WO2015171486A1 - Feuilletage pour une machine à aimant permanent - Google Patents

Feuilletage pour une machine à aimant permanent Download PDF

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Publication number
WO2015171486A1
WO2015171486A1 PCT/US2015/029015 US2015029015W WO2015171486A1 WO 2015171486 A1 WO2015171486 A1 WO 2015171486A1 US 2015029015 W US2015029015 W US 2015029015W WO 2015171486 A1 WO2015171486 A1 WO 2015171486A1
Authority
WO
WIPO (PCT)
Prior art keywords
slots
lamination
magnet
rotor bar
rotor
Prior art date
Application number
PCT/US2015/029015
Other languages
English (en)
Inventor
Mike MELFI
Rich SCHIFERL
Stephen Umans
Robert F. Mcelveen
William E. Martin
Original Assignee
Baldor Electric Company
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 US14/271,922 external-priority patent/US20140283373A1/en
Application filed by Baldor Electric Company filed Critical Baldor Electric Company
Publication of WO2015171486A1 publication Critical patent/WO2015171486A1/fr

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K29/00—Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices
    • H02K29/03—Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices with a magnetic circuit specially adapted for avoiding torque ripples or self-starting problems
    • 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

Definitions

  • the disclosure relates to laminations that may be used for rotors in interior pole magnet (IPM) motors, and with subsequent operations to form rotor bar slots, the same laminations may be used for line-start, IPM motors.
  • a lamination which has been optimized for use in a non-line start IPM motor for low cogging, minimal usage of magnet material, and maximum torque per ampere may be further processed to include rotor bars slots to allow the lamination's use in connection with an LSIPM motor.
  • This provides manufacturing flexibility in that the same lamination may be used in both applications (albeit modified through further processing in the LSIPM motor application) to provide efficient, power dense, and economical motors over previous designs.
  • Figure 1 is a perspective view of a line start permanent magnet motor (a LSIPM motor);
  • Figure 2 is a partial cross-section view of the motor of Figure 1 along plane 2-2;
  • Figure 3 shows an illustrative embodiment of a lamination used in a rotor of an interior permanent magnet motor without line start capability (i.e., a non-line start IPM motor).
  • Figure 4 shows an illustrative embodiment of the lamination of Figure 3 after further processing for use in the LSIPM motor of Figure 1.
  • Figure 1 illustrates an exemplary electric motor 10.
  • the motor 10 comprises a line start permanent magnet motor.
  • the exemplary motor 10 comprises a frame 12 capped at each end by drive and opposite drive end caps 14,16, respectively.
  • the frame 12 and the drive and opposite drive end caps 14,16 cooperate to form the enclosure or motor housing for the motor 10.
  • the frame 12 and the drive and opposite drive end caps 14,16 may be formed of any number of materials, such as steel, aluminum, or any other suitable structural material.
  • the drive and opposite drive end caps 14,16 may include mounting and transportation features, such as the illustrated mounting feet 18 and eyehooks 20.
  • stator windings disposed in the stator. (See Figure 2). Stator windings are electrically
  • stator windings are further coupled to terminal leads (not shown), which electronically connect the stator windings to an external power source (not shown), such as 480 VAC three-phrase power or 110 VAC single- phase power.
  • a conduit box 24 houses the electrical connection between the terminal leads and the external power source.
  • the conduit box 24 comprises a metal or plastic material, and advantageously, provides access to certain electrical components of the motor 10. Routing electrical current from its external power source through the stator windings produces a magnetic field that induces rotation of the rotor.
  • a rotor shaft 26 coupled to the rotor rotates in conjunction with the rotor about a center axis 28. That is, rotation of the rotor translates into a corresponding rotation of the rotor shaft 26.
  • the rotor shaft may couple to any number of drive machine elements, thereby
  • machines such as pumps, compressors, fans, conveyors, and so forth, may harness the rotational motion of the rotor shaft 26 for operation.
