WO2021189050A1

WO2021189050A1 - A universal core electrical machine

Info

Publication number: WO2021189050A1
Application number: PCT/US2021/023506
Authority: WO
Inventors: Daniel Lee SANDERS
Original assignee: Sanders Daniel Lee
Priority date: 2020-03-20
Filing date: 2021-03-22
Publication date: 2021-09-23

Abstract

Disclosed herein is a universal core electrical machine, in accordance with some embodiments. Accordingly, the universal core electrical machine comprises a stator and a rotor. Further, the stator comprises electromagnets and a support assembly. Further, the electromagnets are radially disposed around a central axis of the stator. Further, inner ends and outer ends of the electromagnets define an internal boundary and an external boundary of the stator. Further, the electromagnets form an internal space and an external space defined by the internal boundary and the external boundary. Further, each electromagnet is independently energized for generating a magnetic flux on an inner end and an outer end of each electromagnet. Further, the support assembly is configured for radially supporting the electromagnets. Further, the rotor is rotatable in relation to the stator. Further, the rotor comprises rotor magnets concentrically disposed around the central axis in the internal space and the external space.

Description

A UNIVERSAL CORE ELECTRICAL MACHINE

FIELD OF THE INVENTION

Generally, the present disclosure relates to the field of an electrical generator or motor structure. More specifically, the present disclosure relates to a universal core electrical machine.

BACKGROUND OF THE INVENTION

The Home Appliances including Kitchen, Floor Care, and corded Power Tools Industries are a large world market and primary user of Fractional HP Electric Motors; and even though there have been many advancements in Electric Motors over the last 30 years since plastics and electronics have become widely available, the Home Appliances Industries are still using motors that do not take advantage of these advancements. These old electric motor designs, commonly known as Universal motors and HVDC (High Voltage Direct Current) motors have been used for many years and have in many cases dictated the appliance design, meaning home appliance designs start with the motor as the core and the appliance is built around it.

These old motor designs cannot meet the higher Efficiency and longer useable life of newer PM BLDC (Permanent Magnet Brushless Direct Current) Motors. Even though many home appliances manufactures have tried switching to using 3 -phase 6-pole PM BLDC motors that are better for the environment and have less drain our domestic power systems that supply electricity to domestic homes, the change from old technology to more efficient

BLDC motors has been very limited because of higher initial investment and production cost because existing PM BLDC motor designs are a fixed design in which an external or internal rotor design cannot be changed from one to the other because it requires a high initial investment cost in both tooling required for production and process equipment while having limited change flexibility. Therefore, a motor with higher efficiency and longer useable life than the universal and HVDC is needed. The motor must have a flexible design such that a single core design can be produced as either an internal, external, or dual rotor, but at a much lower cost than the current PM BLDC motors. Further, the motor serves as a viable option for manufactures of Home Appliances.

Therefore, there is a need for a universal core electrical machine that may overcome one or more of the above-mentioned problems and/or limitations.

SUMMARY OF THE INVENTION

This summary is provided to introduce a selection of concepts in a simplified form, that are further described below in the Detailed Description. This summary is not intended to identify key features or essential features of the claimed subject matter. Nor is this summary intended to be used to limit the claimed subject matter’s scope.

Disclosed herein is a universal core electrical machine, in accordance with some embodiments. Accordingly, the universal core electrical machine may include a stator and a rotor. Further, the stator may include a plurality of electromagnets and a support assembly. Further, the plurality of electromagnets may be radially disposed around a central axis of the stator. Further, each electromagnet of the plurality of electromagnets radially extends away from the central axis. Further, each electromagnet may include an inner end and an outer end. Further, a plurality of inner ends of the plurality of electromagnets defines an internal boundary of the stator. Further, a plurality of outer ends of the plurality of electromagnets defines an external boundary of the stator. Further, the plurality of electromagnets forms an internal space defined by the internal boundary and an external space defined by the external boundary. Further, each electromagnet of the plurality of electromagnets may be configured to be independently energized for generating a magnetic flux on the inner end and the outer end of each electromagnet. Further, the support assembly may be configured for radially supporting the plurality of electromagnets around the central axis. Further, the support assembly may be configured for allowing independent energizing of each electromagnet by insulating the plurality of electromagnets. Further, the rotor may be rotatable in relation to the stator. Further, the rotor may include a plurality of rotor magnets concentrically disposed around the central axis in at least one of the internal space and the external space. Further, the plurality of rotor magnets may be configured for rotating around the central axis in relation to the plurality of electromagnets based on the generating of the magnetic flux.

