US20090140593A1 - Methods and apparatus for a permanent magnet machine with added rotor slots - Google Patents
Methods and apparatus for a permanent magnet machine with added rotor slots Download PDFInfo
- Publication number
- US20090140593A1 US20090140593A1 US12/269,517 US26951708A US2009140593A1 US 20090140593 A1 US20090140593 A1 US 20090140593A1 US 26951708 A US26951708 A US 26951708A US 2009140593 A1 US2009140593 A1 US 2009140593A1
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- United States
- Prior art keywords
- rotor
- additional slots
- permanent magnet
- magnet machine
- magnets
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/22—Rotating parts of the magnetic circuit
- H02K1/27—Rotor cores with permanent magnets
- H02K1/2706—Inner rotors
- H02K1/272—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
- H02K1/274—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
- H02K1/2753—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets the rotor consisting of magnets or groups of magnets arranged with alternating polarity
- H02K1/276—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
- H02K1/2766—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM] having a flux concentration effect
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/64—Electric machine technologies in electromobility
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49009—Dynamoelectric machine
- Y10T29/49012—Rotor
Definitions
- the present invention generally relates to magnetic devices such as electrical motors, and more particularly relates to interior permanent magnet machines.
- IPM machines are favored for fuel cell and hybrid electric vehicle operations due to their desirable characteristics—i.e., good torque density, good overall efficiency, good constant power range, etc.
- the rotor field in a permanent magnet machine is obtained by virtue of its structure, unlike other machines such as induction, switched or synchronous reluctance machines, in which the field is generated by a stator current supplied by a source.
- permanent magnet machines exhibit superior efficiency as compared to other such machines.
- winding harmonics the majority of which is the 6 th harmonic and it's integer multiples, generated from the 5 th and 7 th winding harmonics.
- These winding harmonics can be lowered by short-pitching the winding. For example, for a six lots per pole design, the winding can be short-pitched by one slot (1 ⁇ 6 short pitch).
- the second and most significant source of torque ripple is slotting effect brought about by burying the magnet inside the rotor.
- the interaction between the rotor slots and the stator slots (the winding slots) generates significant torque ripple.
- One way to minimize this effect is to skew either the rotor or the stator, which results in some averaging, effectively cancelling much of the torque ripple and the cogging. Skewing is widely known in the industry and is routinely performed to lower cogging and ripple torque. This approach, however, lowers machine torque and adds manufacturing complexity and cost.
- FIG. 1 depicts, in cross-section, various internal permanent magnet (IPM) machines
- FIG. 2 depicts, in cross-section, an IPM machine in accordance with one embodiment
- FIG. 3 depicts, in cross-section, an IPM machine in accordance with an alternate embodiment.
- the various embodiments are directed to a permanent magnet machine (“PM machine”), and more specifically an internal permanent magnet machine (“IPM machine”) that includes a rotor with additional slots near the rotor surface, thereby creating an additional slotting effect.
- PM machine permanent magnet machine
- IPM machine internal permanent magnet machine
- the structure can cancel or lower the slotting effect of the rotor barriers through an averaging effect. In this way, torque ripple and cogging can be reduced.
- IPM 100 includes a stator 101 having a plurality of windings 102 magnetically interacting with magnets 110 within rotor 106 .
- Various cavities are provided within region 104 of rotor 106 , and all or a portion of these cavities are filled with permanent magnets in the conventional manner, depending upon the number of layers incorporated into the structure.
- FIG. 1( b ) depicts a two-barrier PM rotor with the second barrier partially filed with magnets 110 .
- FIG. 1( c ) illustrates a two-barrier PM rotor with no magnets in the second layer—i.e., the second layer comprises only an air-filled cavity.
- the added second barrier shown in FIG. 1( b ) adds resistance to the lower magnet barrier, lowering the air-gap magnet flux.
- addition of the second barrier in the rotor can mechanically weaken the rotor.
- addition of any such second barrier is not geometrically feasible due to limited space (e.g., the rotor of FIG. 1( a )).
- Rotors with more than two barriers may also be provided; however, such designs undesirably increase manufacturing complexity. Increasing the number of barriers improves rotor saliency, and thus improves machine torque. Moreover, the second rotor barrier often works as a barrier to the inner magnet layer, consequently lowering the magnet flux in the air-gap. Lowering of magnet flux in the air-gap reduces the magnet torque, but is somewhat compensated by the increased saliency of the rotor.
