. U.S. Patent No. 10,256,690 is the name of the application filed on December 22, 2017. It is a continuation of U.S. Patent Application No. 15/852,972 and current U.S. Patent No. 10,170,953 for "PLANAR COMPOSITE STRUCTURES AND ASSEMBLIES FOR AXIAL FLUX MOTORS AND GENERATORS" and asserts its rights under 35 U.S.C.§ 120, U.S. Patent No. 10,170,953 Claim the rights under 35 U.S.C.§ 119(e) in U.S. Provisional Application No. 62/530,552, filed on July 10, 2017, titled "STRUCTURES AND METHODS OF STACKING SUBASSEMBLIES IN PLANAR COMPOSITE STATORS TO OBTAIN HIGHER WORKING VOLTAGES", and U.S. Patent No. 10,170,953 is also a partial continuation of U.S. Patent Application No. 15/611,359 titled "STRUCTURES AND METHODS FOR CONTROLLING LOSSES IN PRINTED CIRCUIT BOARDS" filed on June 1, 2017 and current U.S. Patent No. 9,859,763 And assert its rights in accordance with 35 U.S.C.§ 120, U.S. Patent No. 9,859,763: (A) is the 15th/No. 283,088 and the current U.S. Patent No. 9,800,109 are a partial continuation case and claim their rights under 35 U.S.C. § 120. U.S. Patent No. 9,800,109 is a partial continuation case and assert their rights under 35 U.S.C. § 120. The name of the application filed 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 U.S.C.§ 119(e) (1 ) U.S. Provisional Patent Application No. 62/236,407, filed on October 2, 2015, titled "STRUCTURES TO REDUCE LOSSES IN PRINTED CIRCUIT BOARD WINDINGS" and (2) filed on October 2, 2015, titled "STRUCTURES FOR THERMAL MANAGEMENT" IN PRINTED CIRCUIT BOARD STATORS"; and (B) the U.S. Provisional Patent Application No. 62/236,422 filed on July 12, 2016 titled "APPRAATUS AND METHOD FOR FORMING A MAGNET ASSEMBLY" Patent application No. 15/208,452 and a part of the current U.S. Patent No. 9,673,688 are a continuation of the case and claim its rights under 35 U.S.C.§ 120. U.S. Patent No. 9,673,688 was filed on January 6, 2016 and claimed under 35 U.S.C.§ 119(e). Rights under U.S. Provisional Patent Application No. 62/275,653 titled "ALIGNMNET OF MAGNETIC COMPONENTS IN AXIAL FLUX MACHINES WITH GENERALLY PLANAR WINDINGS". This application is also a partial continuation and is claimed under 35 U.S.C.§ 120. It was filed on May 18, 2018 and published as U.S. Patent Publication Application No. US 2018/0351441, titled "PRE-WARPED ROTORS FOR CONTROL OF MAGNET-STATOR" GAP IN AXIAL FLUX MACHINES", U.S. Patent Application No. 15/983,985, U.S. Patent Publication Application No. US 2018/0351441 asserted under 35 U.S.C.§ 119(e) (1) filed on June 5, 2017 The US Provisional Patent Application No. 62/515,251 and (2) titled "PRE-WARPED ROTORS FOR CONTROL OF MAGNET-STATOR GAP IN AXIAL FLUX MACHINES" filed on June 5, 2017 is titled "AIR CIRCULATION IN AXIAL FLUX MACHINES" ” the rights of each party under U.S. Provisional Patent Application No. 62/515,256. The entire contents of each of the above-mentioned applications, publications, and patents are hereby incorporated 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 Application No. 2018-0351441 A1 ("'441 In the axial flux motor or generator disclosed in "Open Applications"), the entire contents of each of which are incorporated herein by reference), the flux generating assembly of the stator (whether composed of a single continuous printing A circuit board or multiple printed circuit board segments) configured so that at any given time when the stator's windings are energized by current, the positions of the peak magnetic flux produced by the stator are evenly distributed relative to the angle about the axis of rotation of the rotor. Similarly, in these machines, the rotor's flux-generating components (whether consisting of a ring magnet or individual magnets housed in pockets) are configured so that at any given point in time, the peak flux generated by the rotor The positions are also evenly distributed relative to the angle around the axis of rotation of the rotor. Therefore, in all such machines, the location of the peak magnetic flux generated by each of the rotor and stator at any given time of machine operation is evenly distributed according to the angle about the axis of rotation of the machine. In other words, for each of the rotor and stator in these machines, the position of the peak flux around the axis of rotation is separated by the same angle from the next adjacent position below the peak flux, so that the flux profile of each of the rotor and stator is Evenly distributed around the axis of rotation.