Further disclosed herein is a universal core electrical machine, in accordance with some embodiments. Accordingly, the universal core electrical machine may include a stator and a rotor. Further, the stator may include a plurality of electromagnets and a support assembly. Further, the plurality of electromagnets may be radially disposed around a central axis of the stator. Further, each electromagnet of the plurality of electromagnets radially extends away from the central axis. Further, each electromagnet may include an inner end and an outer end. Further, a plurality of inner ends of the plurality of electromagnets defines an internal boundary of the stator. Further, a plurality of outer ends of the plurality of electromagnets defines an external boundary of the stator. Further, the plurality of electromagnets forms an internal space defined by the internal boundary and an external space defined by the external boundary. Further, each electromagnet of the plurality of electromagnets may be configured to be independently energized for generating a magnetic flux on the inner end and the outer end of each electromagnet. Further, the support assembly may be configured for radially supporting the plurality of electromagnets around the central axis. Further, the support assembly may be configured for allowing independent energizing of each electromagnet by insulating the plurality of electromagnets. Further, the support assembly may include a plurality of bobbins. Further, the plurality of bobbins may be radially arranged around the central axis. Further, a bobbin of the plurality of bobbins may include an interior cavity in an interior of the bobbin and an exterior cavity on an exterior surface of the bobbin. Further, the bobbin may be configured for receiving an electromagnet core of an electromagnet of the plurality of electromagnets in the interior cavity and an electromagnet winding of the electromagnet in the exterior cavity. Further, the radially supporting of the plurality of electromagnets around the central axis may be based on the receiving. Further, the rotor may be rotatable in relation to the stator. Further, the rotor may include a plurality of rotor magnets concentrically disposed around the central axis in at least one of the internal space and the external space. Further, the plurality of rotor magnets may be configured for rotating around the central axis in relation to the plurality of electromagnets based on the generating of the magnetic flux.

Both the foregoing summary and the following detailed description provide examples and are explanatory only. Accordingly, the foregoing summary and the following detailed description should not be considered to be restrictive. Further, features or variations may be provided in addition to those set forth herein. For example, embodiments may be directed to various feature combinations and sub-combinations described in the detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate various embodiments of the present disclosure. The drawings contain representations of various trademarks and copyrights owned by the Applicants. In addition, the drawings may contain other marks owned by third parties and are being used for illustrative purposes only. All rights to various trademarks and copyrights represented herein, except those belonging to their respective owners, are vested in and the property of the applicants. The applicants retain and reserve all rights in their trademarks and copyrights included herein, and grant permission to reproduce the material only in connection with reproduction of the granted patent and for no other purpose.

Furthermore, the drawings may contain text or captions that may explain certain embodiments of the present disclosure. This text is included for illustrative, non-limiting, explanatory purposes of certain embodiments detailed in the present disclosure.

FIG. 1 is a disassembled view of a universal core electrical machine, in some embodiments.

FIG. 2 is a perspective view of the plurality of electromagnets of the stator, in accordance with some embodiments.

FIG. 3 is a top view of the plurality of electromagnets of the stator, in accordance with some embodiments.

FIG. 4 is a top view of the plurality of electromagnets and the magnetic flux associated with the plurality of electromagnets, in accordance with some embodiments.

FIG. 5 is a perspective view of the plurality of electromagnets of the stator and the rotor in the internal rotor configuration, in accordance with some embodiments.

FIG. 6 is a top view of the plurality of electromagnets of the stator and the rotor in the internal rotor configuration, in accordance with some embodiments.

FIG. 7 is a perspective view of the plurality of electromagnets of the stator and the rotor in the external rotor configuration, in accordance with some embodiments.

FIG. 8 is a top view of the plurality of electromagnets of the stator and the rotor in the external rotor configuration, in accordance with some embodiments.

FIG. 9 is a perspective view of the plurality of electromagnets of the stator and the rotor in the dual rotor configuration, in accordance with some embodiments. FIG. 10 is a top view of the plurality of electromagnets of the stator and the rotor in the dual rotor configuration, in accordance with some embodiments.

FIG. 11 is a perspective view of the support assembly of the stator, in accordance with some embodiments.

FIG. 12 is a top perspective view of the bobbin of the plurality of bobbins, in accordance with some embodiments.

FIG. 13 is a side perspective view of the bobbin of the plurality of bobbins with the electromagnet core of the electromagnet, in accordance with some embodiments.

FIG. 14 is a perspective view of a plurality of bobbins of the support assembly, in accordance with some embodiments.

FIG. 15 is a side view of the plurality of bobbins of the support assembly, in accordance with some embodiments.

FIG. 16 is a top view of the plurality of bobbins of the support assembly, in accordance with some embodiments.

FIG. 17 is a bottom perspective view of the upper plate of the support assembly, in accordance with some embodiments.

FIG. 18 is a bottom view of the upper plate of the support assembly, in accordance with some embodiments.

FIG. 19 is a top perspective view of the lower plate of the support assembly, in accordance with some embodiments.

FIG. 20 is a top view of the lower plate of the support assembly, in accordance with some embodiments.

FIG. 21 is a disassembled view of a universal core electrical machine, in some embodiments.

DETAIL DESCRIPTIONS OF THE INVENTION

As a preliminary matter, it will readily be understood by one having ordinary skill in the relevant art that the present disclosure has broad utility and application. As should be understood, any embodiment may incorporate only one or a plurality of the above-disclosed aspects of the disclosure and may further incorporate only one or a plurality of the above- disclosed features. Furthermore, any embodiment discussed and identified as being “preferred” is considered to be part of a best mode contemplated for carrying out the embodiments of the present disclosure. Other embodiments also may be discussed for additional illustrative purposes in providing a full and enabling disclosure. Moreover, many embodiments, such as adaptations, variations, modifications, and equivalent arrangements, will be implicitly disclosed by the embodiments described herein and fall within the scope of the present disclosure.