- FIGS. 2 and 3 depicts various embodiments of an IPM machine 200 in accordance with one embodiment of the present invention in which additional rotor slots 235 are provided along the periphery—i.e., near the rotor surface 202 .
- a cavity within rotor 106 is filled or partially filled by magnet 110 , in which case various air slots (pockets) or barriers are formed adjacent thereto, i.e.: air slots 125 .
- the term “cavity” is thus used to refer to the empty regions existing prior to insertion of magnet 110 .
- the term “rotor barriers” refers to all barriers or air slots 125 that are provided within the hub area of rotor 106 (i.e., excepting slots 235 ). While FIG. 2 illustrates a cross-sectional view of magnets 110 and air slots 125 , it will be understood that the cavity extends into region 104 of the rotor of rotor 106 and will define a three-dimensional volume having any suitable shape.
- each additional slot may be selected to achieve the desired design objectives.
- Such attributes are preferably chosen to produce an averaging effect with respect the rotor barriers existing within rotor 106 . Such optimization may be performed empirically or through conventional computer modeling methods known in the art.
- FIGS. 2 and 3 show two different embodiments incorporating such additional slots in a single-barrier and double-barrier rotor, respectively.
- pairs of rectangular magnets 110 are configured angled toward each other—i.e., defining an obtuse angle facing outward toward the stator surface.
- two such additional slots 235 are included per pole; however, any number of such slots 235 may be used. Furthermore, the slots need not be distributed symmetrically or evenly with respect to magnets 110 .
- each slot 235 is preferably equal, though slots with varying sizes are comprehended by this invention.
- the additional slots may have a cross-sectional area that is substantially less than an aggregate cross-sectional area of the rotor barriers.
- FIG. 3 shows an alternate embodiment for a two-layer rotor, wherein two additional slots 235 are placed on the exterior of the two first layer magnets 110 .
- additional slots 235 are located at a radius substantially corresponding to the corner of magnets 110 closest to surface 103 .
- slots 235 within region 104 of rotor 106 may also be selected to achieve particular design objectives.
- slots 235 are located 1-1.5 mm from surface 202 . It will be appreciated, however, that the invention is not so limited.
Abstract
Description
- This application claims priority to U.S. Provisional Patent Application Ser. No. 60/991,310, filed Nov. 30, 2007.
- The present invention generally relates to magnetic devices such as electrical motors, and more particularly relates to interior permanent magnet machines.
- Interior permanent magnet (IPM) machines are favored for fuel cell and hybrid electric vehicle operations due to their desirable characteristics—i.e., good torque density, good overall efficiency, good constant power range, etc. The rotor field in a permanent magnet machine is obtained by virtue of its structure, unlike other machines such as induction, switched or synchronous reluctance machines, in which the field is generated by a stator current supplied by a source. As a result, permanent magnet machines exhibit superior efficiency as compared to other such machines.
- However, as with surface PM machines, an IPM machine is burdened by the fact that the permanent magnet field is present even when the machine is not powered, resulting in losses induced by the rotating permanent magnet field of the rotor. Furthermore, such structures are subject to ripple and cogging torque, which has two major sources. The first is winding harmonics, the majority of which is the 6th harmonic and it's integer multiples, generated from the 5th and 7th winding harmonics. These winding harmonics can be lowered by short-pitching the winding. For example, for a six lots per pole design, the winding can be short-pitched by one slot (⅙ short pitch).
- The second and most significant source of torque ripple is slotting effect brought about by burying the magnet inside the rotor. The interaction between the rotor slots and the stator slots (the winding slots) generates significant torque ripple. One way to minimize this effect is to skew either the rotor or the stator, which results in some averaging, effectively cancelling much of the torque ripple and the cogging. Skewing is widely known in the industry and is routinely performed to lower cogging and ripple torque. This approach, however, lowers machine torque and adds manufacturing complexity and cost.
- Accordingly, it is desirable to provide improved, manufacturable IPM machines that reduce cogging and torque ripple. Other desirable features and characteristics of the present invention will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing technical field and background.
