DUAL ROTOR HOMOPOLAR AC MACHINE
20220140712 · 2022-05-05
Assignee
Inventors
- Scott Sudhoff (West Lafayette, IN, US)
- Jiazhou Zhong (West Lafayette, IN, US)
- Steve Pekarek (West Lafayette, IN, US)
Cpc classification
H02K19/18
ELECTRICITY
International classification
H02K19/18
ELECTRICITY
Abstract
A homopolar alternating current machine (HAM) is disclosed which includes a stator having a plurality of segments radially protruding outward, each segment includes a main winding, a first auxiliary winding, and a second auxiliary winding, whereby each of the first and second auxiliary windings are coupled to each other in a parallel manner, a first rotor disposed proximate the stator, a second rotor disposed proximate the stator, and a dc flux source corresponding to each of the first and second rotors, whereby substantially no excitation of the first and the second auxiliary windings of each stator segment of the plurality of segments is needed to operate the HAM, whereby when energized, there is substantially no DC flux in each of the main winding, wherein operating the HAM results in a substantially sinusoidal current waveform without a DC offset, and wherein the HAM can be operated as a motor or generator.
Claims
1. A homopolar alternating current machine (HAM), comprising: a stator having a body axially extending from a first end to a second end and further having a plurality of segments radially protruding outward from the body, each segment comprising a main winding disposed centrally about the segment, a first auxiliary winding disposed at a proximal end of the segment, and a second auxiliary winding disposed at a distal end of the segment, whereby each of the first and second auxiliary windings are coupled to each other in a parallel manner; a first rotor disposed proximate the first end of the stator; a second rotor disposed proximate the second end of the stator; and a dc flux source corresponding to each of the first and second rotors, whereby substantially no excitation of the first and the second auxiliary windings of each stator segment of the plurality of segments is needed to operate the HAM, whereby when energized, there is substantially no DC flux in each of the main winding, wherein operating the HAM is associated with a substantially sinusoidal current waveform without a DC offset, and wherein the HAM can be operated as a motor or a generator.
2. The HAM of claim 1, wherein the DC flux source associated with each of the first and second rotors is a permanent magnet.
3. The HAM of claim 2, wherein each permanent magnet includes at least some amount of heavy-rare-earth material.
4. The HAM of claim 3, wherein the heavy-rare-earth material is dysprosium.
5. The HAM of claim 2, wherein each permanent magnet is substantially free of heavy-rare-earth material.
6. The HAM of claim 5, wherein the non-heavy-rare-earth containing material is selected from the group consisting of Nd.sub.2Fe.sub.14B, SmCo.sub.5, AlNiCo, ferrite, PtCo, MnAlC, and a combination of one or more thereof.
7. The HAM of claim 2, wherein each permanent magnet is coupled to the associated rotor and configured to rotate with the rotor.
8. The HAM of claim 2, wherein each permanent magnet is decoupled from the associated rotor and configured to remain stationary.
9. The HAM of claim 1, wherein the DC flux source associated with each of the first and second rotors is a field winding, disposed between the associated rotor and the body of the stator.
10. The HAM of claim 1, wherein the HAM is capable of generating a power density of about 32 kW/L at about 91% efficiency.
11. An alternating current (AC) system for operating a homopolar AC machine (HAM), comprising: a HAM, comprising: a stator having a body axially extending from a first end to a second end and further having a plurality of segments radially protruding outward from the body, each segment comprising a main winding disposed centrally about the segment, a first auxiliary winding disposed at a proximal end of the segment, and a second auxiliary winding disposed at a distal end of the segment; a first rotor disposed proximate the first end of the stator; a second rotor disposed proximate the second end of the stator; and a dc flux source corresponding to each of the first and second rotors, whereby substantially no excitation of the first and the second auxiliary windings of each stator segment of the plurality of segments is needed to operate the HAM, and whereby when energized, there is substantially no DC flux in each of the main windings, reducing magnetic cross section requirements (mass) and, wherein operating the HAM is associated with a substantially sinusoidal current waveform without a DC offset; an interface circuit coupled to the HAM, whereby the interface circuit is adapted to operate the HAM in one of a generator or a motor, wherein the interface circuit is coupled to each of the main windings.