An alternative design is disclosed herein that has cost advantages over conventional designs for specific loads and machine configurations, wherein the stator and/or rotor may instead be configured to have a non-uniform distribution of magnetic flux about the axis of rotation of the rotor shape. For example, in some embodiments, the stator may be configured so that it describes a portion of an arc surrounding the main axis of the machine. If such a stator segment can be positioned, then due to the integration of the machine with the attached load, at a radius greater than an equal area of the stator evenly distributed around the same axis, the torque generated can be equal to that of the stator segment in which it is positioned. The increase in radius is proportional to the assumption that the equivalent flux and current density in the gap limit the stator. However, the cost of maintaining the equivalent flux in the gap of an "eccentric" stator segment increases with the angle subtended by the segment. Inversely proportional to the magnet volume. In most cases, this trade-off is undesirable. However, in an application where peak torque at a particular angle or range of shaft angles is desired, the magnet material may be unevenly distributed relative to the rotor such that the stator is exposed to peak flux density at the shaft corners where peak torque is desired. For generator applications where the power supply has periodic torque production capabilities, a machine designed according to this principle may provide similar advantages.

The design of the stator and magnet system for generating peak torque at a specific angle is not limited to one stator segment and/or one concentration of magnet material on the rotor, but this is the simplest embodiment. Embodiments that include one or more unevenly distributed stator segments and/or one or more unevenly distributed magnet segments may provide a useful combination of angle-dependent torque capabilities. It will be appreciated that different combinations of one or more unevenly distributed stator segments and one or more unevenly distributed magnet segments may be used to achieve the same or similar torque capabilities as a function of angle. For example, the same or similar torque capabilities as a function of angle can be achieved by interchanging the distribution of stator segments and rotor magnet positions. This allows the designer to achieve a trade-off between magnet material cost and stator area while achieving the same or similar torque capabilities as a function of angle.

The design of a machine for producing 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 stator losses due to eddy currents can be zero when the stator does not overlap the magnets. Another possibility for continuous rotation is to distribute the magnets so that the stator segments always see flux, but by a magnitude smaller than the "peak torque" angle.

Some embodiments described herein may be particularly advantageous in applications where machine radius may be significantly increased relative to a conventional design. In these applications, flat circuit board stator (PCS) segments positioned at a radius greater than a uniform flat circuit board stator can achieve per unit stator area of higher peak torque. Furthermore, in contrast to a thin annular stator with a large radius, the stator segments can be "assembled" or configured on a standard-sized printed circuit board "panel." This may allow for 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 cyclic torque requirement. Furthermore, for balancing purposes, these machines often 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 magnetic materials in the stator segmented generator. Other potential applications include washing machines or other applications where the motor or generator moves through a restricted angle and cyclic or "reversing" type loads.

One of the basic observations of the novel concepts disclosed in this article can be reduced to a "scaling" argument of the originally equidistant stator or stator segmentation based on fundamental design considerations, which has nothing to do with the internal organization and connections of the stator. In a conventional toroidal PCS consistent with one of the descriptions in the '625 patent, the torque can be expressed as follows:

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. The term r dr dθ is a differential area element, and rf _dens is the torque density magnitude corresponding to the equation τ = rxF . The force density is θ-oriented due to the axial magnetic flux and radial current density, that is: f _dens = J ( r ) xB

Here, the force density is the product of the current density supported by the stator and the magnetic flux density resulting from the rotor magnet circuit and the stator reaction at that current density. For purposes of illustration, assume that B is radial. In the stator designed according to the '625 patent, diverging radial traces are effectively introduced from the inner radius r1 to reduce the current density by a factor of 1/r. Extract one of the model systems for this effect: J ( r ) = J ₀ r ₁ / r

where J ₀ is 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, τ _peak = J ₀ BAr _1The current density supported by the stator depends on the number of internal vias 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 accommodates features at a spacing close to manufacturing limits. Therefore, J ₀ cannot be strictly regarded as a constant. For example, if r1=0, the channel cannot be accommodated, and J ₀ =0. However, for motors of practical interest _, J0 will approach a value that depends primarily on thermal considerations and clearance requirements. Treating J ₀ as a constant for comparison purposes with an original equidistant stator tends to make a conventional stator positioned about a central axis with a smaller r1 perform more competitively than a stator positioned around a larger radius.

The area A of a stator or stator segment with an angular range δ is:

For the stator of the conventional design, δ =2 π . For stator segments, δ ideally corresponds to an integer number of pole pairs. To compare stator segmentation to conventional cost-based designs, a reasonable comparison of equal-area stator and magnet assemblies can be made. As the inner radius r ₁ increases, there are multiple solutions of δ and r ₂ for any r ₁ , and the multiple solutions of δ and r ₂ are regarded as independent variables here. In particular, when considering δ, the pole spacing on a segment does not need to comply with the usual constraints of evenly placing poles on 2π rad as in a conventional stator. This implies considerable design flexibility of segmentation and the ability to achieve equal area A that conventional stators do not enjoy. Examples of the advantages of using smaller δ to displace the stator area to larger r ₁ include: (1) stator segments with larger r ₁ provide higher peak torque per unit area; (2) when stator segments and Peak torque can be used when the magnetic materials completely overlap at a specific rotor angle (or angle range); (3) When the magnetic materials and the stator do not overlap, there is no eddy current loss in the machine; (4) The peak torque can be used at r ₁ , r ₂ and δ obtain stator segmentation when the segments can be "nested" on a printed circuit board panel to minimize wasted material and cost; and (5) the peak torque per unit area (or per unit cost) increases with the stator segmentation The radius increases.

