TRANSVERSE FLUX ELECTRICAL MACHINE STATOR COMPONENTS
A phase module of a transverse flux electrical machine (TFEM) includes a pair of halves adapted to receive therein a plurality of cores and a coil therein. The cores are discretely located in the phase with radially angularly distributed core-receiving spaces. The plurality of cores and the coil are secured in the halves with resin. The proximal radial portion of the phase module is bored to define the interior diameter of the phase module. A method of assembling a phase module and a kit thereof are encompassed by the present application.
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The present invention relates to, claims priority from and is a non-provisional patent application of U.S. Provisional Patent Application No. 61/704,793, filed Sep. 24, 2012, entitled MODULAR TRANSVERSE FLUX ELECTRICAL MACHINE, these documents are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION1. Field of the Invention
This invention relates generally to transverse flux electrical machines. The present invention more specifically relates to transverse flux alternators and motors assembly.
2. Description of the Related Art
Alternators and motors are used in a variety of machines and apparatuses to produce electricity from mechanical movements. They find applications for energy production and transportation, to name a few. Alternators and motors can use Transverse Flux Permanent Magnet (TFPM) technologies.
Transverse flux machines with permanent magnet excitation are known from the literature, such as the dissertation by Michael Bork, Entwicklung und Optimierung einer fertigungsgerechten Transversalfluβmaschine [Developing and Optimizing a Transverse Flux Machine to Meet Production Requirements], Dissertation 82, RWTH Aachen, Shaker Verlag Aachen, Germany, 1997, pages 8 ff. The circularly wound stator winding is surrounded by U-shaped soft iron cores (yokes), which are disposed in the direction of rotation at the spacing of twice the pole pitch. The open ends of these U-shaped cores are aimed at an air gap between the stator and rotor and form the poles of the stator. Facing them, permanent magnets and concentrators are disposed in such a way that the magnets and concentrators that face the poles of a stator core have the opposite polarity. To short-circuit the permanent magnets, which in the rotor rotation are intermittently located between the poles of the stator and have no ferromagnetic short circuit, short-circuit elements are disposed in the stator.
Put otherwise, transverse flux electrical machines include a circular stator and a circular rotor, which are separated by an air space called air gap, that allows a free rotation of the rotor with respect to the stator, and wherein the stator comprises soft iron cores, that direct the magnetic flux in a direction that is mainly perpendicular to the direction of rotation of the rotor. The stator of transverse flux electrical machines also comprises electrical conductors, defining a toroid coil, which is coiled in a direction that is parallel to the direction of rotation of the machine. In this type of machine, the rotor comprises a plurality of identical permanent magnet parts, which are disposed so as to create an alternated magnetic flux in the direction of the air gap. This magnetic flux goes through the air gap with a radial orientation and penetrates the soft iron cores of the stator, which directs this magnetic flux around the electrical conductors.
In the transverse flux electrical machine of the type comprising a rotor, which is made of a plurality of identical permanent magnet parts, and of magnetic flux concentrators, the permanent magnets are oriented in such a manner that their magnetization direction is parallel to the direction of rotation of the rotor. Magnetic flux concentrators are inserted between the permanent magnets and redirect the magnetic flux produced by the permanent magnets, radially towards the air gap.
The transverse flux electrical machine includes a stator, which comprises horseshoe shaped soft iron cores, which are oriented in such a manner that the magnetic flux that circulates inside these cores, is directed in a direction that is mainly perpendicular to the axis of rotation of the rotor.
The perpendicular orientation of the magnetic flux in the cores of the stator, with respect to the rotation direction, gives to transverse flux electrical machines a high ratio of mechanical torque per weight unit of the electrical machine.
It is therefore desirable to produce an electrical machine that is easy to assemble. It is also desirable to provide an electrical machine that is economical to produce. Other deficiencies will become apparent to one skilled in the art to which the invention pertains in view of the following summary and detailed description with its appended figures.
It is one aspect of the present invention to alleviate one or more of the shortcomings of background art by addressing one or more of the existing needs in the art.
The following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the invention. It is not intended to identify key/critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented later.