12. The system of claim 1, wherein the DC flux source associated with each of the first and second rotors is a permanent magnet.
13. The system of claim 12, wherein each permanent magnet includes at least some amount of heavy-rare-earth material.
14. The system of claim 13, wherein the heavy-rare-earth material is dysprosium.
15. The system of claim 12, wherein each permanent magnet is substantially free of non-heavy-rare earth material.
16. The system of claim 15, wherein the non-heavy-rare-earth containing material is selected from the group consisting of Nd.sub.2Fe.sub.14B, SmCo.sub.5, AlNiCo, ferrite, PtCo, MnAlC, and a combination of one or more thereof.
17. The system of claim 2, wherein each permanent magnet is coupled to the associated rotor and configured to rotate with the rotor.
18. The system of claim 2, wherein each permanent magnet is decoupled from the associated rotor and configured to remain stationary.
19. The system of claim 1, wherein the DC flux source associated with each of the first and second rotors is a field winding, disposed between the associated rotor and the body of the stator.
20. The system of claim 1, wherein the HAM is capable of generating a power density of about 32 kW/L at about 91% efficiency.
Description
BRIEF DESCRIPTION OF DRAWINGS
[0010]
[0011]
[0012]
[0013]
[0014]
[0015]
DETAILED DESCRIPTION
[0016] For the purposes of promoting an understanding of the principles of the present disclosure, reference will now be made to the embodiments illustrated in the drawings, and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of this disclosure is thereby intended.
[0017] In the present disclosure, the term “about” can allow for a degree of variability in a value or range, for example, within 10%, within 5%, or within 1% of a stated value or of a stated limit of a range.
[0018] In the present disclosure, the term “substantially” can allow for a degree of variability in a value or range, for example, within 90%, within 95%, or within 99% of a stated value or of a stated limit of a range.
[0019] A novel approach in homopolar AC machines is presented that can meet torque density requirements of the vehicular market. Towards this end, several different Dual Rotor Homopolar AC Machines (DHAM) are presented as a novel rotating electric machine which can operate either as a motor or as a generator. Each of these versions has a novel dual rotor topology and utilizes both radial and axial flux paths. Furthermore, each of these configurations includes a segmented stator, including a plurality of segments, whereby each segment includes a main winding centrally disposed about the corresponding stator segment and two auxiliary windings each disposed on either side of the main winding. In each case, there is a DC flux source incorporated into the machine. The DC flux source may be a set of permanent magnets (rare earth or non-rare earth permanent magnets), or alternatively a field winding disposed about the stator body but corresponding to each rotor. In either case, each rotor includes said DC flux source. In the permanent magnets case, the permanent magnets can be coupled to a corresponding rotor and thus rotate as the rotor rotates. Alternatively, in the case of field windings, the field winding is mounted between each rotor and the stator body and is thus stationary. These six versions include: 1) a stationary permanent magnet version, whereby each permanent magnet is decoupled from a corresponding rotor and thus is stationary with respect to the rotor, 2) a rotating PM machine, whereby each permanent magnet is coupled to the corresponding rotor and thus configured to rotate with the rotor, 3) a field winding version whereby the permanent magnets are replaced with field windings that are positioned between the stator body and a corresponding rotor in a stationary manner. Each of the above versions can be presented with a segmented stator that has A) uniform stator segments; and B) short and long stator segments, making up the six versions. It should be noted that various embodiments for the permanent magnets are possible, e.g., a superconducting puck, as discussed below.