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。 Assuming that a design procedure for a prototype conventional stator with δ = 2 π satisfies a specific torque τ _p , when the segments completely overlap the magnetic material, it can be inferred that the subtended magnetic poles in the prototype design span an angle δ The design of the set of stator segments yields an angular range of

one peak torque. Therefore, one of the practical design procedures for the segment is to design a conventional stator prototype in which the torque requirements increase the ratio of the poles in the conventional stator relative to the poles intended to remain in the segment. This procedure, although advantageous, cannot take advantage of the freedom of segmented design because the pole spacing is constrained both to the segmented angular range and to the 2π range of conventional designs. The segmentation 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 rotor at specific angles can achieve various torque capabilities that vary depending on the angle. One or more areas on the rotor may carry magnetic material (one or more pole pairs) containing different flux densities and may 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 Application Published No. 2018-0351441 A1 (the "'441 Publication") (each of which is incorporated by reference Examples of motors and/or generators in which non-uniformly distributed stators and/or rotors, such as those disclosed herein, may be employed are described above. First, illustrative examples of such machines will be described in conjunction with Figures 1A and 1B. Next, examples of stators and rotors having flux profiles that are unevenly distributed around a rotor's axis of rotation and that can be used in such machines will be described with reference to FIGS. 2 to 8 .

Figure 1A shows the use of a flat composite stator 110 with a rotor assembly 104a and An example of a system 100 in an assembly of 104b, shaft 108, wire 114 and controller 112. An expanded view showing these components and their assembled components is shown in Figure 1B. The pattern of the magnetic poles in the permanently magnetized portions 106a, 106b of the rotor assembly is also clearly visible in the expanded view of FIG. 1B. Figure 1A is an example of an embodiment in which electrical connections 114 are made at the outer radius of PCS 110 and the stator is mounted to a frame or housing at the outer periphery. Another useful configuration (the "outwheel" configuration) involves mounting the stator at the inner radius so that the electrical connector 114 is at the inner radius and replacing the shaft 108 by a ring that separates the rotor halves. It is also possible to configure the system with only one magnet 106a or 106b or with multiple stators inserted between consecutive magnet assemblies. Wires 114 may also convey information about the position of the rotor based on readings from a Hall effect or similar sensor mounted on the stator. Although not shown, for similar purposes, an encoder attached to shaft 108 may provide position information to controller 112 .

The system 100 in FIGS. 1A and 1B may act as a motor or a generator, depending on the operation of the controller 112 and components connected to the shaft 108 . As a motor system, the controller 112 operates the switches such that the current in the stator 110 produces a torque about the shaft 108 due to the magnetic flux originating in the gap of the magnets 104a, 104b connected to the shaft. Depending on the design of the controller 112, the flux in the gap and/or the position of the rotor may be measured or estimated to operate the switch to achieve torque at the shaft 108. As a generator system, a mechanical rotational power source connected to shaft 108 produces a voltage waveform at terminals 112 of the stator. These voltages can be applied directly to a load, or they can be rectified by a three-phase (or multi-phase) rectifier within the controller 112 . The rectifier implementation 112 may be "self-commutating" using diodes in generator mode, or may be constructed using the control switches of the motor controller, but operated so that the shaft torque is opposite to the torque provided by the mechanical wave source, and Mechanical energy is converted into electrical energy. Thus, the same configuration of Figure 1A can function as both a generator and a motor, depending on how the controller 112 is operated. Additionally, controller 112 may include filter components that mitigate switching effects, reducing EMI/RFI from the wires 114, reducing losses and providing additional flexibility in the power supplied to or from the controller.

Figure 2 shows the geometry of three stators 202, 204 and 206 with different angular and radial extents but equal areas. Stators 204 and 206 have different inner radii. Stator 206 shows typical relative dimensions of the stator described by the '625 patent. The stator 204 is a thin annular design. In stator 204, the inner radius is increased, but a stator with these relative dimensions cannot efficiently utilize a "panel" of printed circuit board material. As presented herein, stator 202 exhibits a stator segment 208 having an area and radius equal to stator 204 . All other equal larger radius stators 202 and 204 will produce a higher peak torque than stator 206 due to the increased radius torque arm.

