WO2022003658A1

WO2022003658A1 - Stator with magnetic disc coils suitable for dc three-phase electric motors

Info

Publication number: WO2022003658A1
Application number: PCT/IB2021/057890
Authority: WO
Inventors: Mahdi FAHIMI
Original assignee: Fahimi Mahdi
Priority date: 2020-06-28
Filing date: 2021-08-28
Publication date: 2022-01-06

Abstract

The stator discs with disk magnetic quines instead of a permanent magnet, reduce the production of heat from rotor rotation, which includes a circular arrangement and these circular shape arrays with equal intervals are parallel to the rotor and on the central diameter of the rotor and separated by small and equal air gaps and the coils between layer and discs provides the ability to produce a sinusoidal wave without distortion.

Description

Stator with magnetic disc coils suitable for DC three-phase electric motors

DC commutator motors or generators having mechanical commutator; Universal AC/DC commutator motors (H02K 23/00) - Arrangements for controlling synchronous motors or other dynamo-electric motors using electronic commutation dependent on the rotor position; Electronic commutators therefor (H02P 6/00)

It has been a long time since the discovery of the law of induction by the English physicist Michael Faraday in 1831 and the American inventor Thomas Davenport who obtained the first patent for the DC electric motor in the United States (1837-132USA). Nikola Tesla of Serbia (1886 – US 0382280) Frank Spree of the United States (1886 – the USA) and Mikhail Dolio Dobrowolski of the Polish engineer who built the first cage-rotor motor in three-phase induction motors in 1889.

Significant progress was made in this area until the English inventor Cedric Lynch succeeded in building a unique motor with a permanent magnet shaft and commutator and a graphite charcoal brush system in 1979, which is the patent of December 18, 1986. The Lynch electromotor could reach 70% efficiency. The motor was made of F-shaped blocks that were placed between metal strips instead of the usual copper coil windings and were held together perfectly by magnets. In 1989, Lynch, with the help of Richard Fletcher and his project team, William Ride of London's innovation network LIN, built a DC electric motor that produced 15 horsepower (11 kW). In the design of Lynch engine armature, iron laminates are made of narrow rectangular pieces arranged in parallel to form a complete circular ring. Since the magnetic flux passes only through the laminates along an axis, insulating materials (Charlock) can be used, which are commonly used in large transformers.

The Lynch motor has a rotating armature located between two banks of eight fixed magnets on a spindle. There are also eight brushes (four negatives, four positive) on the front that allow electricity to flow from the power source to the armature. The design of motor lynch reinforcement is significantly different from other types of motors. Reinforcement coils consist of U-shaped insulated copper strips like an adjusting fork. One leg is then bent 45 degrees clockwise, while the other leg is bent 45 degrees counterclockwise. Before reaching the end of the armature, each coil base has several bends so that it can pass through the ferrite ring radially before the end of the 90-degree end. The outer edge of each copper strip has a hook that rotates 90 degrees with a 90-degree connection. The inner edge of the copper strips is just the insulation on the front that forms the traffic surface and the brushes are placed in it. Between each copper, coil bases are pieces of iron ferrite cores and the insulation formed by the ferrite ring. The ferrite ring carries the magnetic flux between the fixed magnets without the need to use copper strips to conduct electricity. As the armature rotates, current flows from a brush into the cylinder outward along one end of a copper coil. The electric current then reaches the center 90 degrees later and before reaching the corresponding brush from the opposite electric polarity of 135 degrees from the initial brush to the front. In traditional radial electric motors, it can not be easily aligned with the direction of the magnetic field, but in Lynch axial motors, it leads to higher efficiency.

In 1992, Lynch, in collaboration with Lemco, was able to build a DC electromotor without commutators and charcoal, but the biggest drawback of the Lynch electromotor was its high volume and weight, and of course, its high electrical energy consumption.

In 1994, Hanselman completed the design of a brushless permanent magnet motor in McGraw Hill, New York, and the world's first electric helicopter, powered by a BLDC electric motor, was designed and flown by Pascal Curtin. The helicopter broke the Guinness Book of World Records on August 12, 2011, and received the IDTechEx Land Sea & Air Electric Vehicle Award in 2012.

Cedric Lynch (European patent EP0230759 A1, German patent DE3679802 D1, US patent 4823039)

With all these advances, DC electric motors are all single-phase, and this disclosure is related to the first three-phase DC electric motor, which is designed with disk-shaped magnetic coils.