  • FIG 2 is a partial cross-sectional view of the motor 10 of Figure 1 along plane 2— 2 of Figure 1. To simplify the discussion, only the top portion of the motor 10 is shown, as the structure of the motor 10 is essentially mirrored along its centerline. As discussed above, the frame 12 and the drive and opposite drive end caps 14,16 cooperate to form an enclosure or motor housing for the motor 10.
  • each stator lamination 30 includes features that cooperate with adjacent laminations to form cumulative features for the contiguous stator core 32.
  • each stator lamination 30 includes a central aperture that cooperates with the central aperture of adjacent stator laminations to form a rotor chamber 33 that extends the length of the stator core 32 and that is sized to receive a rotor.
  • each stator lamination 30 includes a plurality of stator slots 34 ( Figures 3 and 4) disposed circumferentially about the central aperture. These stator slots 34 cooperate to receive one or more stator windings 35, which are illustrated as coil ends in Figure 2, that extend the length of the stator core 32.
  • the stator slots 34 have a width 36 and define stator teeth 37 with a stator tooth width 38. Together the stator slot width 36 and stator tooth width 38 define a stator tooth pitch 39.
  • the stator tooth width 38 and the stator slot width 36 are generally angular distances measured about the axis of rotation 28.
  • the stator tooth pitch 39 generally corresponds to the distance between generally identical points of adjacent teeth or slots, e.g., centerline to centerline, or clockwise-most edge to clock-wise most edge.
  • stator and rotor may be designed to limit cogging torque of motor and optimize steady state performance of the motor.
  • stator teeth 37 and winding slots 34
  • the stator slots and teeth 34,37 may have a generally constant cross-sectional profile and may be evenly spaced circumferentially about the axis of rotation 28 as measured by a line passing through a line passing through a longitudinal axis of the slots or teeth.
  • the number of teeth (and/or slots) may also be an integer multiple of the number of phases of power the motor.
  • the stator windings may also be arranged according to the number of poles and the number of phases of power delivered to the motor.
  • the rotor assembly 40 resides within the rotor chamber 34, and similar to the stator core 32, the rotor assembly 40 comprises a plurality of rotor laminations 42 aligned and adjacently placed with respect to one another to form a contiguous rotor core 44 with an outer diameter "D r ".
  • End members 46 are disposed on opposite ends of the rotor core 44 and may be generally circular in cross-section with an outer diameter that generally approximates the diameter of the rotor laminations 42.
  • Each rotor lamination 42 has a generally circular cross-section and is formed of a magnetic material, such as electrical steel.
  • each lamination 42 includes features that, when aligned with adjacent laminations 42, form cumulative features that extend axially through the rotor core 44.
  • the rotor laminations 42 cooperate to form a shaft chamber 47 located in the center of the lamination 42 that extends through the center of the rotor core 44 and that is configured to receive the rotor shaft 26 therethrough.
  • the rotor shaft 26 is secured with respect to the rotor core 44 such that the rotor core and the rotor shaft rotate as a single entity about the rotor center axis 28.
  • magnet slots in each lamination, magnet slots, and in the case of the LSIPM, rotor bar slots, may also cooperate to form passages extending through the rotor core 44.
  • Figure 2 shows a configuration of the motor as a LSIPM motor with the rotor assembly 40 including rotor bars 48, disposed in the rotor core 44 electrically connected to rotor end members 46 to form the starting cage, these may be omitted in the non-line start 1PM.
  • the exemplary motor 10 includes drive and opposite drive bearing sets 50,52, respectively, that are secured to the rotor shaft 26 and that facilitate rotation of the rotor assembly 40 within the stationary stator core 32.
  • the bearing sets 50,52 transfer the radial and thrust loads produced by the rotor assembly 40 to the motor housing.