Accordingly, while embodiments are described herein in detail in relation to one or more embodiments, it is to be understood that this disclosure is illustrative and exemplary of the present disclosure, and are made merely for the purposes of providing a full and enabling disclosure. The detailed disclosure herein of one or more embodiments is not intended, nor is to be construed, to limit the scope of patent protection afforded in any claim of a patent issuing here from, which scope is to be defined by the claims and the equivalents thereof. It is not intended that the scope of patent protection be defined by reading into any claim limitation found herein and/or issuing here from that does not explicitly appear in the claim itself.

Thus, for example, any sequence(s) and/or temporal order of steps of various processes or methods that are described herein are illustrative and not restrictive.

Accordingly, it should be understood that, although steps of various processes or methods may be shown and described as being in a sequence or temporal order, the steps of any such processes or methods are not limited to being carried out in any particular sequence or order, absent an indication otherwise. Indeed, the steps in such processes or methods generally may be carried out in various different sequences and orders while still falling within the scope of the present disclosure. Accordingly, it is intended that the scope of patent protection is to be defined by the issued claim(s) rather than the description set forth herein.

Additionally, it is important to note that each term used herein refers to that which an ordinary artisan would understand such term to mean based on the contextual use of such term herein. To the extent that the meaning of a term used herein — as understood by the ordinary artisan based on the contextual use of such term — differs in any way from any particular dictionary definition of such term, it is intended that the meaning of the term as understood by the ordinary artisan should prevail.

Furthermore, it is important to note that, as used herein, “a” and “an” each generally denotes “at least one,” but does not exclude a plurality unless the contextual use dictates otherwise. When used herein to join a list of items, “or” denotes “at least one of the items,” but does not exclude a plurality of items of the list. Finally, when used herein to join a list of items, “and” denotes “all of the items of the list.”

The following detailed description refers to the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the following description to refer to the same or similar elements. While many embodiments of the disclosure may be described, modifications, adaptations, and other implementations are possible. For example, substitutions, additions, or modifications may be made to the elements illustrated in the drawings, and the methods described herein may be modified by substituting, reordering, or adding stages to the disclosed methods. Accordingly, the following detailed description does not limit the disclosure. Instead, the proper scope of the disclosure is defined by the claims found herein and/or issuing here from. The present disclosure contains headers. It should be understood that these headers are used as references and are not to be construed as limiting upon the subjected matter disclosed under the header.

The present disclosure includes many aspects and features. Moreover, while many aspects and features relate to, and are described in the context of a universal core electrical machine, embodiments of the present disclosure are not limited to use only in this context.

Overview:

The present disclosure describes a universal core electrical machine. Further, the universal core electrical machine may include a universal core motor. The universal core motor comprises a plurality of independent electromagnets. The plurality of independent electromagnets is open on both ends and has equal magnetic flux present on both ends. The plurality of independent electromagnets provides a versatility of manufacturing and lower cost.

The plurality of independent electromagnets can be manufactured from laminated motor steel as used in traditional motors or sintered magnetic material but is not limited to such. Furthermore, the plurality of independent electromagnets can comprise any geometric profile or shape as required or needed by design or manufacturing constraints.

The versatility that the universal core motor provides is due to the plurality of independent electromagnets which can be configured to include a plurality of internal rotor magnets, a plurality of external rotor magnets, or both the plurality of internal rotor magnets and the plurality of external rotor magnets.

A plurality of coil bobbins is used to insulate and support the plurality of independent electromagnets. Furthermore, the plurality of coil bobbins is mechanically retained in an upper plate and/or a lower plate. The assembly for the upper and/or lower plate and the coil bobbins may or may not incorporate the presence of a plurality of rotor bearings.

Further, the universal core motor reduces initial costs for manufacturers in the home appliances industry and allows for versatility of design for the configuration of the motor. Further, the universal core motor allows an internal rotor configuration, an external rotor configuration, or a dual rotor configuration. Further, the universal core motor accomplishes the versatility of the design using a plurality of independent electromagnets. The plurality of independent electromagnets is open on both ends and has equal magnetic flux present on both ends. The plurality of independent electromagnets with independent magnetic flux provides a simpler design and allows for a lower cost of manufacturing. The plurality of independent electromagnets provides the versatility of manufacturing, by allowing configuring of the motor core to comprise an internal rotor, an external rotor, or a dual rotor.

The plurality of independent electromagnets can be manufactured from laminated motor steel as used in traditional motors or sintered magnetic material but is not limited to such. Furthermore, the plurality of independent electromagnets can comprise any geometric profile or shape as required or needed by the design. Therefore, the geometric profile is the profile selected for the preferred embodiment of the universal core motor, but it is understood it is not meant to limit the scope of the universal core motor and can modify to accommodate any design or manufacturing constraints.

The first component to manufacture for the universal core motor is the plurality of independent electromagnets. This allows for further configuration later in the manufacturing process. Once the plurality of independent electromagnets is ready, the universal core motor can be configured to comprise the internal rotor configuration, the external rotor configuration, or the dual rotor configuration. The internal rotor configuration comprises a plurality of internal rotor magnets concentric to the inner radius of the radial distribution of the plurality of electromagnets.