Brushless DC motor

United States Patent 6975050

A system and method for reducing the cost of producing a brushless DC motor are presented. The brushless DC motor provides higher power density and efficiency with an increased tool run time. The brushless DC motor includes a rotor assembly that has an unmagnetized permanent magnet affixed to a shaft. The permanent magnet remains unmagnetized until the motor is partially assembled. A plurality of coils for producing a magnetic field is wound about the rotor assembly. The coils include end turns that enclose the rotor assembly such that the rotor assembly is not removable. Since the windings are wound with the rotor assembly already enclosed, the windings do not require large end coils to allow subsequent insertion of the rotor. Minimizing the end coils reduces the length of wire required per turn, thereby reducing the resistance of the winding. Also, since the permanent magnet is unmagnetized when the coils are wound around the rotor assembly the winding process is simplified by not coupling energy into the wire which would influence the winder operation. The wound assembly is inserted into a stator stack comprised of magnetic material that provides a magnetic flux return path for the magnetic flux generated by the permanent magnet. Using an unmagnetized permanent magnet facilitates easy insertion of the wound assembly into the stator stack, reduces the accumulation of magnetic debris during the manufacturing process, and permits the motor assembly to be sealed before magnetizing the permanent magnet.

The design mentioned uses a permanent magnet, but the purpose of my design is a disk-shaped stator piece with disk magnetic coils instead of a permanent magnet.

Brushless DC drive motor with external rotor for use in disc drives and like devices

United States Patent 5652470

A brushless DC drive motor with an external rotor has three pole shoes on a substantially ring-shaped stator for every two poles on the rotor. The stator winding is commutated by a three-phase commutation network in such a fashion that the first, second, and third networks in the stator winding are cyclically connected to an external DC source by rotor position. Each of the networks comprises at least one stator coil wrapped around a neck of a single corresponding one of the pole shoes.

Brushless three-phase dc motor

United States Patent 5834873

A three-phase brushless dc motor includes a permanent-magnet rotor magnet arrangement having at least four poles and a Y-connected, or star-connected, three-phase stator winding. The winding's phases are arranged non-overlapping in slots of a slotted stator, the currents flowing in the three phases being controlled via at least three semiconductor elements by at least three magnetic-field-sensitive rotor position sensors. Each sensor is associated with a respective two of the winding's three phases and triggers a commutation that switches off the current in one of the associated two phases and switches on the current in the other of the associated two phases. The sensors are located to sense the permanent-magnet flux emanating from the rotor poles themselves. The rotor position sensors are provided at special angular locations on the stator.

This invention is related to the field of DC electric motors and can be used with high power and low energy consumption with point-to-point control capability in the construction of high-power generators, electric motorcycles, and all-electric vehicles. Electromotors control their peak efficiency by changing the switching time between the magnets (changing the poles S and N). This timing is traditionally adjusted at the time of switching by changing the frequency of the drive (controller) circuit, so a change in the speed and power of the electromotor reduces the peak performance of the device. The purpose of the invention is to stabilize the power and strength of the electric motor even at low speeds to increase efficiency, which is achieved by designing disk-shaped magnetic coils and independent windings with a three-phase DC design.

Electric motors control their peak efficiency by changing the switching time between the magnets (changing poles S and N). This timing is traditionally adjusted at the time of switching by changing the frequency of the drive (controller) circuit, so a change in the speed and power of the electromotor reduces the peak performance of the device. The purpose of the invention is to stabilize the power and the power of the motor even at low speeds to increase efficiency, which is achieved by designing disk-shaped magnetic coils and independent windings with a three-phase DC design. In addition, the problems caused by the direct connection of the current with the rotating armature have been eliminated. According to the history of previous technical knowledge, the design of disk-shaped magnetic coils in the invention and the design of three-phase independent windings in advancing the technical knowledge of BLDC electromotors is an important step in eliminating previous problems and ultimately outstanding advantages such as:

Low energy consumption at high powers compared to previous technologies
Reduce magnetic force losses and reduce heat production
Low volume and light
Able to produce effective torque within the defined power range
Lack of brush system and commutator and reduction of friction losses
Able to produce effective power in all increased cycles (RPM range)
Easily controllable by electronic controllers.