Generally, an object of the present invention provides a modular Transverse Flux Electrical Machine (TFEM), which can also be more specifically appreciated as Transverse Flux Permanent Magnet (TFPM), which includes phase modules thereof.
An object of the invention is generally described as a modular electrical machine including a plurality of phase modules adapted to be axially assembled.
Generally, an object of the invention provides a TFEM including a plurality of phase modules assembled together with an intervening phase shift generally set at 120° [electrical] to provide standard symmetrical electric current overlapping over a complete 360° electrical cycle. A two-phases electrical machine would have a 90° phase shift and would use a similar logic and is also encompassed by the present invention.
One object of the invention provides at least one phase module including cooperating halves.
At least one object of the invention provides at least one phase module including a plurality of cores, and associated poles, angularly spaces apart from one another with different angular distances therebetween.
At lease one aspect of the invention provides at least one phase including at least three adjacent cores, and associated poles, angularly distanced apart with a substantially similar angular distance therebetween and each at least three adjacent cores being further angularly spaced apart from an adjacent at least three adjacent cores, and associated poles, with a different angular distance thereof.
At least one aspect of the invention provides at least two adjacent cores, and associated poles, angularly radially separated with an angle of 10.8° and angularly radially separated from adjacent cores with at least one significantly different angle.
At least one object of the invention provides a set of poles, and intervening angular distance therebetween, that is repeated at least two times in a phase to locate the poles in the phase module.
At least one object of the invention provides a modular TFEM including a plurality of phase modules axially secured together by opposed support portions.
At least one aspect of the invention provides a phase module including a plurality of identical angular portions thereof.
At least one aspect of the invention provides a plurality of angular portions having intervening locating mechanism thereof adapted to locate and secure adjacent angular portions together.
At least one aspect of the invention provides an angular portion including a wire opening thereof adapted to receive therein coil wires extending outside the phase module.
At least one object of the invention provides a TFEM including a stator skewing angularly locating cores therein in respect with the rotation axis of the TFEM.
At least one object of the invention provides a plurality of phase modules including a cooperating positioning mechanism thereof adapted to mechanically angularly locate adjacent phase modules axially assembled together.
At least one aspect of the invention provides at least one phase module including a plurality of core-receiving spaces thereof.
At least one aspect of the invention provides at least one phase module including a housing including a circumferential cavity adapted to receive therein a cooperating portion of the cores to further mechanically radially locate and secure the cores to the phase module housing.
At least one object of the invention provides a phase modules including a plurality of angular portions adapted to be sequentially assembled together to allow inserting a coil therein before all the angular portions are assembled together.
At least one object of the invention provides a phase module including a plurality of angular portions configured to allow insertion of a coil therein when the assembled angular portions are angularly covering less than 200°.
At least one object of the invention provides a TFEM stator including resin therein for securing the coil and the cores inside the angular portions and also to maintain them in their respective locations when the internal portion of the phase module is machined, bored or honed.
At least one object of the invention provides a TFEM stator including injected resin therein for securing the angular portions together with the coil.
At least one object of the invention provides a rotatable transverse flux electrical machine (TFEM) comprising a stator including at least one phase, the at least one phase module comprising a pair of opposed halve members respectively including a plurality of core-receiving spaces sized and designed to receive, locate and secure therein a plurality of cores; and a coil operatively disposed in respect with the cores inside each phase modules.
At least one object of the invention provides a method of assembling a phase of a rotatable transverse flux electrical machine (TFEM), the method comprising assembling a plurality of cores in respective cores-receiving spaces radially disposed in a first halve member; assembling a coil in an operating position with the plurality of cores; assembling a second halve member with the first halve member; and injecting resin between the assembled halves to secure the plurality of cores and the coil in the phase.
At least one object of the invention provides a kit for assembling a phase in a rotatable transverse flux electrical machine (TFEM), the kit comprising a pair of halves; a plurality of cores adapted to be located between the halves; a coil adapted to be located between the halves in operating position in respect with the plurality of cores; and resin to secure the coil and the plurality of cores with the pair of halves.