  • Each bearing set 50,52 includes an inner race 54 disposed circumferentially about the rotor shaft 26. The tight fit between the inner race 54 and the rotor shaft 26 causes the inner race 54 to rotate in conjunction with the rotor shaft 26.
  • Each bearing set 50,52 also includes an outer race 56 and rotational elements 58, which are disposed between the inner and outer races 54,56.
  • the rotational elements 58 facilitate rotation of the inner races 54 while the outer races 56 remain stationary and mounted with respect to the drive and opposite drive end caps 14,16.
  • the bearing sets 50,52 facilitate rotation of the rotor assembly 40 while supporting the rotor assembly 40 within the motor housing, i.e., the frame 12 and the drive and opposite drive end caps 14,16.
  • the bearing sets 50,52 are coated with a lubricant.
  • the bearing sets 50, 52 may be other constructions, such as sleeve bearings, pin bearings, roller bearings, etc.
  • Figure 3 shows a lamination 42A which has been optimized for use in a non- line start IPM motor.
  • Figure 4 shows the same lamination 42B after further processing to form rotor bar slots to allow its use in a LSIPM motor.
  • the features of the laminations 42A, 42B may be selected to provide for low cogging and maximum torque per ampere.
  • the features of the laminations 42A, 42B may be selected to provide a large magnet size and magnet alignment with the stator in a specific manner to accommodate low cogging.
  • the angle of the magnets, the width of the poles, and the positions of the leading edge and trailing edge of the pole relative to the stator teeth and the direction of rotation (“LU") may be selected as desired to limit cogging.
  • the terms "leading” and “trailing” are simply used for convenient reference relative to the direction of rotation (“LU").
  • Arranging the leading edge of each pole to align with a stator tooth and arranging the trailing edge of the respective pole to be generally not aligned with a stator tooth may reduce cogging torque.
  • the lamination 42A as shown in Figure 3 in connection with a LSIPM motor through further processing to include rotor bars slots as shown in Figure 4, the lamination also requires sufficient material for the rotor bars.
  • the rotor laminations 42A, 42B may be formed with magnet slots 70 and magnets 72 arranged in V configuration at a magnet angle 74 to form a pole width 76 defined by leading and trailing edges 77, 78 that provides a sufficient area in the lamination for the rotor bars between the magnets while providing magnet alignment to accommodate low cogging.
  • the magnet angle may correspond to the angle formed between the edges of adjacent magnet slots.
  • the magnet angle may also correspond to an angle between reference lines passing through points on adjacent magnets where the pole of each magnet changes direction. For instance, adjacent magnets may have a north pole on one side of each of the magnets and a south pole on another side of each of the magnets.
  • the magnet angle may correspond to the angle between a first reference line passing through a center plane of one magnet where the poles switch direction and a second reference line passing through a center plane of an adjacent magnet where the poles switch direction.
  • the magnets 72 may be rotationally symmetrically disposed about the axis of rotation and generally define the poles of the motor.
  • the magnets 72 may be disposed in different repetition patterns, such as at intervals of 180 degrees, 60 degrees, 45 degrees, etc, for example.
  • the magnets may be magnetized in a generally radial direction to establish inwardly and outwardly disposed north and south poles on the magnets. This means that adjacent magnets cooperate to establish alternate north and south poles on the periphery of the rotor.
  • the rotor may be constructed with any even number of poles.
  • An exemplary lamination for a four pole motor non-LS, IPM motor is shown in Figure 3 and the same lamination used in a LSIPM motor is shown in Figure 4.
  • the angle between the magnets of a pole generally defines the pole width, the position of the leading edge 77, and the position of the trailing edge 78.
  • the magnet angle 74 may be obtuse, for example, approximately 109, 111 , 1 13, 1 15, 1 17, 1 19, 121 , 123, 125, 127, or 129 degrees.