Solution of problem

Electric motors usually consist of a stator and a rotor that can be placed in an enclosure. The rotor creates a magnetic field near the stator. The stator creates magnetic field disturbances by moving the rotor to a position that minimizes magnetic field disturbances. The rotor consists of a series of permanent magnets attached to the shaft. The stator may be of a series of coils connected to the harness. The rotor consists of a series of permanent magnets attached to the shaft. The stator may be of a series of coils connected to the harness. The restraint can accommodate a bearing to ensure that the rotor can rotate to minimize magnetic field disturbances.

main problem:

1 These types of electric motors provide maximum torque at standstill; This torque decreases linearly with increasing speed. 2 The thermal energy from the rotation of the rotor weakens the magnetic strength of the permanent magnets, which reduces the power of the DC motor, and 3 Inability to limit or control engine speed.

Solution: This electromotor uses low-volume, high-volume disc-shaped magnetic coils (152) enclosed in an aluminum enclosure included. This aluminum coating acts as a heatsink in which the heat loss is very small. This configuration, while increasing the output power, provides high efficiency, the ability to maintain or combine with electrical devices, reducing weight and size.

In this invention, it is possible to control one or more coils independently, if less torque is needed, parts can be turned off using the control circuit. These circuits are capable of controlling at least 70% of one or more magnetic coils. Some are set up to allow the electrical device to control at least 60% of the coil independently.

Control circuit: It is a switching oscillator or (high-frequency oscillator circuit) and is formed using MOSFET (111) and inductor (88) transistors which have inductive properties (111) MOSFET transistor Tr 1 Tr 2 (IRF540N) - (88) 60 Microhenry inductor (112) Abrupt reactor diode and LM566CN IC, electrochemical capacitors and rectifier diode bridge, resistor and Zener diode are other elements used in voltage controlled oscillator circuit.

One of the most important requirements of any voltage-controlled oscillator in a phase-locking loop is that the voltage-frequency curve is monotonic. In other words, this curve must change in the same way, usually as the voltage increases, the frequency increases. Sometimes in some specimens and as a result of Spurious Resonances, this uniformity may not be present, which makes the ring unstable. For this reason, for this to work properly, this phase must be prevented.

To adjust the oscillator, changing the resonance point in the circuit is very necessary, which is the best way to achieve this goal by adding a capacitor at both ends of the inductor. In this circuit, inductive reactance is located between the base and the ground, so compared to other configurations of oscillating circuits, it is not at risk of problems such as false oscillation and other anomalies.

The current disclosure uses 18 oscillator circuits controlled by two microcomputers (113) MCUs are driven in a standard master-slave configuration in which a motor control unit is connected to only one common communication bus or several coil control units. MCU uses an ATMEGA 64 programmer IC and in its programming, the calculated sequences include:

1 Sequence-based activation (coils are toggled in rotational mode with alternating polarity, respectively)

2 Optimal force activation (coils are activated when their single feedback data indicates the application of the desired force to the rotor)

3 Optimal efficiency activation (coils are activated in such a way as to minimize the motor dynamics of power consumption)

4 Dynamic reduction of the number of active coils (less power per torque)

5 Dynamic reduction of active coil power percentage (smoother torque)

6 pulse width modulation of the coil signal for the possibility of precise control of the power applied to the coils

By generating a frequency by the oscillator and generating a magnetic charge that is placed through the inductor (88) at a certain distance from the disk-shaped magnetic coils, the electromotor starts to move. A DC to DC converter circuit is used to power the electric motor.

The diameter and length of the lacquered copper wire used in the above coils are calculated for electromotor power of 4200 watts and 60 volts of DC direct current. These values are variable to design and construct electromotors with higher power and 100%.

Armiger axis (10) with a metal plate (15) on which two holes (28) embedded by the screw and metal pin (16) to an aluminum shell (17) is quite fixed and the five rows of stator coil-shaped magnetic disk (152) with an 8 mm distance by metal plates (8), which are embedded in two different types (95 and 94) in two types of ball bearings. Stators are tightened by six loud bolts (6). At the end and the beginning of these five rows of a stator, two types (97), which are fixed with metal plates on the shell with metal pin (88), have been used for fluid rotation.

The number of seventeen small symmetrical coils (129) and (5) with insulation (9) on each stator are accurate and regular with aerial distance (7) and the electrical wires are transmitted to the initial controller circuit (113) through two gaps (46 and 44), which was longitude on the axis (10). The electrical connection of the stators is established by printed circuit fibers (37) and platinum placed on insulating plates (38) designed and manufactured for this purpose.

Longitudinal grooves (31) are designed on the shell of the electric motor (17) which are responsible for cooling (Heatsink) with regular air distance. (33) Part of the crust has the basis of the engine that is embedded behind the terminal (27) of the DC power input. This special configuration creates high and stable torque in all rounds (RPMs) for electromotor.