[0020] Where permanent magnets are used, the permanent magnets can have heavy-rare-earth materials, with atomic numbers ranging from 62-71, which includes dysprosium, in combination with other materials. Many commonly used neodymium iron boron magnets include dysprosium, and are thus considered heavy-rare-earth. Alternatively, the permanent magnets may be constructed from non-heavy-rare-earth material that is selected from the group consisting of Nd.sub.2Fe.sub.14B, AlNiCo, ferrite, PtCo, MnAlC, and a combination of one or more thereof.
[0021] There are several different windings: the main windings and auxiliary windings. The power transfer to the machine is through the main windings of the machine which constitute three or more phases. Nominally, a three-phase system is employed for the main windings, although any number of phases greater than two could be used. The voltage and current waveforms associated with the main windings are nominally sinusoidal, and the torque produced by the machine is nominally constant. Unlike other homopolar machines, the flux through the main winding does not have a dc bias leading to better material utilization.
[0022] The auxiliary windings of the machine (there are two: upper and lower), are coupled together in parallel as the voltage across the two windings is substantially identical, while the required currents are opposite. The local connection between terminals of the auxiliary windings on each stator segment is as follows: if the auxiliary windings are wound in the same manner (i.e., both are wound clockwise or both are wound counterclockwise), then the top and bottom terminals of the top auxiliary winding are coupled to the top and bottom terminals of the bottom auxiliary winding, respectively. If however, the two auxiliary windings are wound opposite one-another, then the top and bottom terminals of the top auxiliary winding are coupled to the bottom and top terminals of the bottom auxiliary winding, respectively Alternatively, the auxiliary windings can be terminaled (i.e., end of each auxiliary winding can be brought out to a corresponding terminal for excitation) outside the machine, for situations in which minute excitation of the auxiliary windings is desirable. Thus, as a whole, little or no excitation of the auxiliary winding is required. The role of the auxiliary winding is to distribute the flux in the desired fashion, which in turn allows the same amount of average power to be delivered to the main windings with a lower peak and rms phase currents for the same peak voltage than would otherwise be possible (which is analogous to operating at a higher power factor).
[0023] The novel DHAM configuration of the present disclosure provides several advantages: 1) The field winding in the case of field-wound type (or the permanent magnets in the case of permanent magnet type, or the use of a superconducting puck, in leu of a permanent magnet) can be stationary. This facilitates cooling, electrical connections to the field, and eliminates mechanical stresses on the field winding in high speed machines. This features also facilitates the use of superconducting field windings, if desired. For low speed machines, the magnets can be placed on the rotor and allowed to rotate, if desired. In this configuration, there is still an advantage in that the magnets are at a smaller radius than the teeth and thus experience less force, and are more easily structurally wrapped than in traditional machines since flux is not crossing a radial airgap in this region. 2) The rotors themselves are nominally lossless, which also facilitates high speed applications in that the machine can be run in a vacuum. 3) The stator structure is segmented, facilitating manufacturing, leading to a high packing factor, as well as facilitating the construction of large machines. 4) The stator structure is easy to wind. This facilitates high winding packing factor helps reduce the size of the machine and improves thermal transfer. 5) The DHAM according to the present disclosure has a wide constant power speed range. This feature advantageously makes it ideal for applications such as flywheel energy storage and electric vehicles. 6) Owing to a compact architecture, space within the machine is available for the inverter allowing one assembly of the machine and inverter in a single package. Additionally benefits of the DHAM and its various embodiments according to the present disclosure includes AC machines with stationary windings (i.e., non-rotating windings), provides large constant power speed range, and owing to its simplicity can be readily manufactured (even more easily than induction machines).
[0024] Another additional benefit of the DHAM of the present disclosure is that in the PM variety, the permanent magnets are placed in specific locations in the machine where it will see less field variation and so have less eddy currents and thus the associated heating. This also facilitates the use of superconducting windings or a superconducting puck for some applications. Thus, the thermal issues seen in PMACs do not pose a challenge. In addition, the DHAM of the present disclosure can use stationary magnets allowing them to be more easily cooled, advantageously eliminating the necessity of high temperature material selection, e.g., dysprosium, and also further avoid mechanical stresses of rotating high speeds.