The external rotor configuration comprises a plurality of external rotor magnets concentric to the outer radius of the radial distribution of the plurality of electromagnets.

The dual rotor comprises both the plurality of internal rotor magnets concentric to the inner radius of the radial distribution of the plurality of electromagnets and the plurality of external rotor magnets concentric to the outer radius of the radial distribution of the plurality of electromagnets. Furthermore, a plurality of coil bobbins is used to insulate and support the plurality of independent electromagnets from the universal core motor. The plurality of coil bobbins can be manufactured from any non-conductive material. Additionally, the plurality of coil bobbins is mechanically retained by an upper plate and/or a lower plate which fastens to each other via a mounting mechanism, interlocking mechanism, or any variation thereof. The universal core motor may also comprise rotor bearings in the center of the assembly.

The universal core motor comprises six independent electromagnets for the plurality of independent electromagnets but can comprise any quantity of independent electromagnets as needed. Furthermore, the preferred embodiment comprises four internal rotor magnets for the plurality of internal rotor magnets, and four external rotor magnets for the plurality of external rotor magnets. Similarly, the plurality of internal rotor magnets and the plurality of external rotor magnets can comprise any quantity of internal rotor magnets and external rotor magnets as needed.

Further, the universal core motor may be accepted by the Home Appliance industries including Vacuum Cleaners and plug-in Power Tool Industries. Further, the universal core motor may include a PM BLDC motor that has a flexible design meeting much different design needs such as Internal Rotor, External Rotor, and Dual Rotor while being simple to manufacture at a lower cost. While still taking advantage of current electronic drive technology. Further, the outer support ring of the stator core of the PM BLDC motor is removed for making the universal core motor. Allowing the stator magnetic cores to be independent of each other. Therefore, simplifying the way they push and pull the magnetic rotor by magnetic attraction and repulsion in that the independent electromagnets have independent magnetic flux paths. Independent electromagnets with independent magnetic flux paths are used to replace the stator and allow a simple design that is easier for manufacturing at a lower cost. Further, the universal core motor may meet the growing need for energy efficiency in power electronics and electric machines, a number of new soft magnetic materials are being investigated. Among them, high silicon Fe-Si alloy has been recognized as a promising candidate for low-to-medium-frequency applications. Compared to the currently most widely used 3 wt. % silicon steel, these new advanced soft magnetic materials possess more favorable properties, including high electrical resistivity, good saturation magnetization, and near-zero magnetostriction. However, these new advanced soft magnetic materials facilitate the formation of ordered phases, resulting in severe brittleness that prohibits mass production using the economical conventional processing methods. Whereas these new advanced soft magnetic materials can be sintered without restrictions. Based on the independent stator electromagnetic cores that are open on both ends and have magnet flux present on both ends. Further, the universal core motor may include, an internal rotor, an external rotor that is an external cylinder closed at one end mounted onto the shaft, or an internal and external rotor simultaneously, dual rotor, creating a high torque option.

Further, the universal core motor may include coil bobbins that are used to insulate and support the independent stator cores. The bobbins can be made from a thermal injection, thermal set plastics, or any other non-electrically conductive material. Further, the coil bobbins are mechanically retained by either Mounting and/or interlocking to an upper and lower plate that may or may not incorporate the rotor bearings.

Further, the present disclosure relates generally to a universal core motor. More specifically, the universal core motor can then be configured as an inner, outer, or dual rotor during the manufacturing process.

FIG. 1 is a disassembled view of a universal core electrical machine 100, in some embodiments. Further, the universal core electrical machine 100 may include a stator 102 and a rotor 104.

Further, the stator 102 may include a plurality of electromagnets 106-116 and a support assembly 118. Further, the plurality of electromagnets 106-116 may be radially disposed around a central axis of the stator 102. Further, each electromagnet of the plurality of electromagnets 106-116 radially extends away from the central axis. Further, each electromagnet may include an inner end and an outer end. Further, a plurality of inner ends

214-224, as shown in FIG. 2, of the plurality of electromagnets 106-116 defines an internal boundary of the stator 102. Further, a plurality of outer ends 202-212, as shown in FIG. 2, of the plurality of electromagnets 106-116 defines an external boundary of the stator 102.

Further, the plurality of electromagnets 106-116 forms an internal space defined by the internal boundary and an external space defined by the external boundary. Further, each electromagnet of the plurality of electromagnets 106-116 may be configured to be independently energized for generating a magnetic flux, as shown in FIG. 4, on the inner end

(such as an inner end 222) and the outer end (such as an outer end 210) of each electromagnet

(such as an electromagnet 114). Further, the support assembly 118 may be configured for radially supporting the plurality of electromagnets 106-116 around the central axis. Further, the support assembly 118 may be configured for allowing independent energizing of each electromagnet by insulating the plurality of electromagnets 106-116. Further, each electromagnet produces independent magnetic flux paths forming the magnetic flux based on the independent energizing. Further, each electromagnet produces equal magnetic flux on each of the inner end and the outer end of each electromagnet. Further, each of the inner end and the outer end may be free.