  • the width of the magnets may be selected to achieve a desired pole width 76. While the widths and edges of the poles generally correspond with the angular positions of edges of the magnets, the width and edges of a pole are not exclusively a function of the size of the permanent magnets associated with the pole.
  • the edge of a pole may be defined as the location where there is a distinct change in the air gap flux density.
  • the air gap flux density may change by more than 30%, 40%, 50%, 60%, 70%, 80%, or more (relative to the flux density in the direction of magnetization) near the edges of the pole.
  • the pole width may be influenced by the flux field, and the flux field may be shaped by, for example, the shape and magnetic properties of the materials in the stator, the rotor, the space between the stator and rotor, air gaps in the rotor laminations, or materials with different magnetic properties introduced to the stator, the rotor, and/or the space between the stator and the rotor. There may be only one magnet per slot or multiple magnets per slot.
  • the magnets may establish a direct axis 80 and a quadrature axis 82.
  • the magnets define a general axis of magnetization (north or south pole) on the periphery of the rotor.
  • the edges of the magnet slots facing the general axis of magnetization which are radially outward from the magnets, establish a generally arcuate saturation boundary area as indicated by reference characters 84a, 84b.
  • the saturation boundary area may correspond to the pole width 74 depending upon the lamination design.
  • the saturation boundary area may also be different from the pole width depending upon the lamination design.
  • the edges of the magnet slots and the edges of the magnets both face the general axis of
  • the magnet slots 70 extend to the peripheral edge of the rotor D r such that an end of the magnet slot is adjacent the peripheral edge.
  • One or more of the magnet slots may have its radially outward end at generally the same radial position relative to the rotor outer diameter D f and the rotor bar slots as shown in the drawings, or one or more magnet slots may extend radially outward and terminate at different distances relative to each other and/or the rotor bar slots, depending upon the application.
  • the magnets 72 disposed in the magnet slots 70 have a smaller longitudinal length in the direction of the magnet slots than the magnet slots such that the magnet when installed in the magnet slot forms a magnet slot aperture 86 between the end of the permanent magnet and the magnet slot.
  • the magnet slot aperture 86 may be filled with conductive material to form additional rotor bars that are also connected to the end members 46.
  • the shape of the poles and the size of the pole width relative to the size of the stator tooth pitch may be arranged to limit adverse cogging.
  • the poles may be configured so that when the leading edges are between teeth, the trailing edge is aligned with a tooth.
  • the magnets (and other aspects of the lamination) are arranged so that both edges 84a, 84b of the pole (air gap flux density changes) do no align with stator teeth at the same time. That is, the poles are spatially desynchronized with the stator teeth.
  • Figures 3 and 4 depict an embodiment in which the pole width 76 as defined by leading and trailing edges 77,78 is such that the leading edge 77 is aligned with a tooth 90 when at the same time the trailing edge 78 is aligned with a slot 92.
  • the smallest difference in angular size between the pole width and an integer multiple of the stator tooth pitch may be greater than or generally equal to 50%, 40% 30%, 20%, or 10% of the stator tooth pitch.
  • the remainder of the pole width divided by the tooth pitch may be a variety of percentages of the tooth pitch.
  • the lamination is configured so that the rotor exhibits relatively little cogging as the rotor rotates between the teeth of the stator.
  • the number of stator teeth 37 may be set as an integer multiple of the number of poles, and the leading and trailing edges 77,78 of each of the pole are angularly disposed with respect to the stator teeth to reduce cogging torque.
  • the lamination may be used directly in a non- line start IPM or further processed for use in a rotor of a LSIPM.
  • the lamination 42 may be further processed to include a series of rotor bar slots 100 that are arranged at positions about the lamination such that when assembled, the rotor bar slots cooperate to form channels for the rotor bars that extend through the rotor core 44.
