WO2014021911A2 - Contrôleur pour moteur réducteur de force contre-électromotrice - Google Patents

Contrôleur pour moteur réducteur de force contre-électromotrice Download PDF

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Publication number
WO2014021911A2
WO2014021911A2 PCT/US2012/065199 US2012065199W WO2014021911A2 WO 2014021911 A2 WO2014021911 A2 WO 2014021911A2 US 2012065199 W US2012065199 W US 2012065199W WO 2014021911 A2 WO2014021911 A2 WO 2014021911A2
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WO
WIPO (PCT)
Prior art keywords
power
motor
rotor
winding
energy
Prior art date
Application number
PCT/US2012/065199
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English (en)
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WO2014021911A3 (fr
Inventor
James F. Murray
Erik J BRAUER
Original Assignee
Convergent Power, Inc.
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Priority claimed from US13/562,214 external-priority patent/US20130187580A1/en
Application filed by Convergent Power, Inc. filed Critical Convergent Power, Inc.
Publication of WO2014021911A2 publication Critical patent/WO2014021911A2/fr
Publication of WO2014021911A3 publication Critical patent/WO2014021911A3/fr

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P6/00—Arrangements for controlling synchronous motors or other dynamo-electric motors using electronic commutation dependent on the rotor position; Electronic commutators therefor
    • H02P6/14—Electronic commutators
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K16/00—Machines with more than one rotor or stator
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P25/00—Arrangements or methods for the control of AC motors characterised by the kind of AC motor or by structural details
    • H02P25/16—Arrangements or methods for the control of AC motors characterised by the kind of AC motor or by structural details characterised by the circuit arrangement or by the kind of wiring
    • H02P25/22—Multiple windings; Windings for more than three phases
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P25/00—Arrangements or methods for the control of AC motors characterised by the kind of AC motor or by structural details
    • H02P25/16—Arrangements or methods for the control of AC motors characterised by the kind of AC motor or by structural details characterised by the circuit arrangement or by the kind of wiring
    • H02P25/24—Variable impedance in stator or rotor circuit

Definitions

  • the disclosed inventions relate to the field of controllers for electric motors, and more particularly to controllers for motors designed to operate so as to reduce Back EMF.
  • the disclosed inventions also relate to the field of direct energy conversion and the production of mechanical torque from the utilization of an electric current, and to the field of electric motors and to utilization of direct current as a "motive force.”
  • the disclosed inventions also relate to the field of power conversion devices which transform electrical power into rotary mechanical power.
  • Some disclosed embodiments relate to a class of motor having multiple stator and rotor sections, such that each rotor section is associated with a specific stator section, although attached to a single output shaft.
  • the lateral axis of each rotor section may be disposed at an oblique angle with respect to the axis of the common shaft, and angularly displaced in accordance with the number of rotor sections employed, for example: 90 mechanical degrees for two rotors, 120 degrees for three rotors, etc.
  • Some disclosed embodiments also relate to multiple motors having two or more motor sections, operating in parallel, each of which is comprised of a stator having two or more salient poles, and a rotor geometry devoid of coils or windings of any kind, affixed obliquely to a motor output shaft, and so disposed as to ensure a constant air gap between the rotor body and the salient poles of an associated stator section.
  • Some embodiments of the invention also relate to multiple motor sections with their associated armatures, mechanically positioned out of phase with one another, but mounted so as to allow the output pinions of each individual motor to impinge upon a common output gear of larger diameter, mounted upon a separate but common output shaft, such that each individual motor's output is combined mechanically, and afforded an amplification of torque.
  • Some embodiments of the invention also relate to a single motor having a stator section with salient poles, and a rotor geometry devoid of windings, affixed obliquely to a motor output shaft, and disposed as to ensure a constant air gap between the rotor body and the salient poles of the stator section.
  • Patents in this area include: U.S. Pat. Nos. 2,917,699; 3,132,269; 3,321,652; 3,956,649; 3,571,639; 3,398,386; 3,760,205; 4, 639,626 and 4,659,953. Also in this area are EPO patent no. 0174290 (3/1986); German patent no. 1538242 (10/1969); French patent no. 2386181 (10/1978) and UK patent no. 1263176 (211972).
  • the basic concept employed in earlier motor art is the interaction between a current carrying conductor(s) and a magnetic field of some kind. This fact is true regardless of motor type. This basic concept appears in DC motors, single phase AC motors, poly phase induction slip motors, which utilize a rotating magnetic field, and in poly phase synchronous motors with externally excited electromagnetic cores, or permanent magnet cores as the case may be.
  • stepper motors which utilize a magnetic "ratcheting" action upon magnetic material in the armature, in response to applied pulses of current
  • various types of reluctance motors in which the rotor moves with respect to a salient pole piece, experiencing a large variation in air gap during its motion. But, these devices typically do not have a constant and continuous air gap of fixed dimension between the rotor and the stator.
  • the prior art has not produced a multiple phase, multiply segmented stator with individual, obliquely disposed, laminated armatures devoted to each stator section, such that each stator/rotor combination employs a continuous air gap of constant dimension, regardless of the elliptical profile of said armatures, but not employing any current carrying conductors, coils, windings or bars within or upon the armatures, as a means of producing torque upon the output shaft.