[0025] Referring to
[0026] Referring to
[0027] Referring to
[0028] Referring to
[0029] As discussed above, regardless of which configuration (i.e., the DHAM 100 shown in
[0030] To better elucidate the working principals of the DHAM according to the present disclosure, reference is made to
wherein R.sub.p is the number of rotor poles. For each phase, there are two sets of rotor teeth, the alpha teeth and the beta teeth. The reluctances between the rotor and the alpha teeth are expressed as:
R.sub.aαe=R.sub.Ae−R.sub.Be sin(2θ.sub.r) (2)
R.sub.bαe=R.sub.Ae−R.sub.Be sin(2θ.sub.r+2π/3) (3)
R.sub.cαe=R.sub.Ae−R.sub.Be sin(2θ.sub.r−2π/3) (4)
The reluctances between the rotor and the beta teeth are expressed:
R.sub.aβe=R.sub.Ae+R.sub.Be sin(2θ.sub.r) (5)
R.sub.bβe=R.sub.Ae+R.sub.Be sin(2θ.sub.r+2π/3) (6)
R.sub.cβe=R.sub.Ae+R.sub.Be sin(2θ.sub.r−2π/3) (7)
where R.sub.Ae and R.sub.Be are constants. The final ‘e’ in the subscript stands for ‘effective’ in the sense of being a parallel combination of all rotor poles. In particular,
Having defined the reluctances, torque may be expressed as:
where the flux terms are depicted in
[0031] Next, is to develop mathematical relationship that describe control of the flux in the phase legs. The alpha leg fluxes are described as:
Φ.sub.aαe=Φ.sub.dc+Φ.sub.ac cos(2θ.sub.r+ϕ) (11)
Φ.sub.bαe=Φ.sub.dc+Φ.sub.ac cos(2θ.sub.r+ϕ+2π/3) (12)
Φ.sub.cαe=Φ.sub.dc+Φ.sub.ac cos(2θ.sub.r+ϕ−2π/3) (13)
The beta leg fluxes are described as:
Φ.sub.aβe=−Φ.sub.dc+Φ.sub.ac cos(2θ.sub.r+ϕ) (14)
Φ.sub.bbe=−Φ.sub.dc+Φ.sub.ac cos(2θ.sub.r+ϕ+2π/3) (15)
Φ.sub.cβe=−Φ.sub.dc+Φ.sub.ac cos(2θ.sub.r+ϕ−2π/3) (16)
[0032] It should be noted that φ.sub.dc and Φ.sub.ac are constants for a given operating point describing the dc and ac amplitude of the flux, as well as the quantity ϕ is also a constant for a given operating point.
[0033] Substitution of the reluctance profiles according to equations 2-7 and the desired fluxes expressed by equations 11-16, the electromagnetic torque may be expressed as:
T.sub.e=6R.sub.pR.sub.BeΦ.sub.dcΦ.sub.ac cos ϕ (17)
[0034] As indicated by equation 17, the torque is proportional to the product of Φ.sub.dc and Φ.sub.ac, and is, ideally, constant, thus expressing an advantageous and desirable property of the DHAM according to the present disclosure.
[0035] Next consideration is the flux through the main winding (e.g., 108 of
Φ.sub.ae=Φ.sub.aαe+Φ.sub.aβe (18)
[0036] Substituting equations 11 and 14 into equation 18, provides the following relationship:
Φ.sub.ae=2Φ.sub.ac cos(2θ.sub.r+ϕ) (19)
From equation 19, the main component of the voltage across one of the a-phase legs is given
which shows another desirable property of the DHAM—that is, the DHAM of the present disclosure is fundamentally, a sinusoidal voltage machine.