Further, the rotor 104 may be rotatable in relation to the stator 102. Further, the rotor 104 may include a plurality of rotor magnets concentrically disposed around the central axis in at least one of the internal space and the external space. Further, the plurality of rotor magnets may be configured for rotating around the central axis in relation to the plurality of electromagnets 106-116 based on the generating of the magnetic flux.

Further, in some embodiments, the support assembly 118 may include a plurality of bobbins 1106-1110, as shown in FIG. 11. Further, the plurality of bobbins 1106-1110 may include a plurality of coil bobbins. Further, the plurality of bobbins 1106-1110 may be radially arranged around the central axis. Further, a bobbin 1106 of the plurality of bobbins 1106-1110 may include an interior cavity 1202, as shown in FIG. 12, in an interior of the bobbin 1106 and an exterior cavity 1204, as shown in FIG. 12, on an exterior surface 1206, as shown in FIG. 12, of the bobbin 1106. Further, the bobbin 1106 may be configured for receiving an electromagnet core 1302, as shown in FIG. 13, of an electromagnet of the plurality of electromagnets 106-116 in the interior cavity 1202 and an electromagnet winding of the electromagnet in the exterior cavity 1204. Further, the bobbin 1106 may be comprised of at least one thermal plastic. Further, the bobbin 1106 may be made by molding the at least one thermal plastic. Further, the bobbin 1106 may be configured for holding the electromagnet core 1302 and the electromagnet winding. Further, the electromagnet winding may include electromagnetic wires. Further, the radially supporting of the plurality of electromagnets 106-116 around the central axis may be based on the receiving. Further, in an embodiment, the plurality of bobbins 1106-1110 may be comprised of at least one non- electrically conductive material. Further, the at least one non-electrically conductive material provides insulation between the plurality of electromagnets 106-116 for the insulating of the plurality of electromagnets 106-116. Further, in an embodiment, the support assembly 118 may include at least one of an upper plate 1102, as shown in FIG. 11, and a lower plate 1104, as shown in FIG. 11. Further, at least one of the upper plate 1102 and the lower plate 1104 may be configured for securing the plurality of bobbins 1106-1110 on at least one of the upper plate 1102 and the lower plate 1104 using at least one securing mechanism for retaining the plurality of bobbins 1106-1110 radially around the central axis. Further, the radially supporting of the plurality of electromagnets 106-116 may be based on the securing.

Further, in some embodiments, the plurality of rotor magnets may be concentrically disposed around the central axis in at least one rotor configuration. Further, the plurality of rotor magnets may include a plurality of internal rotor magnets 502-508, as shown in FIG. 5. Further, the plurality of internal rotor magnets 502-508 may be disposed in the internal space in an internal rotor configuration of the at least one rotor configuration. Further, in an embodiment, the plurality of rotor magnets may include a plurality of external rotor magnets 702-708, as shown in FIG. 7. Further, the plurality of external rotor magnets 702-708 may be disposed in the external space in an external rotor configuration of the at least one rotor configuration. Further, in an embodiment, the plurality of rotor magnets may include a plurality of internal rotor magnets 902-908, as shown in FIG. 9, and a plurality of external rotor magnets 910-916, as shown in FIG. 9. Further, the plurality of internal rotor magnets 902-908 may be disposed in the internal space and the plurality of external rotor magnets 910-916 may be disposed in the external space in a dual rotor configuration of the at least one rotor configuration.

Further, in some embodiments, the plurality of electromagnets 106-116 may include six electromagnets. Further, the plurality of rotor magnets may include four rotor magnets.

Further, in some embodiments, the plurality of inner ends 214-224 of the plurality of electromagnets 106-116 forms an inner peripheral side of the stator 102. Further, the plurality of outer ends 202-212 of the plurality of electromagnets 106-116 forms an outer peripheral side of the stator 102. Further, the plurality of electromagnets 106-116 forms the internal space on the inner peripheral side of the stator 102 and the external space on the outer peripheral side of the stator 102.

Further, in some embodiments, the internal space may include a cylindrical space and the external space may include an annular cylindrical space. Further, the cylindrical space and the annular cylindrical space may be coaxial. Further, in an embodiment, the cylindrical space may be associated with an internal diameter and the annular cylindrical space may be associated with an external diameter. Further, the external diameter may be greater than the internal diameter.

Further, in some embodiments, an electromagnet of the plurality of electromagnets

106-116 may include an electromagnet core. Further, the electromagnet core may be comprised of at least one material. Further, the at least one material may include at least one soft magnetic material. Further, the at least one soft magnetic material may include a high silicon Fe-Si alloy.

FIG. 2 is a perspective view of the plurality of electromagnets 106-116 of the stator 102, in accordance with some embodiments.

FIG. 3 is a top view of the plurality of electromagnets 106-116 of the stator 102, in accordance with some embodiments.

FIG. 4 is a top view of the plurality of electromagnets 106-116 and the magnetic flux associated with the plurality of electromagnets 106-116, in accordance with some embodiments.