  • Alternator of the Alternator Patent can be operated as a motor only when used in conjunction with the basic motor concepts described herein (i.e., requires field flux and current-carrying conductors).
  • Alternator of the Alternator Patent makes use of an electromagnetic field winding, or a permanent magnet as its source of magnetic flux.
  • Alternator of the Alternator Patent does not require a shaft position indicator, or a commutator of any kind in order to function.
  • Alternator of the Alternator Patent does not require a position sensitive, electronically controlled, pulsed power supply, in order to generate electricity.
  • Back EMF arises from, among other things, the mistaken assumption that Back EMF is required to produce torque. This, in turn, leads to design compromises which must be made in order to implement traditional electrodynamic machine geometries.
  • a conventional DC Motor consisting of a stator with salient field poles, and a rotor-armature with a self-contained commutator.
  • Application of a DC current to the rotor leads produces a rotary motion of the rotor (i.e., motor action).
  • the rotation of the rotor conductors in a magnetic field also induces a voltage in the conductor that opposes the current applied to the rotor leads (i.e., generator action).
  • V is the voltage developed
  • B is the flux density
  • 1 is the conductor length
  • v is the tangential velocity of the conductor as it rotates.
  • Equation 2 denotes only potential, not power. Electrical power can be expressed as the product of voltage and current. Current is missing from the second relationship (equation 2), but it can also be included by multiplication to both sides of the equation:
  • V L dl/dt + 1 dL/dt.
  • the first term in equation 6 is the product of inductance (L) and the rate of change of current (I) with respect to time (t). This is the previously discussed Transformer Voltage Vt.
  • the second term is the product of the current (I) and the rate of change of Inductance (L) with respect to time (t). This is the previously discussed Speed Voltage Vs.
  • Equation 9 expresses the quantity commonly referred to as the reactive energy.
  • E T I d ⁇ + ⁇ dl.
  • Equation 1 1 The energy relationship described in equation 1 1 can be further explained with reference to FIG. 1, which depicts a plot of flux ( ⁇ ) versus current (I) of the air gap energy components. As shown, the line 100 represents the total magnetic energy given by
  • Em ⁇ .
  • region 1 10 above line 100 indicates the (I d ⁇ ) reactive energy region and region 120 below line 100 indicates the ( ⁇ dl) dissipative energy region.
  • FIGS. 2A and 2B show a cross-sectional representation of a prior art reluctance motor.
  • rotor 210 is in a position between two stator 200 poles yielding the motors largest air gap 220 designated as (gl).
  • the flux lines thus created will reach across this gap 220 as they are formed, and cause the rotor 210 to rotate to the position depicted in FIG. 2B, thereby reducing the reluctance in the magnetic circuit and reducing the air gap 230 to its smallest dimension designated as (g2).
  • a torque impulse is also created during this motoring action, and the average mechanical work which is delivered on the rotor 210 will be found to be directly equal to the change in energy ( ⁇ dl) within the air gap.
  • FIG. 3 is a double graph representing the energy relationship for the prior art motor illustrated in FIGS. 2A and 2B.
  • the plot labeled 300 corresponding to air gap (gl) represents the relationship between the excitation flux and the excitation current at the point in time where the gap dimension is largest (e.g., air gap 220 as depicted in FIG. 2A).
  • Ii the excitation current
  • ⁇ the relatively lower value of the associated flux
  • equation 1 1 For illustrative purposes, the following four calculations using equation 1 1 can be made representing the component energies associated with each air gap size (gl and g2).
  • an exemplary standard DC motor with a power rating of 3.528 Horse Power has the following characteristics:
  • Terminal Voltage 124 Volts DC.
  • the DC motor has not yet begun to rotate, and there is no Back EMF, but the starting torque is relatively large at 637.986 in-lbs, which is 5.165 times the running torque.
  • the Back EMF that develops as a function of the motor's increasing rotational speed reduces the start-up current of 135.965 amps down to the full load ampere (FLA) value of 26.326 amps. This "high start-up current,” behavior is standard and expected in conventional Speed Voltage dependent motors.
  • one advantage of some embodiments of the present invention is that it automatically controls and orchestrates the motor's internal functions, such as current limit, current switching, and direction of power flow.
  • an electric motor is disclosed, some embodiments having a single rotor segment, and other embodiments having a plurality of motor segments, each segment having a stator, having stator poles and stator windings and a rotor having a flux path element.
  • the flux path elements are attached to a rotor shaft at an oblique angle to the longitudinal axis of the shaft.
  • the flux path elements have a shape that provides a uniform air gap between them and the stator poles when the shaft is rotated.
  • the rotor shafts of said motor segments are mechanically coupled to each other.
  • the flux path elements comprise a silicon steel lamination stack or a solid ferrite plate.
  • the motor has a shaft angle sensor and a motor controller, and the motor controller receives a shaft angle from the sensor and supplies current pulses to the stator windings according to the shaft's angular position signal.
  • stator poles are positioned in pole pairs with the rotor and rotor shaft between them and form isolated stator magnetic field circuits when the stator windings are supplied with electrical current, such that a magnetic field is established having a single magnetic polarity in each of the poles of said pole pairs, with each pole of the pole pairs having opposite magnetic polarity.
  • more than two poles are installed in each stator section.
  • the rotor flux path elements have a shape defined by the volume contained between two parallel cuts taken through a right circular cylinder at an angle other than 90 degrees with respect to the axis of symmetry of said cylinder, each flux path element having front and back faces that are substantially elliptical, and having major and minor axes.