Figure 3 shows the "panning" or packing of stator segments (section 208 shown in Figure 2) on a standard size printed circuit board panel 302. Use the configuration shown to efficiently utilize panel 302. The cost of stator segments 208 is inversely proportional to panel 302 utilization.

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

Figure 5 shows an example configuration of stator segments 208 relative to magnets 502 on a rotor 504. In the example shown, a dense angular range 506 (also referred to herein as a "dense magnet region") of the magnets 502 on the rotor 504 is provided to achieve peak torque at an angle of overlap with the stator segment 208. The magnets 502 The non-dense angular range 508 (also referred to herein as the "non-dense magnet region") is configured to provide a lower torque capability independent of angle. Although not shown in the figure, it will be understood that in some embodiments, or adding non-magnetic elements to the non-dense magnet area 508 to balance the weight of the entire rotor 504. Additionally, it should be understood that in some embodiments, an additional rotor section (not shown) has a corresponding but oppositely polarized magnet configuration. Can Positioned above the illustrated portion of the rotor 504, the stator segment 208 can be positioned in a gap between the two rotor portions, with flux lines extending in a direction parallel to the axis of rotation of the rotor to opposite polarity between pairs of magnets. Additionally, although not shown in FIG. 5 , it should be understood that the stator segments 208 may include, for example, conductive traces and/or vias disposed on one or more dielectric layers that are configured to form in When current is excited, the winding generates magnetic flux in a direction parallel to the rotation axis of the rotor. The windings may be configured to receive one or more current phases from a power supply (not shown in Figure 5), and may be configured into one or more spirals, one or more serpentine patterns, or otherwise to create this magnetic flux.

As shown in Figure 5, in some embodiments, stator segment 208 may be attached via an arcuate attachment member 510 (one or more fasteners 512 may be used to attach stator segment 208 to arcuate attachment member 510) to be held in place, and one or more windings (not shown) of the stator segment 208 may be connected to terminals 514 associated with the attachment member 510, which may be connected to a controller (Fig. 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 with the rotor 504 positioned at an angle such that the stator segments 208 overlap the dense magnet sections 506 that provide peak torque.

Figure 7 shows an alternative configuration of Figures 4 and 5. As shown in the figure, in addition to or instead of using a non-dense magnet region 508 (not shown in FIG. 7) and a dense angular range 506, the stator segments 208a-208g may Configured so that they fully or nearly describe an annular stator with constant available torque at any angle. In some embodiments, a subset of stator segments 208a-208g may be smaller, may be configured on a coarser pitch, may contain fewer winding "turns", and/or may be supplied with a smaller number of windings than one or more other The stator segment 208 has a small power, allowing a machine with concentrated magnets to provide angle-specific peak torque while Still provides torque capability at any angle. For example, in some embodiments, stator segment 208a may be configured, configured, and/or energized differently than other stator segments 208b-208g for this purpose.

Regardless of the particular configuration of magnet(s) 502 and stator segment(s) 208 employed, care is taken, in at least some scenarios, to ensure that at least one stator segment 208 is at each position consistent with at least one rotation of the rotor 504 during one revolution of the rotor 504 . One magnet 502 at least partially overlaps so that the rotor 504 is not "stuck" in a position where no flux from the stator segment 208 interacts with the flux from one magnet 502 .

In each of the above example configurations, the stator segment(s) 208 and/or the magnet(s) 502 of the rotor 504 are configured to have a flux profile that is unevenly distributed about the main axis of rotation of the machine. In particular, the stator segment(s) 208 are configured so that at any given point in time when the stator's windings are energized by current, the location of the peak magnetic flux produced by the stator is unevenly distributed relative to the angle about the axis of rotation of the rotor. Similarly, in these machines, the magnets 502 of a rotor 504 are also configured so that the location of the peak flux produced by the rotor at any given point in time is also unevenly distributed relative to the angle about the axis of rotation of the rotor. Therefore, for each of the rotors and stators in these machines, at least some locations of the peak flux about the axis of rotation are angularly separated from adjacent locations of the peak flux, such that the flux profile generated by the assembly rotates around The axes are unevenly distributed.

8 illustrates a cross-section of an example embodiment of an axial flux motor 802 configured as shown in FIGS. 5 and 6 in accordance with aspects of the invention. A component of components and integrated with a washing machine load 804. As shown, a stator segment 208 of the motor 802 may be secured to a housing 806 housing a washer tub 808 via an attachment component 510 and one or more fasteners 512, and the washer tub 808 may be secured via bearing elements. 810 Laike Rotationally coupled to housing 806 . A rotor 504 of the motor 802 may directly drive the washer tub 808 via a shaft 812 that may extend from the washer tub 808 and/or be fixedly attached to the washer tub 808 . For the configuration shown, stator segments 208 may be used and a collection of magnets 502 configured into a dense magnet region 506 and one or more non-dense magnet regions 508 (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 spin mode, as the rotor 504 rotates at a substantially constant speed relative to the stator segment 208 through an angular range due to the uneven distribution of the flux profiles of the rotor and stator about the rotor's axis of rotation, The periodicity of the torque generated by the interaction between the magnetic flux generated by the rotor and stator is irregular. The reverse action required for the "wash" mode may be a relatively low speed, high torque operating mode in which torque is supplied at a specific angle. In this case, the interaction of stator segments 208 with dense magnet areas 506 may provide peak torque requirements.