FIG. 5 is a perspective view of the plurality of electromagnets 106-116 of the stator 102 and the rotor 104 in the internal rotor configuration, in accordance with some embodiments. Further, FIG. 5 is an assembled view of the plurality of electromagnets 106- 116 and the rotor 104. Further, the rotor 104 in the internal rotor configuration may include the plurality of rotor magnets. Further, the plurality of rotor magnets may include the plurality of internal rotor magnets 502-508.

FIG. 6 is a top view of the plurality of electromagnets 106-116 of the stator 102 and the rotor 104 in the internal rotor configuration, in accordance with some embodiments.

FIG. 7 is a perspective view of the plurality of electromagnets 106-116 of the stator 102 and the rotor 104 in the external rotor configuration, in accordance with some embodiments. Further, the rotor 104 in the external rotor configuration may include the plurality of rotor magnets. Further, the plurality of rotor magnets may include the plurality of external rotor magnets 702-708.

FIG. 8 is a top view of the plurality of electromagnets 106-116 of the stator 102 and the rotor 104 in the external rotor configuration, in accordance with some embodiments.

FIG. 9 is a perspective view of the plurality of electromagnets 106-116 of the stator 102 and the rotor 104 in the dual rotor configuration, in accordance with some embodiments. Further, the rotor 104 in the dual rotor configuration may include the plurality of rotor magnets. Further, the plurality of rotor magnets may include the plurality of internal rotor magnets 902-908 and the plurality of external rotor magnets 910-916.

FIG. 10 is a top view of the plurality of electromagnets 106-116 of the stator 102 and the rotor 104 in the dual rotor configuration, in accordance with some embodiments.

FIG. 11 is a perspective view of the support assembly 118 of the stator 102, in accordance with some embodiments. FIG. 12 is a top perspective view of the bobbin 1106 of the plurality of bobbins 1106- 1110, in accordance with some embodiments.

FIG. 13 is a side perspective view of the bobbin 1106 of the plurality of bobbins 1106-1110 with the electromagnet core 1302 of the electromagnet, in accordance with some embodiments. Further, the electromagnet core 1302 may be received in the interior cavity 1202. Further, the bobbin 1106 may be configured for holding the electromagnet core 1302.

FIG. 14 is a perspective view of a plurality of bobbins 1402-1412 of the support assembly 118, in accordance with some embodiments.

FIG. 15 is a side view of the plurality of bobbins 1402-1412 of the support assembly 118, in accordance with some embodiments.

FIG. 16 is a top view of the plurality of bobbins 1402-1412 of the support assembly 118, in accordance with some embodiments.

FIG. 17 is a bottom perspective view of the upper plate 1102 of the support assembly 118, in accordance with some embodiments.

FIG. 18 is a bottom view of the upper plate 1102 of the support assembly 118, in accordance with some embodiments.

FIG. 19 is a top perspective view of the lower plate 1104 of the support assembly 118, in accordance with some embodiments.

FIG. 20 is a top view of the lower plate 1104 of the support assembly 118, in accordance with some embodiments.

FIG. 21 is a disassembled view of a universal core electrical machine 2100, in some embodiments. Further, the universal core electrical machine 2100 may include a stator 2102 and a rotor 2104.

Further, the stator 2102 may include a plurality of electromagnets 2106-2116 and a support assembly 2118. Further, the plurality of electromagnets 2106-2116 may be radially disposed around a central axis of the stator 2102. Further, each electromagnet of the plurality of electromagnets 2106-2116 radially extends away from the central axis. Further, each electromagnet may include an inner end and an outer end. Further, a plurality of inner ends of the plurality of electromagnets 2106-2116 defines an internal boundary of the stator 2102.

Further, a plurality of outer ends of the plurality of electromagnets 2106-2116 defines an external boundary of the stator 2102. Further, the plurality of electromagnets 2106-2116 forms an internal space defined by the internal boundary and an external space defined by the external boundary. Further, each electromagnet of the plurality of electromagnets 2106-2116 may be configured to be independently energized for generating a magnetic flux on the inner end and the outer end of each electromagnet. Further, the support assembly 2118 may be configured for radially supporting the plurality of electromagnets 2106-2116 around the central axis. Further, the support assembly 2118 may be configured for allowing independent energizing of each electromagnet by insulating the plurality of electromagnets 2106-2116. Further, the support assembly 2118 may include a plurality of bobbins. Further, the plurality of bobbins may be radially arranged around the central axis. Further, a bobbin of the plurality of bobbins may include an interior cavity in an interior of the bobbin and an exterior cavity on an exterior surface of the bobbin. Further, the bobbin may be configured for receiving an electromagnet core of an electromagnet of the plurality of electromagnets 2106-2116 in the interior cavity and an electromagnet winding of the electromagnet in the exterior cavity. Further, the radially supporting of the plurality of electromagnets 2106-2116 around the central axis may be based on the receiving.

Further, the rotor 2104 may be rotatable in relation to the stator 2102. Further, the rotor 2104 may include a plurality of rotor magnets concentrically disposed around the central axis in at least one of the internal space and the external space. Further, the plurality of rotor magnets may be configured for rotating around the central axis in relation to the plurality of electromagnets 2106-2116 based on the generating of the magnetic flux.