  • the flux element angle with respect to the axis of symmetry is substantially 45 degrees.
  • multiple rotors are attached to a common shaft, or to independent shafts coupled through a clutch or similar selectablely engageable coupler, and the rotor flux path elements are arranged on said common shaft such that the major axes of the flux path elements are equally spaced on the shaft and wherein the stator poles are in the same position with respect to the common shaft for each motor segment.
  • the motor has two motor segments and two rotor flux path elements and the rotor flux path elements are arranged on the common shaft such that their major axes are spaced 90 degrees apart.
  • the motor has rotor counterweights to statically and dynamically balance the mass of the rotor flux elements.
  • the motor has starter windings adapted to start the motor in a desired rotational direction.
  • One advantage of the presently disclosed system and method is that it addresses the drawbacks of existing systems.
  • Another advantage of the presently disclosed system is to provide a direct current motor which develops a significantly reduced Speed Voltage (V s ) component of the Back EMF.
  • Another advantage of the presently disclosed system is to provide a direct current motor which makes use of a plurality of salient poles within its stator structure that may possess characteristics different than typically employed by existing Speed Voltage dependent systems.
  • the stator poles should be arranged or constructed to be protected from flux movement in two directions in order to minimize eddy currents, and related iron losses.
  • fabricating all or part of the pole pieces from different metals, using grain orientation, using ferrite materials, using distributed air gap material, or laminations disposed at right angles with respect to one another are some techniques that may be implemented to inhibit the production of eddy currents, and thereby lessen iron losses.
  • Another advantage of the presently disclosed system is to provide a direct current motor which employs a uniquely shaped rotor having a constant air gap with respect to the salient pole pieces.
  • the constant air gap contributes to a smaller rate of change of inductance in the magnetic circuit, thereby reducing the speed voltage component Vs.
  • Another advantage of the presently disclosed system is to provide a direct current motor which employs a shaped rotor having no coils, windings, conductors or bars within its structure. This also contributes to a lower speed voltage component Vs of the Back EMF.
  • Another advantage of the presently disclosed system is to provide a direct current motor whose operation is governed by controller, such as an electronic controller, so designed as to orchestrate, synchronize, and control all the internal functions of the direct current motor.
  • controller such as an electronic controller
  • Another advantage of the presently disclosed system is to provide a direct current motor with a surplus of salient pole windings which are configured to store re-usable magnetic energy within the stator power coil windings.
  • the surplus windings arise from the additional windings possible with the presently-disclosed designs compared to the amount of windings on a similar capacity, traditionally designed DC motor.
  • stator and rotor geometries in conjunction with an electronic controller such that rotation is achieved by means of reluctance switching, synchronized by a position sensor, and acting in response to an electronic controller such that motor input power is properly managed and directed so as to produce a continuous rotation, while simultaneously recovering unused energy momentarily stored within the stator windings.
  • One embodiment of the presently disclosed system employs a rotor fabricated from a stack of steel disks, chemically insulated from one another to discourage and reduce eddy currents.
  • the disks may be pressed upon an arbor which, in turn, is obliquely disposed with respect to the intended axis of rotation, and suitably machined so as to produce an assembly with a peripheral contour generally equivalent to that of a cylinder.
  • the stator may be composed of a plurality of salient pole sets, each set comprising a pair of poles, and associated windings, arranged 180 degrees apart from one another upon the stator, and each pole set angularly displaced from one another by a desired number of mechanical degrees.
  • each pole set may also be provided with a concave pole face, whose radius is slightly greater than the radius of the rotor.
  • the rotor therefore, defines an air gap of continuous dimension when rotated.
  • the rotor is in magnetic series with each set of magnetic poles, thereby completing the magnetic circuit, and the rotor reacts to each set of energized poles by undergoing a mechanical displacement equal in degrees to the pole set's mechanical distribution around the periphery of the stator assembly.
  • the zone in which the flux is coupled to the active pole pieces may vary in position along the length of each pole face. However, the width of the air gap separating the pole face from said rotor will not vary.
  • Another advantage of some embodiments is that, under certain conditions, such as the application of DC power to a reactive load, system energy derived from
  • Transformer Voltage may be placed in storage periodically during operation, and its subsequent dissipation or its utilization may be implemented based upon circuit geometry, and/or the interaction with other circuit components.
  • Another advantage of embodiments of the disclosed embodiments is to provide proper coil switching functions in accordance with data delivered to the controller electronics from a shaft position sensor.
  • the data may be utilized for instructing proper switching sequences for directing DC Power from both the positive and negative power supplies, to the proper magnetic windings so as to promote and sustain rotary motion.
  • Another advantage of some embodiments is to provide proper coil switching functions in accordance with data delivered to the controller electronics from the shaft- mounted angular position sensor so as to direct "Reactive" power from the magnetic windings to the positive and negative recapture reservoirs for storage and future use, either internally, within the motor system, or externally for powering an additional load.
  • Another advantage of some embodiments is to "boost" the voltage available in the positive and negative recapture reservoirs, to a value compatible with that of the potentials maintained in the Positive and Negative Power Supplies, and then monitor, and control power feedback as required by the system.
  • FIG. 1 is a plot of flux versus current of air gap energy components in a typical prior art device.