Example embodiments of apparatus and methods according to the invention

The following paragraphs (A1) to (A14) describe examples of devices that may be implemented in accordance with the invention.

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

(A2) The motor or generator of paragraph (A1), wherein the rotor may be further configured to produce a first flux profile that is non-uniformly distributed about the axis of rotation.

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

(A4) The motor or generator of paragraph (A3), wherein the one or more magnets are Each of the segments may further have a respective surface location where the first magnetic flux has a maximum density, and the respective surface locations may be non-uniformly distributed about the axis of rotation.

(A5) A motor or generator as in any of paragraphs (A2) to (A4), wherein the rotor may be further configured such that when the rotor rotates relative to the stator at a substantially constant speed through an angular range, The 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 of paragraphs (A2) to (A5), wherein the stator may be further configured to produce a second flux profile that is unevenly distributed about the axis of rotation.

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

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

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

(A10) The motor or generator of any of paragraphs (A2) through (A9), wherein the stator may be further configured such that at any given time the conductive traces are energized by current, the second magnetic Usually one or more locations of maximum density are distributed unevenly around the axis of rotation.

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

(A12) The motor or generator of any one of paragraphs (A1) to (A11), wherein the stator may be further configured such that when the rotor rotates relative to the stator at a constant speed through Within an angular range, the periodicity of the torque generated due to the interaction of 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 being supported by the support structure and generated parallel to an axis of rotation a first magnetic flux, the support structure rotates about the axis of rotation when assembled with the stator, the stator generates a second magnetic flux parallel to the axis of rotation, wherein the one or more magnet segments are configured and arranged to A flux profile is produced that is unevenly distributed around the axis of rotation.

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

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

(M1) A method that may include unevenly arranging one or more flux-generating windings of a stator about an axis of rotation of a rotor of an axial flux motor or generator.

(M2) The method of paragraph (M1), wherein configuring the one or more flux generating windings further includes non-uniformly configuring one or more printed circuit board segments containing the windings about the axis of rotation.

(M3) The method of paragraph (M1) or paragraph (M2), wherein configuring the one or more printed circuit board segments may further comprise configuring the one or more printed circuit board segments such that the windings are At any given time of excitation, the location or locations of maximum density of the second magnetic flux are distributed unevenly around the axis of rotation.

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

(M5) The method of any one of paragraphs (M1) to (M4), wherein configuring the one or more flux generating windings may further comprise configuring the one or more flux generating windings such that when the rotor is in accordance with a The periodicity of the torque generated by the interaction of the magnetic flux generated by the rotor and the stator is irregular as the constant speed rotates relative to the stator through an angular range.

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

Various aspects of the invention may be used alone, in combination, or in various configurations not specifically discussed in the above embodiments and are therefore not limited to the details herein and the components set forth in the description above or illustrated in the drawings. configuration. For example, aspects described in one embodiment may be combined in any manner with aspects described in other embodiments.

Additionally, the disclosed aspects may be embodied in a manner of which examples are provided. The actions performed as part of a method can be ordered in any suitable manner. Thus, embodiments may be constructed in which actions are performed in an order different from that illustrated, which may include performing some actions concurrently even though the actions are shown as sequential actions in the illustrative embodiments.

The ordinal numbers used to modify a claimed element in the scope of the application (such as "first", "second", "third", etc.) do not by themselves imply the priority of one claimed element over another claimed element. , the order or sequence or the temporal order in which the actions of a method are performed, but are used only to distinguish a claim element with a specific name from another element with the same name (but using an ordinal number) to distinguish a request element. .

Furthermore, the phrases and terminology used herein are for the purpose of description and should not be regarded as limiting. As used in this article, "includes", "includes" or "has", "contains", "involves" and ” and variations thereon are meant to cover the items listed thereafter and their equivalents and additional items.