The coil used instead of permanent magnets can have different forms. For example, cubic, trapezoid, or other forms may be appropriate. But to get a smooth and stable torque, the design of the inter-layer coil and the discs of the shape is important for the production of smooth sine wave output. Also, Micro Stepped makes it possible to control the slow-motion of the electromotor.

Advantage effects of invention

One of the advantages of this special motor is the cost reduction by reducing the amount of copper used in the coils and the size required to be placed in them. For example, the weight of a copper coil in an electric motor is proportional to the magnitude of the current; the larger the current, the heavier the wire. This relationship is not linear, but it is quadratic. In the electromotor in question, each coil or (although independent) monitors a relatively small amount of current with a large number of small magnetic coils.

This electric motor uses less copper wire, where the loss of resistance power is substantially equal to the loss of resistance power of a motor similar to coils. The copper stored in proportion to the number of CN of coils in this motor relative to the number of DN of coils in pre-made electric motors is proportional to the potential cost savings.

In this electric motor, the invention requires five times fewer copper wires than a three-phase electric motor with a permanent magnet of similar power. Having five times fewer wires reduces the amount of iron core needed to inflate the wires around them. As a result, the entire unit can be mounted in a much smaller chamber, further reducing the weight of the material. If the body of an electric motor is made of a good conductor such as aluminum, it can be used as a coolant, and in addition, the mass of the materials used is reduced. A weight that is reduced by at least 20%. Another special advantage can be the configuration to continuously optimize the coil time, for example, if the sum of more than the entire operating area of an electric motor, provides a maximum savings of up to 40%. The number of coils and the number of magnetic coils is a constant area of operation of the electric motor. In the axial configuration, certain visualizations of the current disclosure can reduce the total number of permanent magnets by at least 25%. The overall savings rate increases with the number of rotors required. This can be achieved by sharing a common rotor and using both rotor magnetic fields instead of one.

: This figure shows a longitudinal cross-sectional view of an electric motor subject to the invention.

: This figure shows an incomplete view of one side of the disc stator of a three-phase DC electric motor.

: This defective surface view of the other side of the electric motor disc stator shows the subject of the invention.

: This figure shows the partial shear view of the electromagnetic coils.

: This figure shows a schematic diagram of three-phase DC electromotor electronic systems.

: This figure shows a schematic overview of a plotter rotor and the coil configuration according to the specific claim.

: This figure shows a complete configuration of .

: This figure is a cross-sectional view of the linear arrangement of the body and the winding configuration shown in the figure. This figure shows the geometric arrangement of the coils in the stator.

: This figure shows the configuration of the control circuit of the electric motor coils.

: This figure shows the configuration in which a motion control unit is connected to one or more coil control units and is connected to a common communication bus.

: This figure shows the force-torque comparison diagram of the invention.

: 1.Shape cut from longitudinal section 2. Disc connection base 3. Thin insulation between disc-shaped plates 4. Disc-shaped plate 5. Asymmetric screw wires 6. Oscillator circuit screw holder 7. Air distance of oscillating circuit transistors 8. Plates metal separator of magnetic disks 9. Insulation between metal plates 10. Middle Axis 11. Wired Third Floor Round Axis 12. Wired Second Floor Round Axis 13. Wired First Floor Round Axle 14. Metal Pins Metal Plates Separating Magnetic Discs 15. Main Metal Sheet Bottom 16. Metal screws 17. Aluminum shell 18. Insulation base between the third-floor plates 19. Insulation base between the second-floor plates 20. Insulation base between the first-floor plates 21. Longitudinal gap groove of the terminal base 22. Fixing piece of the bearing base with the shell 23. Bearing stand 24. Electromotor upper door holder screw 25. Shaft bearing 26. Metal plate fastening piece 27. Power input terminal base 28. Lower main metal screw hole 29. Power input cable 30. Input power connection socket 31. Longitudinal grooves of aluminum shell 32. Holes of disc-shaped plates 33. The lateral base of the engine

: 4. Disc-shaped plate 5. Asymmetric screw wires 6. Oscillator circuit screw holder 7. Air distance of oscillating circuit transistors 33. The lateral base of the engine 34. First-floor disc plate fiber 35. Second-floor disc plate fiber 36. Disc plate adjustment holes Figure- 37. Printed fiber 38. Insulation plates 39. Asymmetric coil connection socket 44. Main input wire slot 45. Symmetric coil connection socket 46. Main input wire slot