  • FIGS. 2A and 2B are cross sectional views illustrating a change in air gap for a prior art device.
  • FIG. 3 is a plot of flux versus current for the linear energy relationship in the air gap for the prior art device shown in FIGS. 2A and 2B.
  • FIGS. 4A and 4B are equivalent schematic circuits for a prior art DC motor illustrating the steady-state and in-rush operation circuit values.
  • FIG. 5 is an overall view of one embodiment of the invention, showing stator sections in cut-away views revealing the disposition of bearings, common output shaft, rotor assemblies, counter weights, stator power windings and stator laminations.
  • FIG. 6 is a schematic diagram of an individual rotor/stator section, depicting the relationships between such components as rotor geometry, magnetic flux, air gaps, salient poles and power windings in accordance with some embodiments.
  • FIG. 7 is a schematic diagram showing maximum and minimum rotor cross- sections relative to air gaps, stator poles and magnetic circuits in accordance with some embodiments.
  • FIG. 8 is a block diagram of an exemplary motor system, depicting forward and rear motor sections, the motor load, the shaft position sensor, the electronic controller and the sump resistor in accordance with some embodiments.
  • FIG. 9 is a diagram of a single-rotor with a constant air-gap in accordance with some embodiments.
  • FIG. 10 is a diagram of a parallel output cluster of motor sections such as the one shown in FIG. 9 in accordance with some embodiments.
  • FIG. 11 is a motor coil energizing scheme for the motors of FIG. 10 in accordance with some embodiments.
  • FIG. 12 is a schematic of coil interconnections for eight motor sections mechanically connected in parallel in accordance with some embodiments.
  • FIG. 13A is a diagram of a motor cluster having brushes and commutator for timing in accordance with some embodiments.
  • FIG, 13B is a diagram of a motor cluster having an optical encoder for timing in accordance with some embodiments.
  • FIG. 14 is a block diagram illustrating the basic components of the disclosed motor system in which recovered energy from the motor's magnetic field is stored and reconditioned for use in powering appliances external to the motor in accordance with some embodiments of the invention.
  • FIG. 15 is a block diagram illustrating the basic components of the disclosed motor system in which recovered energy from the motor's magnetic field is stored, reconditioned, and then fed back to the capacitors in the appropriate primary power supply, where it is reused by the motor in accordance with some embodiments of the invention.
  • FIG. 16 is a schematic flow diagram disclosing one method utilized to supply direct current power to the motor windings, recapture the available energy, and then transform said energy into electrical power which can be delivered to external devices, either unaltered, as direct current, or through an inverter, so as to supply alternating current in accordance with some embodiments of the invention.
  • FIG. 17 is a schematic flow diagram disclosing one method utilized to supply direct current power to the motor windings, recapture the available energy, and then transform said energy into electrical power which can be delivered, through a feedback mechanism, to the capacitors in the appropriate primary power supply so as to reduce the amount of power required from external sources to propel the motor in accordance with some embodiments of the invention.
  • FIG. 18 is a functional schematic controller circuit diagram in accordance with some embodiments of the invention.
  • FIGS. 5-8 illustrate one embodiment of the motor disclosed herein.
  • the motor consists of a double stator housing (1, 2) physically separated, but functionally joined together by means of a continuous shaft (10), upon which are mounted two armatures (3, 4), one within each stator assembly.
  • the shaft is carried by bearing sets (1 1), located within end-bells (14, 15).
  • Rotor assemblies (3, 4) each consist of a stack of silicon steel laminations (9), a molded ferrite core, or any other high permeability magnetic material designed to suppress eddy currents, and machined so as to produce a section of a right circular cylinder canted at an angle of 45 degrees with respect to the motor shaft (10).
  • the rotor structure When viewed face on, the rotor structure appears to be elliptical in shape. However, the side view depicts a rhomboid tilted at 45 degrees. This angle may not be the most optimal angle, and it should be realized that other angles may be employed without departure from the spirit of the invention.
  • the common shaft (10) may also carry counter weights (7, 8), as depicted, which function to ensure a smooth rotary motion by suppressing mechanical vibrations produced by the uneven mass distribution of the elliptical armature 5 sections (3,4).
  • each motor segment may include a clutch (25), or some other selectablely engageable coupler in order to couple independent shafts into a common shaft (10).
  • a clutch 25
  • motor segments from one on upwards can be coupled in this, or a similar, manner.
  • Each stator assembly contains an individual stack of stator laminations (16, 17) or a magnetic ferrite cylinder, from which extend two or more salient pole projections (12, 13), each of which is wound with a power coil (18).
  • the face of each pole projection (5, 6) is extended to the right and the left of center to ensure continuous air gaps of constant dimension (19, 20), which are aligned parallel to the rotor's edge contour regardless of its angular disposition.
  • each stator section is parallel to each other, but the rotor sections are displaced upon the shaft by a predetermined mechanical angle: 90 degrees for two pole sets 120 degrees for three pole sets, etc.
  • the motor shaft extends several inches beyond the end bell housings (14, 15) on each side of the motor.
  • One end of the shaft is utilized as a take off point for mechanical power, or load, while the other side of shaft carries a shaft position indicator (21), which is an angular transducer, and may consist of a simple rotary encoder, or a more complex device containing discrete optical sensors and slotted disks.