208:Stator segmentation

502:Magnet

504:Rotor

506: dense magnet section/dense angular range/dense magnet area

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

510: Attachment parts

512: Fasteners

514:Terminal

Claims (43)

A motor or generator comprising: a rotor having an axis of rotation and configured to produce a first magnetic flux parallel to the axis of rotation, wherein a first profile of the first magnetic flux surrounds the axis of rotation non-uniform distribution; and a stator configured to generate a second magnetic flux parallel to the axis of rotation, the second magnetic flux being different from the first magnetic flux, wherein the second magnetic flux has a second profile Uneven distribution around this axis of rotation. The motor or generator of claim 1, wherein the rotor includes one or more magnet segments unevenly distributed around the rotation axis, each of the one or more magnet segments generating one of the first magnetic fluxes. part. The motor or generator of claim 2, wherein each of the one or more magnet segments has a respective surface position at which the respective first magnetic flux generated by the magnet segment The portions have a maximum density and the respective surface locations are unevenly distributed around the axis of rotation. The motor or generator of claim 1, 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 disposed on at least one dielectric layer to generate one or more respective portions of the second magnetic flux when excited by an electric current. The motor or generator of claim 5, wherein the stator is configured such that at any given time when the conductive traces are energized by current, the one or more respective portions of the second magnetic flux have a maximum density of Or multiple positions are unevenly distributed around this axis of rotation. The motor or generator of claim 6, wherein the conductive traces are disposed on the at least one dielectric layer and coupled to a power source to generate a rotating magnet corresponding to a polyphase set of current output by the power source. Pass. The motor or generator of any one of claims 1 to 7, wherein the rotor and the stator are configured such that when the rotor rotates relative to the stator through an angular range at a constant speed, due to the first magnetic The periodicity of the torque generated by the interaction between the magnetic flux and the second magnetic flux is irregular. The motor or generator of any one of claims 1 to 7, wherein: the rotor and the stator are configured to generate a torque capability between the rotor and the stator when the rotor rotates about the rotation axis through a For complete mechanical rotation, the torque capability varies non-periodically depending on the angular position of the rotor relative to the stator. The motor or generator of any one of claims 1 to 7, wherein: the rotor includes at least first, second and third magnets oriented to generate electricity in a first direction parallel to the axis of rotation respective portions of the first magnetic flux; no other magnets oriented to produce magnetic flux in the first direction are angularly positioned in the between the first magnet and the second magnet; no other magnets oriented to generate magnetic flux in the first direction are angularly positioned between the second magnet and the third magnet; and the first magnet and the A first angular distance between the second magnets is at least twice a second angular distance between the second magnet and the third magnet. The motor or generator of claim 10, wherein: the stator includes at least first, second and third windings oriented to rotate parallel to one of the axes of rotation when excited by a current of a first polarity. A second direction produces a respective portion of the second magnetic flux; no other windings oriented to produce a magnetic flux in the second direction when excited by a current of the first polarity are angularly positioned between the first winding and the third winding. between the two windings; no other windings oriented to produce magnetic flux in the second direction when excited by current of the first polarity are angularly positioned between the second winding and the third winding; and the A third angular distance between the first winding and the second winding is at least twice a fourth angular distance between the second winding and the third winding. The motor or generator of any one of claims 1 to 7, wherein: a first portion of the rotor is configured to generate a first peak magnetic field parallel to the axis of rotation at a first position relative to the rotor. flux density; a second portion of the rotor configured to produce a second peak flux density parallel to the axis of rotation at a second position relative to the rotor; a first portion of the stator configured to produce a flux density at a second position relative to the rotor; A third position relative to the stator produces a flat a third peak magnetic flux density along the axis of rotation; and the rotor and the stator are configured such that a first torque between the rotor and the stator when the first position is angularly aligned with the third position Capacity is greater than a second torque capacity between the rotor and the stator when the second position is angularly aligned with the third position. The motor or generator of claim 12, wherein: the rotor and the stator are configured such that the first torque capability when the first position is angularly aligned with the third position is at least greater than when in the second position. 25 percent of the second torque capability when angularly aligned with the third position. The motor or generator of claim 12, wherein: the rotor and the stator are configured such that the first torque capability when the first position is angularly aligned with the third position is at least in the second position. Twice the second torque capability when angularly aligned with the third position. The motor or generator of any one of claims 1 to 7, wherein: a first portion of the stator is configured to generate a first peak magnetic field parallel to the axis of rotation at a first position relative to the stator. flux density; a second portion of the stator configured to produce a second peak flux density parallel to the axis of rotation at a second position relative to the stator; a first portion of the rotor configured to produce a flux density at a second position relative to the stator; A third position relative to the rotor produces a third peak flux density parallel to the axis of rotation; and the rotor and the stator are configured so as to be angularly aligned with the third position in the first position A first torque capability between the rotor and the stator is greater than a second torque capability between the rotor and the stator when the second position is angularly aligned with the third position. The motor or generator of claim 15, wherein: the rotor and the stator are configured such that the first torque capability when the first position is angularly aligned with the third position is at least greater than when in the second position. 