Further, in some embodiments, the plurality of bobbins may be comprised of at least one non-electrically conductive material. Further, the at least one non-electrically conductive material provides insulation between the plurality of electromagnets 2106-2116 for the insulating of the plurality of electromagnets 2106-2116.

Further, in some embodiments, the support assembly 2118 may include at least one of an upper plate and a lower plate. Further, at least one of the upper plate and the lower plate may be configured for securing the plurality of bobbins on at least one of the upper plate and the lower plate using at least one securing mechanism for retaining the plurality of bobbins radially around the central axis. Further, the radially supporting of the plurality of electromagnets 2106-2116 may be based on the securing.

Further, in some embodiments, the plurality of rotor magnets may be concentrically disposed around the central axis in at least one rotor configuration. Further, the plurality of rotor magnets may include a plurality of internal rotor magnets. Further, the plurality of internal rotor magnets may be disposed in the internal space in an internal rotor configuration of the at least one rotor configuration. Further, in an embodiment, the plurality of rotor magnets may include a plurality of external rotor magnets. Further, the plurality of external rotor magnets may be disposed in the external space in an external rotor configuration of the at least one rotor configuration. Further, in an embodiment, the plurality of rotor magnets may include a plurality of internal rotor magnets and a plurality of external rotor magnets. Further, the plurality of internal rotor magnets may be disposed in the internal space and the plurality of external rotor magnets may be disposed in the external space in a dual rotor configuration of the at least one rotor configuration.

Further, in some embodiments, the plurality of electromagnets 2106-2116 may include six electromagnets. Further, the plurality of rotor magnets may include four rotor magnets.

Further, in some embodiments, the plurality of inner ends of the plurality of electromagnets 2106-2116 forms an inner peripheral side of the stator 2102. Further, the plurality of outer ends of the plurality of electromagnets 2106-2116 forms an outer peripheral side of the stator 2102. Further, the plurality of electromagnets 2106-2116 forms the internal space on the inner peripheral side of the stator 2102 and the external space on the outer peripheral side of the stator 2102.

Although the present disclosure has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the disclosure.

Claims

What is claimed is:

1. A universal core electrical machine comprising: a stator comprising: a plurality of electromagnets radially disposed around a central axis of the stator, wherein each electromagnet of the plurality of electromagnets radially extends away from the central axis, wherein each electromagnet comprises an inner end and an outer end, wherein a plurality of inner ends of the plurality of electromagnets defines an internal boundary of the stator, wherein a plurality of outer ends of the plurality of electromagnets defines an external boundary of the stator, wherein the plurality of electromagnets forms an internal space defined by the internal boundary and an external space defined by the external boundary, wherein each electromagnet of the plurality of electromagnets is configured to be independently energized for generating a magnetic flux on the inner end and the outer end of each electromagnet; and a support assembly configured for radially supporting the plurality of electromagnets around the central axis, wherein the support assembly is configured for allowing independent energizing of each electromagnet by insulating the plurality of electromagnets; and a rotor rotatable in relation to the stator, wherein the rotor comprises a plurality of rotor magnets concentrically disposed around the central axis in at least one of the internal space and the external space, wherein the plurality of rotor magnets is configured for rotating around the central axis in relation to the plurality of electromagnets based on the generating of the magnetic flux.

2. The universal core electrical machine of claim 1, wherein the support assembly comprises a plurality of bobbins, wherein the plurality of bobbins are radially arranged around the central axis, wherein a bobbin of the plurality of bobbins comprises an interior cavity in an interior of the bobbin and an exterior cavity on an exterior surface of the bobbin, wherein the bobbin is configured for receiving an electromagnet core of an electromagnet of the plurality of electromagnets in the interior cavity and an electromagnet winding of the electromagnet in the exterior cavity, wherein the radially supporting of the plurality of electromagnets around the central axis is based on the receiving.

3. The universal core electrical machine of claim 2, wherein the plurality of bobbins are comprised of at least one non-electrically conductive material, wherein the at least one non-electrically conductive material provides insulation between the plurality of electromagnets for the insulating of the plurality of electromagnets.

4. The universal core electrical machine of claim 2, wherein the support assembly further comprises at least one of an upper plate and a lower plate, wherein at least one of the upper plate and the lower plate is configured for securing the plurality of bobbins on at least one of the upper plate and the lower plate using at least one securing mechanism for retaining the plurality of bobbins radially around the central axis, wherein the radially supporting of the plurality of electromagnets is further based on the securing.

5. The universal core electrical machine of claim 1, wherein the plurality of rotor magnets are concentrically disposed around the central axis in at least one rotor configuration, wherein the plurality of rotor magnets comprises a plurality of internal rotor magnets, wherein the plurality of internal rotor magnets are disposed in the internal space in an internal rotor configuration of the at least one rotor configuration.

6. The universal core electrical machine of claim 5, wherein the plurality of rotor magnets comprises a plurality of external rotor magnets, wherein the plurality of external rotor magnets are disposed in the external space in an external rotor configuration of the at least one rotor configuration.