  • stator power windings may be connected in series or in parallel as preferred.
  • the windings receive their drive pulses from switching transistors, MOSFETs, or other solid state switching devices within the controller (22), which in turn receive their firing instructions directly, or indirectly, from the shaft position sensor (21).
  • Power resistor (23) is used as a sump to harmlessly dissipate any remaining energy associated with the collapsing magnetic fields within the stator as the motor rotates.
  • FIG. 6 illustrates a schematic cross-sectional view of the flux path of the rotor in two mechanical positions, each 90 degrees apart. Note, in FIG. 7A, that the elliptical cross-section presents a longer path to the magnetic flux than does the cross-section illustrated in FIG. 7B. Note as well that these figures represent approximate flux paths and not actual cross sectional views of the rotor.
  • This process does not require the presence of a "secondary" magnetic coil, the addition of which would tend to decrease a motor's overall inductance, by means of quadrature coupling, or armature reaction, during normal operation.
  • One embodiment of this invention employs two rotors, each fabricated from a stack of laminated disks, pressed upon arbors which are obliquely disposed with respect to the intended axis of rotation, and then integrally machined in order to provide both rotors with peripheral contours equivalent to that of a cylinder while retaining their overall elliptical shape.
  • Each stator section is formed by a lamination stack having two, spaced-apart, salient pole projections terminating in concave pole faces whose radii are slightly larger than the radius of each rotor. Both rotors thereby define air gaps of constant dimension while rotating.
  • Each rotor is in magnetic series with two air gaps and two pole pieces and a complete magnetic circuit which contains its own coils for the production of magnetic flux.
  • Each magnetic rotor circuit is separate and distinct from each other magnetic rotor circuit, although they share a common output shaft.
  • An angular position sensor or shaft encoder is positioned at one end of the output shaft, and sends electronic position signals to a DC power supply/controller, which in turn sends pulses to the motor stator sections as required.
  • an exemplary motor utilizes a rotor geometry consisting of a lamination stack or a molded ferrite shape, canted at a specific angle with respect to the output shaft, while retaining a circular cross section to the axis of rotation, and presenting an overall elliptical appearance in its own plane.
  • This arrangement allows for a constant air gap to be maintained between the rotor's edge and the pole pieces thereby producing mechanical torque without the utilization of coils or conductors residing anywhere upon said rotor.
  • One embodiment of the motor employs a plurality of "elliptical" rotors mounted upon the same output shaft, but positioned such that each rotor section is advanced a certain number of mechanical degrees from the others such that torque production over 360 degrees of rotation is shared equally by the number of rotors utilized.
  • the motor also has a plurality of pole sets and separate magnetic circuits, such that each elliptical rotor section is associated with its own external source of magnetic flux, regardless of the fact that they share a common output shaft. Accordingly, the salient stator pole projections will all reside in the same plane and be parallel to each other, while the rotor sections will be displaced upon the output shaft by predetermined mechanical angles; 90 degrees for two pole sets, 120 degrees for three pole sets, etc. Those skilled in the art will realize that this arrangement may be reversed without departing from the spirit of the invention. Likewise, those skilled in the art will also realize that it is possible to construct a single, standalone, motor utilizing a single rotor and stator section.
  • the right hand rotor on the same shaft will simultaneously present its shortest cross sectional path to its associated pole projections.
  • the shaft position sensor (21) will cause the controller (22) to energize starting windings (not shown) which will rotate the motor shaft in the desired direction, while simultaneously sending a current pulse into the left hand pole set depicted in FIG. 5.
  • starting windings not shown
  • the average torque available on the motor output shaft will be a function of the cooperative effort developed by both rotors over each mechanical revolution.
  • the output torque developed by this method is strictly a reluctance torque, generated as the lines of magnetic flux within each rotor section alternately shrink in an attempt to provide themselves with the shortest possible magnetic path between poles.
  • this torque-producing mechanism does not involve any interaction of either stator' s magnetic field with a current carrying conductor of any kind, neither in the form of a Speed Voltage interaction, nor in the form of a transformer coupling with a time-varying field.
  • the torque appearing on the motor shaft is a direct function of the rotor's geometry interacting with forces produced at the boundaries between the rotor body and the stator poles, and by internal cam action particular to the rotor geometry in the presence of a contracting flux.
  • fly-back diodes are provided in association with each power winding.
  • the diodes direct pulses generated by the collapsing fields into a sump or load resistor (23), where they may be harmlessly dissipated as excess heat.
  • said energy may be used to power other electrical appliances external to the motor, or may be applied to a capacitive storage element and then utilized to send power back to the main power supply.
  • an electric motor cluster comprises several stator sections each possessing a minimum of two salient pole projections, wound with power windings, and each having a single armature rotor.
  • Each individual rotor is angularly displaced one from the other, while mounted upon a common frame, and geared together such that each motor section contributes to the rotation of a common output shaft.
  • Each motor section shall consist of stator and armature elements as described in PCT application number PCT/US09/46246, filed on June 4, 2009, and entitled "PULSED MULTI- ROTOR CONSTANT AIR GAP RELUCTANCE MOTOR.”
  • the motor may consist of the following features:
  • a stator consisting of a stack of laminations, or a molded ferrite core, so constructed as to provide at least one set of salient magnetic poles, spaced apart 180 mechanical degrees, and situated so as to allow an air gap to exist between the stator structure and the armature of the motor.