Embodiments of the present invention each have at least one of the above-mentioned objects and/or aspects, but do not necessarily have all of them. It should be understood that some aspects of the present invention that have resulted from attempting to attain the above-mentioned objects may not satisfy these objects and/or may satisfy other objects not specifically recited herein.
Additional and/or alternative features, aspects, and advantages of embodiments of the present invention will become apparent from the following description, the accompanying drawings, and the appended claims.
DESCRIPTION OF EMBODIMENT(S) OF THE INVENTIONOur work is now described with reference to the Figures. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention by way of embodiment(s). It may be evident, however, that the present invention may be practiced without these specific details. In other instances, when applicable, well-known structures and devices are shown in block diagram form in order to facilitate describing the present invention.
The embodiments illustrated below depict a TFEM 10 with thirty-two (32) pairs of poles and a 510 mm diameter at the air gap and a 100 mm length of the magnets. The configuration of the TFEM 10, an external rotor instead of an internal rotor, the number of phases can change in accordance with the desired power output, torque and rotational speed without departing from the scope of the present invention.
A TFEM 10 is illustrated in
Still referring to
Each axial side member 26 is configured to receive and secure thereto an axial rotor support member 54. The axial rotor support member 54 is recessed in a circular cavity 56 (visible in
As it is also possible to appreciate from the embodiment illustrated in
The TFEM 10 is further equipped with a protective plate 70 adapted to store and protect electrical connectors and electrical wires that extends from the TFEM 10 through an electrical outlet 74.
Turning now to
A semi-exploded stator portion 14 is illustrated in
The illustrative embodiment of
As best seen from
A section view of the TFEM 10 is illustrated in
In the TFEM 10 of the type comprising a rotor portion 18 including a plurality of identical permanent magnets 94 and of magnetic flux concentrators 98, the permanent magnets 94 are oriented in such a manner that their magnetization direction is parallel to the direction of rotation of the rotor portion 18, along rotation axis 22. Magnetic flux concentrators 98 are disposed between the permanent magnets 94 and redirect the magnetic flux produced by the permanent magnets 94 radially towards the air gap 126. In contrast, the stator portion 14 comprises “horseshoe-shaped” soft iron cores 130, which are oriented in such a manner that the magnetic flux that circulates inside these cores 130 is directed in a direction that is mainly perpendicular to the direction of rotation of the rotor portion 18. The perpendicular orientation of the magnetic flux in the cores 130 of the stator portion 14, with respect to the rotation direction, gives to TFEM a high ratio of mechanical torque per weight unit of the electrical machine.
The rotor portion 18 has been removed in
Focusing on the stator skew element, in reference with
Therefore, each core 130 includes a pair of poles 144 extending from respective core's legs 142 (not visible in
In the present embodiment, as shown in
The phase module 30 can alternatively be constructed with an alternated halves 150 disposition to prevent having halves 150 evenly angularly disposed on each side of the phase module 30. The alternate layout of the halves 150 over the circumference of a complete phase module 30 thus increases the mechanical strength of the phase module 30 because the junction between two adjacent angular portions 146 (on one side of the phase module 30) is going to be mirrored (on the opposite side of the phase module 30) by a continuous portion of the counterpart opposed halve 150. In this embodiment, the fact that the haves 150 are not angularly evenly disposed along the circumference of a phase module 30 on each side thereof, implies that the angular portions 146 are overlapping each other.
Moving now to
A set 148 of poles 136 is repeated with intervening radial angle 152 that has a value adapted to complete an angle of 45° [mechanical] 156 in the present illustrative embodiment. The actual intervening angle 152 of the illustrated embodiment is 12.656°[mechanical] and this angle, required to complete the angle of 45° of the embodiment, could be different should another configuration of set 148 of poles 136 be desirable. In other words, a new set of poles 148 begins each 45° [mechanical] and is repeated a number of times in the present configuration. The number of sets 148 in the illustrative embodiment is eight (8), two per angular portion 146 of 90°. The angle of 45° of the embodiment is 360° [mechanical]/8 and could alternatively be 30°, 60° or 90° and fit in the angular portion 146 of 90° in the illustrated embodiment.