- A more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in conjunction with the following figures, wherein like reference numbers refer to similar elements throughout the figures.
-
FIG. 1 depicts, in cross-section, various internal permanent magnet (IPM) machines; -
FIG. 2 depicts, in cross-section, an IPM machine in accordance with one embodiment; and -
FIG. 3 depicts, in cross-section, an IPM machine in accordance with an alternate embodiment. - The following detailed description is merely illustrative in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. The invention may be described herein in terms of functional and/or logical block components and various processing steps. It should be appreciated that such block components may be realized by any number of hardware, software, and/or firmware components configured to perform the specified functions. For the purposes of conciseness, conventional techniques and systems related to electrical motors, magnetism, and the like are not described in detail herein.
- In general, the various embodiments are directed to a permanent magnet machine (“PM machine”), and more specifically an internal permanent magnet machine (“IPM machine”) that includes a rotor with additional slots near the rotor surface, thereby creating an additional slotting effect. In this way, the structure can cancel or lower the slotting effect of the rotor barriers through an averaging effect. In this way, torque ripple and cogging can be reduced.
- Interior PM machines often incorporate one or more rotor barriers (or simply “barriers”).
FIGS. 1( a) and (b), for example, illustrate partial cross-sections through variousexemplary IPM machines 100 with single anddouble barrier rotors 106 More particular,FIG. 1( a) illustrates arotor 106 withmagnets 110 and air slots (pockets) orair barriers 125 incorporated into the structure at various locations with respect tomagnets 110. As is conventional, IPM 100 includes astator 101 having a plurality ofwindings 102 magnetically interacting withmagnets 110 withinrotor 106. Various cavities are provided withinregion 104 ofrotor 106, and all or a portion of these cavities are filled with permanent magnets in the conventional manner, depending upon the number of layers incorporated into the structure. -
FIG. 1( b), more particularly, depicts a two-barrier PM rotor with the second barrier partially filed withmagnets 110. Similarly,FIG. 1( c) illustrates a two-barrier PM rotor with no magnets in the second layer—i.e., the second layer comprises only an air-filled cavity. The added second barrier shown inFIG. 1( b) adds resistance to the lower magnet barrier, lowering the air-gap magnet flux. However, as mentioned previously, addition of the second barrier in the rotor can mechanically weaken the rotor. Also, for some machines, addition of any such second barrier is not geometrically feasible due to limited space (e.g., the rotor ofFIG. 1( a)). - Rotors with more than two barriers may also be provided; however, such designs undesirably increase manufacturing complexity. Increasing the number of barriers improves rotor saliency, and thus improves machine torque. Moreover, the second rotor barrier often works as a barrier to the inner magnet layer, consequently lowering the magnet flux in the air-gap. Lowering of magnet flux in the air-gap reduces the magnet torque, but is somewhat compensated by the increased saliency of the rotor.
- In hybrid applications, when the PM machine is part of a transmission, very often the machine is rotating in conjunction with a different gear-set even though machine is producing no torque or is producing very low torque. If the no-load or light load operation is a substantial portion of the machine drive cycle, the overall efficiency of the transmission is affected. Rotating magnet flux also induces voltage in the stator winding, commonly referred to as back EMF. The high magnet flux of a permanent magnet rotor may induce very high voltage in the stator, especially during high speed operation of the machine. Therefore, lowering of the machine air-gap flux is very desirable for such machines.