  • Each salient magnetic pole projection may be wound with power windings, the function of which is to produce a magnetic field of considerable strength, and direct th e same through the air gaps and into the body of the motor's armature.
  • An armature also consisting of a stack of laminations, or a molded ferrite shape, so designed as to present each set of field poles with a cylindrical contour, perceived beyond each air gap, while retaining an elliptical profile with respect to the output shaft.
  • the armature sections carry no electrical windings of any kind, and require no slip rings or, field coils or permanent magnets.
  • armature segments may require shaft-mounted counter weights to offset their eccentricity, and maintain angular balance during rotation.
  • the power windings wound upon the salient pole projections are energized by pulses of electric current produced by a DC power supply and provided through an electronic controller unit, or through a mechanical commutator, etc.
  • the pulses are automatically applied to the salient pole nearest the longest flux path available through a particular rotor section, as determined by a shaft position sensor, or the geometry of a commutator.
  • the shaft position sensor Upon detecting motion, the shaft position sensor communicates the change in position of the output shaft to the electronic controller, and current flow is then terminated in each active stator section, and instantly initiated in the stator section windings next scheduled to be activated.
  • the shaft position sensor communicates the change in position of the output shaft to the electronic controller, and current flow is then terminated in each active stator section, and instantly initiated in the stator section windings next scheduled to be activated.
  • FIGS. 9-13 illustrate one embodiment of the motor cluster disclosed herein. Reviewing FIG. 9, it may be seen, that each motor section consists of a metallic housing 1 containing a stator stack 16 and an armature assembly 3, which is mounted upon an output shaft 10, which is carried by two sets of bearings 11, located within end bells 14.
  • the rotor assembly 3 within each motor section consists of a stack of silicon steel laminations 9, or a molded ferrite of appropriate shape, or any other high permeability magnetic material designed to suppress eddy currents, machined so as to produce a section of a right circular cylinder canted at an angle of 45 degrees with respect to the motor output shaft 10.
  • the rotor structure appears to be circular in shape.
  • the side view depicts an ellipse tilted at 45 degrees. This angle may not be the most optimal angle, and it should be realized that other angles may be employed without departing from the spirit of the invention.
  • Each motor shaft 10 may also carry counter weights 7, as depicted, which function to ensure a smooth rotary motion by suppressing mechanical vibrations produced by the mass distribution of the eccentric armature design 3.
  • Each motor shaft carries a high speed output pinion 24 which s designed to mesh with the main output gear as shown in FIGS. 9 and 10.
  • Each stator assembly contains an individual stack of stator laminations 16 or a magnetic ferrite cylinder, from which extend two or more salient pole projections 12, each of which is wound with a power coil 18.
  • the face of each pole projection 5 is extended to the right and the left of center to ensure continuous air gaps 19 of constant dimension.
  • the pole faces are aligned parallel to the rotor's edge contour regardless of its angular disposition.
  • each motor element consists of a laminated, four pole stator stack 62, an air gap 68, an elliptical rotor 67, an individual motor output shaft 64, and an output pinion 63. Further, it will be noted, that each output pinion is in mesh with a central output gear or "bull gear" 65 which drives the main output shaft 66.
  • This arrangement allows for four motors to be energized at any one time, with power overlaps and torque-sharing occurring at 45 degree intervals. This feature serves to smooth out the total torque delivered to the output shaft, allowing for a more continuous delivery of power, as each contributing motor develops its output torque out of phase with respect to each of the others.
  • Total motor action during operation may be appreciated by studying the coil energizing truth table depicted in FIG. 1 1, while the power coil interconnection schematic may be reviewed in FIG. 12.
  • FIG. 11 the horizontal portions of each chart depict energized coils and the sloped portions of the chart represent the magnetic reset of the energized coils. There are shown coil sets for eight motors as described in the above text with respect to FIG. 10.
  • switches S 1A through S8A, and switches S IB through S8B are used to control the power winding coil sets in each motor section.
  • the coil sets are labeled A, A' and B, B' for each motor as shown in FIG. 10.
  • These switches are schematically accurate, but may represent either solid state switching devices located within the electronic motor controller, or actual contact bars located upon a more traditional commutating device. These distinctions are more clearly explained in FIG. 13.
  • FIGS. 13A and 13B depict two variations of some embodiments of the present invention.
  • FIG. 13 A demonstrates the parallel motor cluster concept employing a traditional electro-mechanical commutating device 56, 57, while FIG.
  • 13B demonstrates a more modem approach employing a shaft-mounted encoder 59, a micro-processor, and an electronic motor controller. It will be noted, that both systems require a source of DC power, as well as a capacitive power sump 58, into which excess "inductive energy” is directed. This "sump” may be equipped with a resistive load, which will consume said inductive energy, or the accumulated potential may be utilized to supply other worthwhile power requirements.
  • each arrangement contains a motor cluster housing 51, a plurality of high speed motor pinions 52 mounted upon individual motor output shafts 53, and a central bull gear 54 mounted upon a main output shaft 55.
  • FIG. 13 A makes use of a mechanical commutation device 56 with standard carbon brush contactors 57, while the device shown in FIG. 13B employs a shaft encoder 59 and an encoder pick-up device 60.