25 percent of the second torque capability when angularly aligned with the third position. The motor or generator of claim 15, wherein: the rotor and the stator are configured such that the first torque capability when the first position is angularly aligned with the third position is at least in the second position. Twice the second torque capability when angularly aligned with the third position. The motor or generator of any one of claims 1 to 7, wherein: the rotor includes a plurality of magnets configured and configured to generate the first magnetic flux, wherein the plurality of magnets are configured Such that a first half angle of the rotor generates a first part of the first magnetic flux, and a second half angle of the rotor generates a second part of the first magnetic flux, and the second part is substantially larger than The first part. The motor or generator of any one of claims 1 to 7, wherein the plurality of magnets that generate the first magnetic flux are arranged in 1-fold angular symmetry with respect to the rotor. The motor or generator of any one of claims 1 to 7, wherein: one or more portions of the rotor are configured to be at one or more first angular positions of a first half angle of the rotor and the Zero or more second angular positions of a second half angle of the rotor produce a plurality of peak magnetic flux densities in a first direction parallel to the axis of rotation, wherein a number of the one or more first angular positions A quantity greater than the zero or more second angular positions. The motor or generator of claim 20, wherein: one or more portions of the stator are configured to be at one or more third angular positions of a first half angle of the stator and at a second half angle of the stator. A plurality of peak magnetic flux densities are generated in a second direction parallel to the rotation axis at zero or more fourth angular positions, wherein a number of the one or more third angular positions is greater than the zero or more third angular positions. A quantity of four corner positions. The motor or generator of any one of claims 1 to 7, wherein: a first half angle of the rotor includes a first number of magnets oriented to rotate in a first direction parallel to the axis of rotation producing respective first portions of the first magnetic flux; a second half-angle of the rotor includes a second number of magnets oriented to produce respective second portions of the first magnetic flux in the first direction; and The first quantity is greater than the second quantity. The motor or generator of claim 22, wherein: a first half angle of the stator includes a third number of windings oriented to rotate parallel to the axis of rotation when excited by a current of a first polarity. a second direction generating respective first portions of the second magnetic flux; A second half-angle of the stator includes a fourth number of windings oriented to produce respective second portions of the second magnetic flux in the second direction when excited by current of the first polarity; and the The third quantity is greater than the fourth quantity. The motor or generator of any one of claims 1 to 7, wherein: the rotor includes one or more magnets configured to generate the first magnetic flux, wherein the one or more magnets do not move around the axis of rotation. uniformly distributed; and the stator includes one or more windings that generate the second magnetic flux when excited by current, wherein the one or more windings are unevenly distributed around the rotation axis. A method for configuring an axial flux motor or generator, comprising configuring one or more magnets of a rotor of the axial flux motor or generator about an axis of rotation of the rotor such that the or a first profile of a first magnetic flux generated by a plurality of magnets distributed unevenly around the rotation axis; and one or more stators of the axial flux motor or generator configured around the rotation axis to generate a first magnetic flux Windings such that a second profile of a second magnetic flux generated by the one or more flux generating windings is distributed unevenly around the rotation axis. The method of claim 25, wherein arranging the one or more flux generating windings includes unevenly arranging one or more printed circuit board segments containing the windings about the axis of rotation. The method of claim 26, wherein configuring the one or more printed circuit board segments further includes positioning the one or more printed circuit board segments such that at any given time the windings are energized by current, by The flux-generating windings produce one or more maximum flux density locations unevenly distributed around the rotation axis. The method of any one of claims 25 to 27, wherein configuring the one or more flux generating windings includes positioning the one or more flux generating windings such that when the rotor rotates relative to the stator at a constant speed Through an angular range, the periodicity of the torque due to the interaction of the magnetic flux generated by the rotor and the stator is irregular. The method of any one of claims 25 to 27, further comprising: positioning the one or more magnets and the one or more flux generating windings such that, if the rotor rotates about the rotation axis through a complete mechanical rotation, A torque capability generated between the rotor and the stator varies non-periodically based on the angular position of the rotor relative to the stator. The method of any one of claims 25 to 27, wherein configuring the one or more magnets includes: orienting at least the first, second and third magnets to generate magnetic flux in a first direction parallel to the axis of rotation; Positioning the first and second magnets such that no other magnets oriented to generate magnetic flux in the first direction are angled between the first magnet and the second magnet; positioning the second and third magnets such that No other elements are oriented to produce magnetism in this first direction The pass magnet is angularly positioned between the second magnet and the third magnet; and the first, second and third magnets are positioned such that a first angular distance between the first magnet and the second magnet is at least is twice the second angular distance between the second magnet and the third magnet. The method of claim 30, wherein configuring the one or more flux-generating windings includes: orienting at least the first, second, and third flux-generating windings to generate flux in a second direction parallel to the axis of rotation; The first and second flux-generating windings are positioned such that no other flux-generating windings oriented to generate flux in the second direction are angularly positioned between the first flux-generating winding and the second flux-generating winding. between; positioning the second and third flux-generating windings such that no other flux-generating windings oriented to generate flux