: 5. Asymmetric screw wires 6. Oscillator circuit screw holder 7. Air distance of oscillating circuit transistors 8. Plates metal separator of magnetic disks 9. Insulation between metal plates 10. Middle Axis 94. Small ball bearings 95. Large ball bearings 96. Asymmetric coil wires 97. Bearings 98. Symmetric and asymmetrical coil plate circuit 129. Symmetric coil wires

: 94. Small ball bearings 95. Large ball bearings 102. A connection point of S coils 103. A connection point of N coils

: 8. Plates metal separator of magnetic disks 88. Metal pin in the middle of the coil on the oscillator circuit 94. Small ball bearings 95. Large ball bearings 113. (Primary control circuit)MCU 114. Oscillator (high and variable voltage oscillator circuit)

: 5. Asymmetric screw wires 6. Oscillator circuit screw holder 7. Air distance of oscillating circuit transistors 8. Plates metal separator of magnetic disks 9. Insulation between metal plates 10. Middle Axis 135. Three-phase fixed coils 137. Symmetrical coil bases 147. Thin insulation plate between the first and second-floor magnetic disc coils 148. Thin insulation plate between second and third-floor magnetic disk coil 149. Magnetic disk coil first floor 150. Second-floor magnetic disk coil 151. Magnetic disc coil third floor 152. Triangular grooves on disc plates (with cooling capability when rotating) 153. A set of disk-shaped magnetic coils

: 10. Middle Axis 149. Magnetic disk coil first floor 150. Second-floor magnetic disk coil 151. Magnetic disc coil third floor 153. A set of disk-shaped magnetic coils

: 94. Small ball bearings 95. Large ball bearings 102. A connection point of S coils 103. A connection point of N coils 105 - 106 - 107 - 108. The linear arrangement of windings and geometric arrangement of stator coils

: 88. Metal pin in the middle of the coil on the oscillator circuit 111. Transistor 112.Quick diode 113. MCU (Primary control circuit) 114. Oscillator (high and variable voltage oscillator circuit)

: 100: Frequency range 130. The amount of rotor movement at rest and peak 132.Frequency waveform 134.Rotor 135. Three-phase fixed screw wires

: This figure shows the force-torque comparison diagram of the invention.

Examples

Today's electric motorcycles usually use a type of electric motor called a HUB MOTOR. These motors are installed in the center of the rear wheel of the motorcycle and fact the motor shell is the same wheel and therefore the motor power is limited to the central diameter of the wheel. This restriction has caused most electric motorcycle manufacturers to consider the maximum power (motor hubs) from 2000 watts to 2500 watts. These types of engines to build any motorcycle model must have a special design that creates high costs in the cost price. Also, low power (motor hubs) has caused people to look at this type of motorcycle through the eyes of toys and distort the culture of using clean energy. Also, high energy consumption in these motors causes loss of battery charge in a very short time and increases the long charging time and high battery consumption.

All of the above problems have been eliminated in the motorcycle model, which is made with a three-phase DC electric motor and has practically eliminated the unevenness of producing electric motorcycles with very high force-torque and low energy consumption. Power transmission in this type of motorcycle is done by timing belts. In this type of power transmission, according to the simple law of wheels and axles, with a three-phase electric motor (with constant power), more than five types of electric motorcycles can be designed in different powers with different speeds. Also, the use of this type of electric motor in the construction of electric motorcycles produces high power, appropriate speed, and minimum energy consumption for the user, and this promotes a culture of using clean energy. (The three-phase electric motor made for electric motorcycles has a power of 4200 watts, which can be increased).

This type of electric motor for many reasons (clean energy, low volume, high power, low energy consumption, and torque control) in various industries, especially in transportation (electric cars, electric buses, and electric motorcycles) and industrial engineering (factory production line) can be used. The application of BLDC three-phase electric motors in industries focuses on production engineering or industrial automation. Ideally suited for manufacturing applications due to their high power, density, speed characteristic, good torque, high efficiency, and low maintenance cost.

Claims

The stator discs with disk magnetic quines instead of a permanent magnet, reduce the production of heat from rotor rotation, which includes a circular arrangement of electromagnetic simulates.
According to claim 1, circular shape arrays with equal intervals are parallel to the rotor and on the central diameter of the rotor, and separated by small and equal air gaps.
According to claim 1 and 2, the coils between layer and discs provides the ability to produce a sinusoidal wave without distortion.
According to claim 1, It is possible to control the air temperature inside the motor, consisting of stators with disc magnetic coils instead of permanent magnets.