  • FIG. 13B it will be noted that electronic signals obtained from the encoder assembly are transmitted to the micro-processor and the electronic motor controller, while power pulses are independently directed to individual motor windings via output conductors energized by the motor controller.
  • the arrangement shown in FIG. 13 A accomplishes these functions electro-mechanically, which may be
  • both systems produce the results depicted in FIG. 11, and both systems ultimately direct inductive energies from collapsing magnetic fields into the capacitive sump indicated by network 58.
  • Vt Transformer Voltage
  • incoming power 1400 may be appropriately conditioned (e.g., rectified, smoothed, or filtered) by a suitable device such as DC power supply 1410, and then passed on to a capacitor bank 1420 for further conditioning, and then passed on to the electronic controller 1430.
  • a suitable device such as DC power supply 1410
  • charge from the battery may first be passed through a DC-to-DC converter (not shown), and then stored in the capacitor bank 1420 at much higher potentials, and then delivered to the electronic controller 1430.
  • Other input power 1400 conditioning mechanisms may also be implemented in accordance with a particular environment or application for the motor 1440.
  • electronic controller 1430 has at least two distinct functions. First, it supplies a series of pulses of proper magnitude and polarity to the motor 1440 so as to produce rotation of the motor shaft 1442 and drive a mechanical load 1444, and second, it directs energy recaptured from the motor 1440 windings to a second capacitor bank 1450 where the recaptured energy accumulates as the motor 1440 continues to rotate.
  • controller 1430 is influenced by input received from a sensor
  • Sensor 1460 which, in some embodiments, is mounted upon the motor shaft 1442. Sensor 1460 functions to allow controller 1430 to monitor various motor 1440 operational characteristics.
  • sensor 1460 may comprise an angular position sensor that functions as a form of shaft encoder which reports specific angular positions of motor shaft 1442, the active quadrants, and other data to the controller 1430 for guiding its operation.
  • Other types of sensors e.g., rotational speed sensors, tachometers, commutator segment sensors, slip rings, brushes, Hall effect devices, optical sensors, magnetic sensors, or shaft encoders and readers, or the like
  • other mounting locations may also be implemented.
  • any number of suitable systems and methods for recapturing the energy may be implemented.
  • some embodiments may implement a capacitor bank 1450 to store the recaptured energy.
  • the recaptured energy may be directed to other storage devices (e.g., batteries), to power an electrical load external to the motor system, as indicated at 1470 and 1472, or otherwise dissipated (e.g., as part of a resistive heat source).
  • external load may be a DC load 1470 or an AC load 1472, depending upon the application and environment. If AC power is desired, then the recovered energy may be directed through an inverter 1474 or other conditioner to produce an AC output as indicated at 1472.
  • FIG. 15 is a schematic block diagram illustrating the basic components of the disclosed motor system in which recovered energy from the motor's magnetic field is stored, reconditioned, and then fed back to the capacitors 1420 in the appropriate primary power supply 1410, where it is reused by the motor 1440 in accordance with some embodiments of the invention.
  • FIG. 15 is substantially similar to FIG. 14, and like elements are numbered alike. A difference in FIG. 15 is that the recaptured energy, residing in the recapture capacitor bank 1450, is not used to power any external appliances. Instead the recaptured energy is appropriately conditioned and then delivered back to assist in powering the motor 1440.
  • Conditioning of the recaptured energy may be accomplished in any suitable fashion.
  • recaptured energy may be sent through a DC-to-DC converter 1510 which boosts the recaptured energy potential back up to the value contained in the primary power supply 1410.
  • the recaptured energy may then be delivered back to the appropriate source capacitors 1420 under the guidance of a feedback control circuit 1520.
  • Feedback circuit 1520 may comprise any suitable circuit for moving the recaptured energy back to the primary power supply 1410.
  • the feedback circuit 1520 may deliver energy back to the primary supply 1400 in accordance with two command criteria: (1) the maximum allowable pre-set value of potential in the recapture bank 1450, and (2) the demand of the motor 1440 operational circuits, as interpreted by the electronic controller 1430.
  • the initiation of power feedback from the recapture bank 1450 to the primary capacitor bank 1420 causes a drop in the power that is required from the incoming power source 1400, and this drop in wattage represents a savings which is exactly proportional to the volume of energy returned by the feedback system per unit time. If desired, it can be measured exactly.
  • this presently disclosed system allows for a given volume of energy to be repeatedly re-used, with only system losses being supplemented by the external power source 1400.
  • FIG. 16 is a schematic flow diagram disclosing an open power system in accordance with some embodiments of the invention.
  • incoming power 1600 is directed to both a positive 1610 and a negative 1620 power supply.
  • Embodiments of the disclosed invention may also provide for power supply conditioning.
  • a capacitor bank 1612 and 1622 may be provided with the respective power supplies 1610 and 1620. Having two power supplies may be desirable for embodiments for which currents of both polarities are desired to operate a Back EMF reducing motor in order to produce a torque of constant value and a steady output speed.
  • the proper blending and switching of positive and negative currents may be achieved by suitable switching elements 1630.
  • Switching elements 1630 may comprise part of controller 1430 and may further comprise any suitable switching elements and associated circuitry for enabling the switching required to energize motor winding 1640. Furthermore, switching elements 1630 may receive input from other system components such as sensor 1460 in order to synchronize switching behavior. In addition, some embodiments may include a starter 1680 or other aid to initiate the rotation of the motor shaft 1442.