7. The universal core electrical machine of claim 5, wherein the plurality of rotor magnets comprises a plurality of internal rotor magnets and a plurality of external rotor magnets, wherein the plurality of internal rotor magnets are disposed in the internal space and the plurality of external rotor magnets are disposed in the external space in a dual rotor configuration of the at least one rotor configuration.

8. The universal core electrical machine of claim 1, wherein the plurality of electromagnets comprises six electromagnets, wherein the plurality of rotor magnets comprises four rotor magnets.

9. The universal core electrical machine of claim 1, wherein the plurality of inner ends of the plurality of electromagnets forms an inner peripheral side of the stator, wherein the plurality of outer ends of the plurality of electromagnets forms an outer peripheral side of the stator, wherein the plurality of electromagnets forms the internal space on the inner peripheral side of the stator and the external space on the outer peripheral side of the stator.

10. The universal core electrical machine of claim 1, wherein the internal space comprises a cylindrical space and the external space comprises an annular cylindrical space, wherein the cylindrical space and the annular cylindrical space are coaxial.

11. The universal core electrical machine of claim 10, wherein the cylindrical space is associated with an internal diameter and the annular cylindrical space is associated with an external diameter, wherein the external diameter is greater than the internal diameter.

12. The universal core electrical machine of claim 1, wherein an electromagnet of the plurality of electromagnets comprises an electromagnet core, wherein the electromagnet core is comprised of at least one material, wherein the at least one material comprises at least one soft magnetic material, wherein the at least one soft magnetic material comprises a high silicon Fe-Si alloy.

13. A universal core electrical machine comprising: a stator comprising: a plurality of electromagnets radially disposed around a central axis of the stator, wherein each electromagnet of the plurality of electromagnets radially extends away from the central axis, wherein each electromagnet comprises an inner end and an outer end, wherein a plurality of inner ends of the plurality of electromagnets defines an internal boundary of the stator, wherein a plurality of outer ends of the plurality of electromagnets defines an external boundary of the stator, wherein the plurality of electromagnets forms an internal space defined by the internal boundary and an external space defined by the external boundary, wherein each electromagnet of the plurality of electromagnets is configured to be independently energized for generating a magnetic flux on the inner end and the outer end of each electromagnet; and a support assembly configured for radially supporting the plurality of electromagnets around the central axis, wherein the support assembly is configured for allowing independent energizing of each electromagnet by insulating the plurality of electromagnets, wherein the support assembly comprises a plurality of bobbins, wherein the plurality of bobbins are radially arranged around the central axis, wherein a bobbin of the plurality of bobbins comprises an interior cavity in an interior of the bobbin and an exterior cavity on an exterior surface of the bobbin, wherein the bobbin is configured for receiving an electromagnet core of an electromagnet of the plurality of electromagnets in the interior cavity and an electromagnet winding of the electromagnet in the exterior cavity, wherein the radially supporting of the plurality of electromagnets around the central axis is based on the receiving; and a rotor rotatable in relation to the stator, wherein the rotor comprises a plurality of rotor magnets concentrically disposed around the central axis in at least one of the internal space and the external space, wherein the plurality of rotor magnets is configured for rotating around the central axis in relation to the plurality of electromagnets based on the generating of the magnetic flux.

14. The universal core electrical machine of claim 13, wherein the plurality of bobbins are comprised of at least one non-electrically conductive material, wherein the at least one non-electrically conductive material provides insulation between the plurality of electromagnets for the insulating of the plurality of electromagnets.

15. The universal core electrical machine of claim 13, wherein the support assembly further comprises at least one of an upper plate and a lower plate, wherein at least one of the upper plate and the lower plate is configured for securing the plurality of bobbins on at least one of the upper plate and the lower plate using at least one securing mechanism for retaining the plurality of bobbins radially around the central axis, wherein the radially supporting of the plurality of electromagnets is further based on the securing.

16. The universal core electrical machine of claim 13, wherein the plurality of rotor magnets are concentrically disposed around the central axis in at least one rotor configuration, wherein the plurality of rotor magnets comprises a plurality of internal rotor magnets, wherein the plurality of internal rotor magnets are disposed in the internal space in an internal rotor configuration of the at least one rotor configuration.

17. The universal core electrical machine of claim 16, wherein the plurality of rotor magnets comprises a plurality of external rotor magnets, wherein the plurality of external rotor magnets are disposed in the external space in an external rotor configuration of the at least one rotor configuration.

18. The universal core electrical machine of claim 16, wherein the plurality of rotor magnets comprises a plurality of internal rotor magnets and a plurality of external rotor magnets, wherein the plurality of internal rotor magnets are disposed in the internal space and the plurality of external rotor magnets are disposed in the external space in a dual rotor configuration of the at least one rotor configuration.

19. The universal core electrical machine of claim 13, wherein the plurality of electromagnets comprises six electromagnets, wherein the plurality of rotor magnets comprises four rotor magnets.

20. The universal core electrical machine of claim 13, wherein the plurality of inner ends of the plurality of electromagnets forms an inner peripheral side of the stator, wherein the plurality of outer ends of the plurality of electromagnets forms an outer peripheral side of the stator, wherein the plurality of electromagnets forms the internal space on the inner peripheral side of the stator and the external space on the outer peripheral side of the stator.