-
FIGS. 2 and 3 depicts various embodiments of anIPM machine 200 in accordance with one embodiment of the present invention in whichadditional rotor slots 235 are provided along the periphery—i.e., near therotor surface 202. - As shown, a cavity within
rotor 106 is filled or partially filled bymagnet 110, in which case various air slots (pockets) or barriers are formed adjacent thereto, i.e.:air slots 125. The term “cavity” is thus used to refer to the empty regions existing prior to insertion ofmagnet 110. The term “rotor barriers” refers to all barriers orair slots 125 that are provided within the hub area of rotor 106 (i.e., excepting slots 235). WhileFIG. 2 illustrates a cross-sectional view ofmagnets 110 andair slots 125, it will be understood that the cavity extends intoregion 104 of the rotor ofrotor 106 and will define a three-dimensional volume having any suitable shape. - The size, location, and geometry of each additional slot may be selected to achieve the desired design objectives. Such attributes are preferably chosen to produce an averaging effect with respect the rotor barriers existing within
rotor 106. Such optimization may be performed empirically or through conventional computer modeling methods known in the art. -
FIGS. 2 and 3 show two different embodiments incorporating such additional slots in a single-barrier and double-barrier rotor, respectively. InFIG. 2 , pairs ofrectangular magnets 110 are configured angled toward each other—i.e., defining an obtuse angle facing outward toward the stator surface. - In one embodiment, two such
additional slots 235 are included per pole; however, any number ofsuch slots 235 may be used. Furthermore, the slots need not be distributed symmetrically or evenly with respect tomagnets 110. - In the illustrated embodiment, the cross-sectional area of each
slot 235 is preferably equal, though slots with varying sizes are comprehended by this invention. For example, the additional slots may have a cross-sectional area that is substantially less than an aggregate cross-sectional area of the rotor barriers. -
FIG. 3 shows an alternate embodiment for a two-layer rotor, wherein twoadditional slots 235 are placed on the exterior of the twofirst layer magnets 110. As with the above embodiment,additional slots 235 are located at a radius substantially corresponding to the corner ofmagnets 110 closest to surface 103. - The depth of
slots 235 withinregion 104 of rotor 106 (i.e., the distance radially from surface 202) may also be selected to achieve particular design objectives. In one embodiment, for example,slots 235 are located 1-1.5 mm fromsurface 202. It will be appreciated, however, that the invention is not so limited. - While at least one example embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. For example, additional barrier layers may be incorporated in addition to the single layer illustrated. It should also be appreciated that the example embodiment or embodiments described herein are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing the described embodiment or embodiments. It should be understood that various changes can be made in the function and arrangement of elements without departing from the scope of the invention and the legal equivalents thereof.
Claims (20)
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
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US12/269,517 US20090140593A1 (en) | 2007-11-30 | 2008-11-12 | Methods and apparatus for a permanent magnet machine with added rotor slots |
DE102009052477A DE102009052477A1 (en) | 2007-11-30 | 2009-11-09 | Method and apparatus for a permanent magnet machine with additional rotor slots |
CN 200910206409 CN101741199B (en) | 2008-11-12 | 2009-11-12 | Methods and apparatus for a permanent magnet machine with an added air barrier |
Applications Claiming Priority (2)
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US99131007P | 2007-11-30 | 2007-11-30 | |
US12/269,517 US20090140593A1 (en) | 2007-11-30 | 2008-11-12 | Methods and apparatus for a permanent magnet machine with added rotor slots |
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US20090140593A1 true US20090140593A1 (en) | 2009-06-04 |
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US12/269,463 Active 2029-02-02 US8138651B2 (en) | 2007-11-30 | 2008-11-12 | Methods and apparatus for a permanent magnet machine with an added air barrier |
US12/269,517 Abandoned US20090140593A1 (en) | 2007-11-30 | 2008-11-12 | Methods and apparatus for a permanent magnet machine with added rotor slots |
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US12/269,463 Active 2029-02-02 US8138651B2 (en) | 2007-11-30 | 2008-11-12 | Methods and apparatus for a permanent magnet machine with an added air barrier |
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- 2008-11-12 US US12/269,463 patent/US8138651B2/en active Active
- 2008-11-12 US US12/269,517 patent/US20090140593A1/en not_active Abandoned
- 2008-11-27 DE DE102008059347A patent/DE102008059347A1/en not_active Withdrawn
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2009
- 2009-11-09 DE DE102009052477A patent/DE102009052477A1/en not_active Withdrawn
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US8928197B2 (en) | 2012-04-17 | 2015-01-06 | GM Global Technology Operations LLC | Pole-to-pole asymmetry in interior permanent magnet machines with arc-shaped slots |
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US20150022126A1 (en) * | 2013-07-18 | 2015-01-22 | GM Global Technology Operations LLC | Method and apparatus for monitoring a permanent magnet electric machine |
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Also Published As
Publication number | Publication date |
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US8138651B2 (en) | 2012-03-20 |
US20090140592A1 (en) | 2009-06-04 |
DE102008059347A1 (en) | 2009-06-25 |
DE102009052477A1 (en) | 2010-06-17 |
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