  • the recaptured energy may be utilized to power appliances 1660 and 1662 external to the motor as depicted at the bottom of FIG. 16, thus producing an "open" power system, wherein the recaptured energy is used external to the instant motor system.
  • appropriate conditioning such as by inverter 1664, may be implemented.
  • FIG. 17 is a schematic flow diagram disclosing a closed power system in accordance with some embodiments of the invention.
  • FIG. 17 is substantially similar to FIG. 16, and like elements are numbered alike.
  • a difference in FIG. 17 is that the recaptured energy, residing, for example, in the recapture bank 1650, is not used to power any external appliances. Instead the recaptured energy is appropriately conditioned and then delivered back to assist in powering the motor winding 1640.
  • the recaptured energy may be fed-back to the positive 1610 and negative 1620 primary power supplies by means of the feedback controller 1710 and appropriate conditioning circuitry.
  • appropriate conditioning circuitry may comprise one or more DC-to-DC converters 1720, 1722 as depicted.
  • Embodiments, such as depicted in FIG. 17, where the recaptured power is fed-back ultimately to the motor windings 1640 are called a closed power system.
  • FIG. 18 is a functional schematic controller circuit diagram in accordance with some embodiments of the invention.
  • input power 1800 is delivered to the system and may be directed to a power supply 1810 (a DC power supply 1810 is depicted for this embodiment).
  • the power supply 1810 supplies power to the motor 1440, and specifically to the pairs of windings 1641 (pair A) and 1642 (pair B). While two pairs (A and B) of windings separated by 90 degrees are shown, other
  • each pair of windings may be connected either in parallel or series and, typically, providing at least two connection points by which power is delivered to the windings (e.g., 1641, 1642).
  • one of the two connection points may be connected to the power supply 1810 as shown.
  • the second connection on each set of windings 1641, 1642 may be connected to the power supply 1810 through circuit interrupters 1820, such as switches A and B, which are controlled so as to turn on or off any given set of windings 1641, 1642. While circuit interrupters 1820 are shown as switches A and B, other suitable interrupters may be implemented, such as transistors, MOSFETS, digital circuitry, or the like.
  • circuit interrupters 1820 are controlled to open or close (i.e., on or off) in response to a sensed condition of the motor 1440.
  • sensor 1460 provides the appropriate sensed condition signal to effectuate control of circuit interrupters 1820.
  • sensor 1460 may comprise a rotational shaft position sensor that communicates the shaft position to trigger circuit interrupters 1820 to operate at the appropriate times with respect to the motor shaft 1442 position to achieve the desired shaft 1442 rotation.
  • Other sensed conditions such as motor RPM, elapsed time, or the like, may also be used (with appropriate sensors 1460) in order to trigger circuit interrupters 1820 and achieve the desired shaft 1442 rotation.
  • Opening of a circuit interrupter 1820 causes the accumulated magnetic flux in the winding to collapse which, in turn, causes electric power to be generated in the winding as described herein.
  • This winding generated power may be directed via an asymmetric conduction device 1830 into a recapture storage device 1450.
  • Asymmetric conduction device 1830 may comprise any suitable circuit element to direct flow in substantially in a desired direction.
  • asymmetric conduction device 1830 may comprise a diode or the like.
  • a power transfer circuit 1840 may transfer some or all the recaptured power from the recapture storage device 1450 back to the power supply 1810 to, among other things, keep the voltage of the recapture storage device 1450 relatively constant (i.e., the herein described "closed operation").
  • recaptured power from the recapture storage device 1450 may be applied to external loads (e.g., 1472, 1470) (i.e., the herein described "open operation").
  • external loads e.g., 1472, 1470
  • FIG. 18 has shown an embodiment of the controller 1430 as an analog circuit, it is equally possible to implement an equivalent digital circuit in a manner known to those of skill in the art. Likewise, for some embodiments of controller 1430, it may be desirable to include automatic over current detection circuits, which will compare actual motor current and feedback current to certain predetermined values, and initiate appropriate shutdown procedures, should these presets, or other safe operating parameters be exceeded.
  • automatic over current detection circuits which will compare actual motor current and feedback current to certain predetermined values, and initiate appropriate shutdown procedures, should these presets, or other safe operating parameters be exceeded.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Synchronous Machinery (AREA)
  • Control Of Multiple Motors (AREA)

Abstract

L'invention concerne des modes de réalisation de contrôleurs pour moteurs électriques et leurs procédés de fonctionnement. Plus particulièrement, les contrôleurs et les procédés de fonctionnement sont destinés à des moteurs conçus pour fonctionner de sorte à réduire la force contre-électromotrice.
PCT/US2012/065199 2012-07-30 2012-11-15 Contrôleur pour moteur réducteur de force contre-électromotrice WO2014021911A2 (fr)

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US13/562,214 US20130187580A1 (en) 2008-06-04 2012-07-30 Controller For Back EMF Reducing Motor
US13/562,214 2012-07-30

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RU2749049C1 (ru) * 2020-07-23 2021-06-03 Валерий Федорович Коваленко Электродвигатель постоянного тока с частичной противо-эдс

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU2749049C1 (ru) * 2020-07-23 2021-06-03 Валерий Федорович Коваленко Электродвигатель постоянного тока с частичной противо-эдс

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