  • the rotor bar slots 100 are spaced radially inward from the rotor outer diameter D r .
  • each of the rotor bar slots may extend radially outward to generally the same radial position relative to the rotor outer diameter D r , or one or more rotor bar slots may extend radially outward and terminate at different radial distances relative to the outer diameter D r , depending upon the application.
  • the rotor bars 48 may present the same shape as the rotor bar slots 100 to provide a tight fit for the rotor bars 48 within the rotor bar slots.
  • the rotor bars 48 may be manufactured with tight tolerances between the rotor bars and the rotor bar slots 100.
  • the rotor bar slots may also be configured to receive electrically conductive material to form the rotor bars 48 for the starting cage of the motor.
  • the conductive material may comprise a molten material introduced into the slots to form cast rotor bars.
  • the end members may also be cast.
  • the rotor bars slots 100,102 forming the starting cage may have a different size, shape, and spacing about the center axis 28.
  • the rotor bar slots 100 may be distributed about the rotor in a manner that is asymmetric rather than evenly distributed, i.e., asymmetric rather than equiangularly spaced, around the outer edge of the lamination surface. Additionally, the rotor bar slots may have an arbitrary shape.
  • the rotor bar slots 100 that are disposed in the saturation boundary area 84a, 84b form a cluster. At least two of the rotor bar slots of the cluster may vary in cross-sectional area by at least 10 percent. At least two of the rotor bar slots of the cluster may also vary dimensionally by at least 5 percent.
  • the laminations may be stacked off-set to one another such that the rotor bar in the slot has a helix relative to the rotor axis of rotation.
  • a rotor bar slot 102 may be provided to align with the quadrature axis 82.
  • the rotor bar slot 102 of the quadrature axis 82 may have a geometry which matches at least one of the rotor bar slots 100 aligned with the direct axis 80.
  • the lamination designs shown in Figures 3-4 are designed to optimize paths for flux over a range of conditions including at rated load.
  • the arrangement of the rotor bars and the magnets allows for passage of rotor flux under a wide range of loads and operating
  • the distance between the rotor bar slots disposed in the saturation boundary area 84a, 84b and the magnet slots 70 is controlled so that preferably each rotor bar slot in the saturation boundary area is positioned away from an adjacent magnet slot by a distance that equals or exceeds four percent (4%) of the pole pitch.
  • the closest approach distance of any one of the rotor bar slots in the saturation boundary area to an adjacent magnet slot must equal or exceed four percent of the pole pitch.
  • the closest approach distance is referred to hereinafter as (“D r b- m ") and is defined by the equation (“D r t > -m") ⁇ 0.04 *("pp").
  • One or more of the rotor bar slots 100 in the saturation boundary area 84a, 84b may be arranged to maintain this parameter relative to an adjacent magnet slot.
  • Rotor bar slots outside of the saturation boundary area for instance, rotor bar slots 102 generally aligned with the quadrature axis 82, may also be positioned to maintain this parameter relative to an adjacent magnet slot,
  • all of the rotor bar slots 100 in the saturation boundary area have a radial interior edge 106 which conforms generally to a side 104 of the magnet 72 in the adjacent magnet slot 70.
  • one or more of the rotor bar slots in the saturation boundary area may be formed to have a radial inward edge 106 which defines a reference plane generally parallel to the adjacent magnet. In this way, one or more of the rotor bar slots may have a distance to the adjacent magnet slot that meets or exceeds the four percent (4%) of the pole pitch ("pp").
  • Rotor bar slots outside of the saturation boundary area for instance, rotor bar slots 102 generally aligned with the quadrature axis 82, may also be shaped in a similar manner to maintain this parameter.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Permanent Field Magnets Of Synchronous Machinery (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)