in the second direction are angularly positioned between the second flux-generating winding and the third flux-generating winding. between the flux-generating windings; and positioning the first, second and third flux-generating windings such that a third angular distance between the first flux-generating winding and the second flux-generating winding is at least equal to the second flux-generating winding. Twice the fourth angular distance between the generating winding and the third flux generating winding. The method of any one of claims 25 to 27, wherein configuring the one or more magnets includes positioning a first magnet to produce a first magnet parallel to the axis of rotation at a first position relative to the rotor. peak flux density, and positioning a second magnet to generate a second peak flux density parallel to the axis of rotation at a second position relative to the rotor; and configuring the one or more flux generating windings including Position a first flux generating winding to in-phase A third peak magnetic flux density parallel to the rotation axis is generated at a third position of the stator; wherein the one or more magnets and the one or more flux generating windings are configured such that at the first position A first torque capability between the rotor and the stator when angularly aligned in the third position is greater than a second torque between the rotor and the stator when angularly aligned in the second position. The method of claim 32, wherein the one or more magnets and the one or more flux generating windings are configured such that the first torque capability when the first position is angularly aligned with the third position is at least greater than Twenty-five percent of the second torque capability when the second position is angularly aligned with the third position. The method of claim 32, wherein the one or more magnets and the one or more flux generating windings are configured such that the first torque capability when the first position is angularly aligned with the third position is at least Twice the second torque capability when the second position is angularly aligned with the third position. The method of any one of claims 25 to 27, wherein configuring the one or more flux generating windings includes positioning a first flux generating winding to generate a magnetic field parallel to the stator at a first position relative to the stator. a first peak flux density of the axis of rotation, and positioning a second flux generating winding to generate a second peak flux density parallel to the axis of rotation at a second position relative to the stator; configuring the or the plurality of magnets including a first magnet positioned to produce a third peak flux density parallel to the axis of rotation at a third position relative to the rotor; and The rotor and the stator are configured such that a first torque capability between the rotor and the stator when the first position is angularly aligned with the third position is greater than when the second position is angularly aligned with the third position. position is a second torque capacity between the rotor and the stator. The method of claim 35, wherein the one or more magnets and the one or more flux generating windings are configured such that the first torque capability when the first position is angularly aligned with the third position is at least greater than The second torque capacity between the rotor and the stator is 25 percent when the second position is angularly aligned with the third position. The method of claim 35, wherein the one or more magnets and the one or more flux generating windings are configured such that the first torque capability when the first position is angularly aligned with the third position is at least Twice the second torque capability when the second position is angularly aligned with the third position. The method of any one of claims 25 to 27, wherein configuring the one or more magnets includes positioning the one or more magnets such that a first half-angle of the rotor creates a first direction parallel to the axis of rotation. A first total amount of magnetic flux and a second half angle of the rotor generate a second total amount of magnetic flux in the first direction, and the second total amount is substantially greater than the first total amount. The method of any one of claims 25 to 27, wherein configuring the one or more magnets includes positioning the one or more magnets to have angular symmetry relative to the rotor. The method of any one of claims 25 to 27, wherein configuring the one or more magnets includes: Orienting one or more first magnets to produce a peak magnetic flux density in a first direction parallel to the axis of rotation; positioning a first magnet at one or more first angular positions on a first half angle of the rotor a number of the one or more first magnets; and a second number of the one or more first magnets positioned at zero or more second angular positions on a second half-angle of the rotor, wherein the One quantity is greater than the second quantity. The method of any one of claims 25 to 27, wherein configuring the one or more flux generating windings includes orienting one or more first flux generating windings to generate magnetic flux in a first direction parallel to the axis of rotation. a peak flux density; positioning a third number of the one or more first flux generating windings at one or more third angular positions on a first half angle of the stator; and A fourth number of the one or more first flux generating windings is positioned at zero or more fourth angular positions on the half angle, wherein the third number is greater than the fourth number. A rotor used in a motor or generator, which includes: a support structure; and one or more magnet segments, which are supported by the support structure and generate a first magnetic field in a first direction parallel to a rotation axis. Through, 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: a first half angle of the rotor includes a first number of the one or more magnet segments, a second half-angle of the rotor includes a second number of the one or more magnet segments, and The first quantity is greater than the second quantity. The rotor of claim 42, wherein: the one or more magnet segments include at least first, second and third magnet segments that generate the first magnetic flux in the first direction; and no other magnet segments are oriented to generate the first magnetic flux in the first direction. A magnet segment that generates magnetic flux in the first direction is angled between the first magnet segment and the second magnet segment; no other magnet segments oriented to generate magnetic flux in the first direction are angled positioned between the second magnet segment and the third magnet segment; and a first angular distance between the first magnet segment and the second magnet segment is at least a distance between the second magnet segment and the second magnet segment Twice the second angular distance between the third magnet segments.