Another unillustrated embodiment of sets 148 includes two (2) cores 130 with a predetermined intervening angular distance (or angle thereof). The set 148 of two cores 130 is separated from the next set 148 of two cores 130 with a different intervening angular distance. This alternate repetitive arrangement of sets 148 is used to build a complete phase module 32. One can appreciate from the illustrated embodiment that the cores 130 are identical and their respective locations dictate the respective locations of their associated poles 136. Other possible embodiment could use cores 130 that are not all identical and the location the poles 136 in the stator module 14 should prevail to ensure proper function of the TFEM.
In reference now with
Still referring to
Moving now to the angular portions 146 assembly illustrated in
A second jig plate 214 is added to the assembled angled portions 146 to secure the phase module 32 between the two jig plates 214 as illustrated in
Resin or polymer is used to interconnect the parts contained in each phase module 32. Each phase module 32 is injected separately in the illustrative embodiment however one skilled in the art could understand it is possible to collectively inject all the assembled phase module 32 together with a properly designed assembly process and a jig sized and designed accordingly. The resin 248, preferably, has to meet two main criteria: 1) sufficient mechanical strength, 2) sufficient thermic conductivity and 3) electrical resistivity. These three requirements ensure all parts of a phase module 32 are adequately maintained together at their respective locations. The injected resin 248 is also a means of filling the gaps and spaces left between the assembled parts to prevent any remaining play due to the tolerances required for manufacturing all the parts and secure all the parts of the assembly together in their operating positions. Sufficient mechanic strength is required to sustain compression mainly due to the torque generated by the operating parts and transferred to the axial members 26 of the TFEM 10. The selected resin 248 should also be a good vibration damper to protect the cores 130, the coil 134 and their respective halves 32 and prevent any undesirable contact between the operating parts of the TFEM 10. Thermal conductivity is another desirable role of the resin 248 that replaces air (empty volumes) in the phase module 32 to cool the internal parts of the TFEM 10 by transferring thermic energy to the environment of the TFEM 10. The resin 248 should also be tolerant to temperature variations that can reach between −40° C. and 180° C. with minimal changes in its mechanical properties. The resin prevents conducting magnetic flux within the internal parts of the phase module 32 that would prevent proper flux transfer with the cores 130 around the coil 134. The resin should also prevent creating Foucault current within the internal parts of the phase module 32 and therefore prevent additional energy loss. Finally, the resin 248 should be adapted to be machined to set the final dimensions of the interior of the stator portion 14 to receive therein the rotor portion 18 with minimal airgap 126 therebetween. Epoxy resin is an example of a resin 248 suitable to be used in the present TFEM 10 among other possible choices of resin 248 or other materials adapted to meet the requirements listed above.
The second jig module 214 is provided with injection inlets 240, to inject resin or polymer in the mold, and injection outlets 244 to purge, or vacuum, air from the mold during the injection process. The same process is used with each of the phase module 32 to get, in the context of the present embodiment that is a three-phased alternator, three injected phase modules 32. Other configurations, other types of mold assembly and mold inlets/outlets can be used without departing from the scope of the exemplified invention.
Three injected phase modules 32 are assembled together as explained above and the result is shown in
The description and the drawings that are presented above are meant to be illustrative of the present invention. They are not meant to be limiting of the scope of the present invention. Modifications to the embodiments described may be made without departing from the present invention, the scope of which is defined by the following claims:
Claims
1. A rotatable transverse flux electrical machine (TFEM) comprising:
- a stator including at least one phase module, the at least one phase module comprising a pair of opposed halve members respectively including a plurality of core-receiving spaces sized and designed to receive, locate and secure therebetween a plurality of cores; and a coil operatively disposed in respect with the cores inside each phase modules.
2. The rotatable transverse flux electrical machine (TFEM) of claim 1, wherein the plurality of cores comprises respective corresponding pair of poles, angularly spaces apart from one another with different angular distances therebetween.
3. The rotatable transverse flux electrical machine (TFEM) of claim 2, wherein at least two adjacent cores, and corresponding poles, are angularly radially spaced apart with an angle of about 10.8° and angularly radially spaced apart from adjacent cores with a different angle.