[0037] Having derived the voltage relationship, next current relationships in each of the main windings is derived. Referring to
F.sub.as=R.sub.aαeΦ.sub.aαe+R.sub.aβeΦ.sub.aβe (21)
The relationship expressed in equation 21 takes advantage of the fact that there is a virtual magnetic core (i.e. no MMF drop) between the two rotors. Substituting equation (2), (5), (11), and (14) into (21) provides
F.sub.as=Ni.sub.asl=2R.sub.AeΦ.sub.ac cos(2θ.sub.r+ϕ)−2R.sub.BeΦ.sub.dc sin(2θ.sub.r) (22)
whereas i.sub.asl is the current in one a-phase stator leg. From equation 22, another attractive feature of the DHAM can be observed according to the present disclosure—that the current waveform is also sinusoidal.
[0038] After having considered the main windings, reference is now made back to
F.sub.axu=Ni.sub.axu=R.sub.aαeΦ.sub.aαe−R.sub.aβeΦ.sub.aβe−F.sub.fd (23)
F.sub.axl=Ni.sub.axl=−R.sub.aαeΦ.sub.aαe+R.sub.aβeΦ.sub.aβe+F.sub.fd (24)
It can be concluded that We conclude that the current need in the upper and lower auxiliary windings is equal in magnitude and opposite in sign; thus, i.sub.aux=−i.sub.axl.
[0039] It is further observed that substitution of equations (2), (5), (11), and (14) into (23) and (24) results in:
F.sub.axu=−F.sub.fd+2R.sub.AeΦ.sub.dc+R.sub.BeΦ.sub.ac sin ϕ−R.sub.BeΦ.sub.ac sin(4θ.sub.r+ϕ) (25)
F.sub.axl=F.sub.fd−2R.sub.AeΦ.sub.dc−R.sub.BeΦ.sub.ac sin ϕ+R.sub.BeΦ.sub.ac sin(4θ.sub.r+ϕ) (26)
Substituting field MMF expressed below in (27) in (25) and (26) the expression for the control winding MMFs will then be provided in (28) and (29):
F.sub.fd=2R.sub.AeΦ.sub.de+R.sub.BeΦ.sub.ae sin ϕ (27)
F.sub.axu=−R.sub.BeΦ.sub.ac sin(4θ.sub.r+ϕ) (28)
F.sub.axl=R.sub.BeΦ.sub.ac sin(4θ.sub.r+ϕ) (29)
From these relationships it can be seen that the control winding currents are purely sinusoidal with no DC offset as expressed below:
The voltages across the auxiliary windings of one leg are given by
[0040] Since the ac component of Φ.sub.aαe is equal to the ac component of Φ.sub.aβe as observed from equations (11) and (14), their time derivatives are equal, and hence the auxiliary winding voltages need to be equal, that is ν.sub.axu=ν.sub.axl. If the auxiliary windings are viewed as a pair, since their voltages are the same, their currents need to be opposite. In essence, this can be achieved by simply tying the two coils together and allowing the coils to be self-excited. Thus no further excitation is necessary. One way of looking at this is that by tying the auxiliary winding together, use of Lenz's law to ensures that equal ac parts are present, similar to a current transformer. Thus, advantageously there is no need to drive another set of windings, resulting in a major benefit of the DHAM of the present disclosure.
[0041] Referring to
[0042] The interleaved stator arrangement (i.e., the stator 206 of the DHAM 200, shown in
[0043] The DHAM configuration shown in
[0044] As discussed herein, the DHAM according to the present disclosure can be operated as a generator or as a motor. In each case, the DHAM of the present disclosure is coupled to an interface circuit adapted to operate the DHAM accordingly. The interface circuitry is coupled to each of the main windings of each stator segment. Additionally, the interface circuitry may also be coupled to each of the auxiliary windings, if energization of the auxiliary windings is desirable.
[0045] Those having ordinary skill in the art will recognize that numerous modifications can be made to the specific implementations described above. The implementations should not be limited to the particular limitations described. Other implementations may be possible.