Abstract

L'invention concerne un procédé qui comprend la formation d'un feuilletage qui peut être utilisé dans un rotor d'un moteur à aimant permanent intérieur ou traité davantage pour être utilisé dans un moteur à aimant permanent intérieur à démarrage direct (LSIPM). Le feuilletage a été optimisé pour un faible couple de détente, une utilisation minimale du matériau aimanté, et un couple par ampère maximal et peut en outre être traité pour comprendre des encoches de barres de rotor pour permettre l'utilisation du feuilletage en rapport avec un LSIPM. Selon le procédé, le feuilletage est formé avec des encoches d'aimants qui sont radialement vers l'intérieur du diamètre extérieur. Les encoches d'aimants sont formées en une pluralité d'agencements en forme de V. Chaque agencement en forme de V possède un bord avant et un bord arrière. Le bord avant et le bord arrière sont agencés de telle sorte que lorsque le bord avant s'aligne sur une dent de stator, le bord arrière respectif ne soit généralement pas aligné sur une dent de stator.
PCT/US2015/029015 2014-05-07 2015-05-04 Feuilletage pour une machine à aimant permanent WO2015171486A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US14/271,922 US20140283373A1 (en) 2011-12-19 2014-05-07 Lamination for a Permanent Magnet Machine
US14/271,922 2014-05-07

Publications (1)

Publication Number Publication Date
WO2015171486A1 true WO2015171486A1 (fr) 2015-11-12

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Application Number Title Priority Date Filing Date
PCT/US2015/029015 WO2015171486A1 (fr) 2014-05-07 2015-05-04 Feuilletage pour une machine à aimant permanent

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
USD960086S1 (en) 2017-07-25 2022-08-09 Milwaukee Electric Tool Corporation Battery pack
EP4123880A1 (fr) * 2021-07-19 2023-01-25 Abb Schweiz Ag Machine à aimant permanent et rotor associé
EP4123881A1 (fr) * 2021-07-21 2023-01-25 Abb Schweiz Ag Rotor à aimant permanent à barrière de flux conductrice
US11780061B2 (en) 2019-02-18 2023-10-10 Milwaukee Electric Tool Corporation Impact tool

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4139790A (en) * 1977-08-31 1979-02-13 Reliance Electric Company Direct axis aiding permanent magnets for a laminated synchronous motor rotor
US5097166A (en) * 1990-09-24 1992-03-17 Reuland Electric Rotor lamination for an AC permanent magnet synchronous motor
US7385328B2 (en) * 2006-05-23 2008-06-10 Reliance Electric Technologies, Llc Cogging reduction in permanent magnet machines
US20130154426A1 (en) * 2011-12-19 2013-06-20 Baldor Electric Company Rotor for a Line Start Permanent Magnet Machine

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4139790A (en) * 1977-08-31 1979-02-13 Reliance Electric Company Direct axis aiding permanent magnets for a laminated synchronous motor rotor
US5097166A (en) * 1990-09-24 1992-03-17 Reuland Electric Rotor lamination for an AC permanent magnet synchronous motor
US7385328B2 (en) * 2006-05-23 2008-06-10 Reliance Electric Technologies, Llc Cogging reduction in permanent magnet machines
US20130154426A1 (en) * 2011-12-19 2013-06-20 Baldor Electric Company Rotor for a Line Start Permanent Magnet Machine

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
USD960086S1 (en) 2017-07-25 2022-08-09 Milwaukee Electric Tool Corporation Battery pack
US11462794B2 (en) 2017-07-25 2022-10-04 Milwaukee Electric Tool Corporation High power battery-powered system
US11476527B2 (en) 2017-07-25 2022-10-18 Milwaukee Electric Tool Corporation High power battery-powered system
US11780061B2 (en) 2019-02-18 2023-10-10 Milwaukee Electric Tool Corporation Impact tool
EP4123880A1 (fr) * 2021-07-19 2023-01-25 Abb Schweiz Ag Machine à aimant permanent et rotor associé
US11742734B2 (en) 2021-07-19 2023-08-29 Abb Schweiz Ag Permanent magnet machine and rotor therefor
EP4123881A1 (fr) * 2021-07-21 2023-01-25 Abb Schweiz Ag Rotor à aimant permanent à barrière de flux conductrice

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