4. The rotatable transverse flux electrical machine (TFEM) of claim 1, wherein the at least one phase comprises a first set of at least three adjacent cores, and corresponding poles, angularly spaced apart with a first angular distance therebetween and further angularly spaced apart from an adjacent second set of at least three adjacent cores, and corresponding adjacent poles, angularly spaced apart with a second angular distance therebetween.
5. The rotatable transverse flux electrical machine (TFEM) of claim 1, wherein a set of poles is repeated at least two times in a phase to locate the poles in the at least one phase.
6. The rotatable transverse flux electrical machine (TFEM) of claim 1, further comprising a stator skewing axially angularly locating cores in the at least one phase in respect with a rotation axis of the TFEM.
7. The rotatable transverse flux electrical machine (TFEM) of claim 1, wherein the halve members comprise a circumferential cavity adapted to receive therein a cooperating portion of the cores to further mechanically radially locate and secure the cores to the halve members.
8. The rotatable transverse flux electrical machine (TFEM) of claim 1, wherein the halve members respectively comprise a plurality of halve portions.
9. The rotatable transverse flux electrical machine (TFEM) of claim 1, wherein the phase module further comprise a coil therein operatively disposed in relation with the plurality of cores between a radial distal wall of the halve members and a radial proximal wall of the halve members.
10. The rotatable transverse flux electrical machine (TFEM) of claim 9, wherein the phase module further comprise resin therein for securing the coil and the plurality of cores in the halves.
11. A method of assembling a phase of a rotatable transverse flux electrical machine (TFEM), the method comprising:
- assembling a plurality of cores in respective cores-receiving spaces radially disposed in a first halve member;
- assembling a coil in an operating position with the plurality of cores;
- assembling a second halve member with the first halve member; and
- injecting resin between the assembled halves to secure the plurality of cores and the coil in the phase.
12. The method of assembling a phase of a rotatable transverse flux electrical machine (TFEM) of claim 11, wherein the halve members are adapted to radially locate the plurality of cores disposed therein.
13. The method of assembling a phase of a rotatable transverse flux electrical machine (TFEM) of claim 11, wherein the halve members include a plurality of angled portions adapted to be sequentially assembled to facilitate the insertion of the coil within the plurality of cores.
14. The method of assembling a phase of a rotatable transverse flux electrical machine (TFEM) of claim 13, further comprising assembling a unification mechanism between adjacent angled portions.
15. The method of assembling a phase of a rotatable transverse flux electrical machine (TFEM) of claim 11, further comprising injecting resin between the assembled halves to secure the plurality of cores and the coil in the phase.
16. The method of assembling a phase of a rotatable transverse flux electrical machine (TFEM) of claim 15, wherein the method comprises installing the pair of halves in a mold to help restricting the flow of injected resin.
17. The method of assembling a phase of a rotatable transverse flux electrical machine (TFEM) of claim 15, wherein the method comprises boring a proximal radial portion of the phase to set an internal diameter of the phase.
18. The method of assembling a phase of a rotatable transverse flux electrical machine (TFEM) of claim 15, further using at least one wall portion of the pair of halves for restricting the flow of injected resin.
19. A kit for assembling a phase in a rotatable transverse flux electrical machine (TFEM), the kit comprising:
- a pair of halves;
- a plurality of cores adapted to be located between the halves;
- a coil adapted to be located between the halves in operating position in respect with the plurality of cores; and
- resin to secure the coil and the plurality of cores with the pair of halves.
20. The kit of claim 19, further comprising a mold for restricting resin injection.
Type: Application
Filed: Sep 24, 2013
Publication Date: Mar 27, 2014
Applicant: EOCYCLE TECHNOLOGIES INC. (Montreal)
Inventors: Raphael NADEAU (Verdun), Daniel MASSICOTTE (Quebec City), Eric ADAMS (Gaspe), Simon COTE (Gaspe), Patrice FORTIN (Gaspe), Jean-Francois BERNIER-SYNNOTT (Gaspe)
Application Number: 14/035,886
International Classification: H02K 3/28 (20060101); H02K 15/12 (20060101);