Synchronous electrical machine with rotor having angularly shifted portions
11444522 · 2022-09-13
Assignee
Inventors
Cpc classification
H02K19/103
ELECTRICITY
H02K19/20
ELECTRICITY
International classification
H02K1/24
ELECTRICITY
H02K19/20
ELECTRICITY
Abstract
The disclosure relates to a brushless and magnet-free synchronous electrical machine, wherein it comprises a stator (20) comprising a ring (22), a winding (28) and a tooth system (24) comprising teeth (26) extending parallel to the axis of rotation from the ring (22), said winding being wound around the tooth system (24), a rotor (10), comprising a first portion (12a) extending in p preferred directions (18a), a second portion (12b) extending in p preferred directions (18b) shifted by p with respect to the preferred directions of the first portion (18a), and an intermediate portion (14) linking the first portion (12a) to the second portion (12b), and a coil (40) for exciting the rotor, fixed with respect to the stator, supplied with a DC electric current, positioned around the intermediate portion (14) of the rotor and configured so as to generate an electric flux in the rotor (10) through magnetic induction.
Claims
1. A synchronous electrical machine configured to drive a rotating element in rotation around an axis of rotation of the electrical machine or to generate electrical energy from the mechanical energy transmitted by said rotating element, wherein the electrical machine comprises: a stator disposed around the axis of rotation of the electrical machine, comprising a ring extending along a preferred plane perpendicular to said axis of rotation and comprising a winding and a denture comprising teeth extending parallel to the axis of rotation from the ring, said winding being coiled around the denture according to the preferred plane and the denture delimiting an inner zone of the stator around the axis of rotation, a rotor, comprising a first portion extending in p first preferred directions parallel to the preferred plane, a second portion extending in p second preferred directions angularly shifted by π/p with respect to the first preferred directions of the first portion and parallel to the preferred plane, and an intermediate portion linking the first portion to the second portion, the rotor being arranged in such a way that at least the second portion and the intermediate portion are in the inner zone of the stator and that the second portion is located on the side of the ring, and an excitation coil for exciting the rotor, fixed with respect to the stator, supplied with DC electric current, positioned around the intermediate portion of the rotor and configured so as to generate a magnetic flux in the rotor through magnetic induction, such that the first portion of the rotor constitutes p north magnetic poles of the rotor and the second portion of the rotor constitutes p south magnetic poles of the rotor.
2. The electrical machine according to claim 1, wherein the electrical machine comprises an integrated electronic device which is arranged inside the stator.
3. The electrical machine according to claim 2, wherein the integrated electronic device is arranged in the inner zone of the stator, and between the rotor and a rear face of the ring of the stator along the axis of rotation.
4. The electrical machine according to-claim 2, wherein the electrical machine comprises a first housing comprising a first cooling fluid and in which the winding of the stator or the integrated electronic device are installed.
5. The electrical machine according to claim 2, wherein the electrical machine comprises a second housing comprising a second cooling fluid, the excitation coil being arranged inside this second housing.
6. The electrical machine according to claim 1, wherein the stator is laminated and is formed in one piece.
7. The electrical machine according to claim 1, wherein the electrical machine comprises a casing in which at least the rotor, the excitation coil mounted around the intermediate portion of the rotor and a drive shaft extending along the axis of rotation are accommodated, the drive shaft comprising a first end which is coupled to a bottom of the casing.
8. A method of making a stator of an electrical machine according to claim 1, the method comprising the following steps: providing a strip of ferromagnetic sheet metal comprising a predetermined width L in a first direction, the width L being measured between a first side and a second side of the strip of ferromagnetic sheet metal, making a plurality of notches by cutting so as to form tabs, and coiling the strip of ferromagnetic sheet metal around a coiling axis so that several tabs are superimposed along a radial axis perpendicular to the coiling axis.
9. The method of making a stator according to claim 8, wherein a distance between each successive notch of said plurality of notches is defined by a formula:
X+n.Math.e wherein X is a distance from an innermost notch that is closest to a position where the coiling the strip of ferromagnetic sheet metal begins, and n is an integer from 0 to K−2 and K is a number of notches, wherein e is determined by coiling or superimposing the tabs in a spiral of Archimedes and is calculated according to a formula:
10. A method of assembling a synchronous electrical machine according to claim 1, the method comprising the following steps: assembling a first sealed housing comprising a first cooling fluid, the stator winding or an integrated electronic device, inserting a first housing assembled on the stator, and at least partially inserting the rotor in the inner zone of the stator.
Description
BRIEF DESCRIPTION OF THE FIGURES
(1) Other characteristics and advantages of the invention will appear during the reading of the following detailed description, for the understanding of which reference shall be made to the attached drawings in which:
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DETAILED DESCRIPTION OF THE INVENTION
(23) The following embodiments are examples. Although the description refers to one or more embodiments, this does not necessarily mean that each reference refers to the same embodiment, or that the characteristics apply only to one embodiment. Simple characteristics of different embodiments can also be combined to provide other embodiments. In the figures, the scales and proportions are not strictly adhered to for the sake of illustration and clarity.
(24) The following figures describe the components of a brushless and magnet-free synchronous electrical machine according to an embodiment of the invention, configured to drive a rotating element in rotation around an axis of rotation of the electrical machine or to generate electric energy from the mechanical energy transmitted by said rotating element.
(25)
(26) The rotor 10 comprises a first portion 12a and a second portion 12b connected by an intermediate portion 14.
(27) The first portion 12a and the second portion 12b have the shape of a straight cylinder having as a base a truncated disc of two segments formed by distinct chords parallel and symmetrical with respect to the centre of the disc. Each first and second portion comprises a bore (respectively referenced 16a and 16b) around the centre of the disc intended to receive the rotating element.
(28) The intermediate portion 14 is a cylinder of revolution comprising in the same way a bore intended to receive the rotating element.
(29) The three bores 16a, 16b and 16c are thus of the same size and aligned so as to form a through bore 16 configured to receive the rotating element in the rotor 10.
(30) As seen in
(31) The intermediate portion 14 may extend parallel to the axis of rotation.
(32)
(33) The stator 20 comprises a ring 22 extending in a preferred plane 23, a denture 24 and a winding 28.
(34) The denture 24 comprises a plurality of teeth (only a part of which is referenced under the reference 26 in the figures for reasons of clarity) extending from the ring 22 parallel to the axis of the ring which will be the axis of rotation of the rotating element. The winding 28 is shown in part in
(35) The teeth of the denture delimit an inner zone 30 of the stator, which forms a cylinder of revolution around the axis of rotation of the rotating element.
(36)
(37) The excitation coil 40 takes the form of a ring in which the conductive wire 42 forming the excitation coil 40 is coiled. The excitation coil is supplied by a direct current generator 44, the value of which can be adjusted.
(38) The inner diameter 46 of the excitation coil 40 must be slightly larger than the outer diameter of the intermediate portion 14 of the rotor in order to allow the magnetic induction thereof.
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(40) The rotating element 100 associated with the electrical machine 50 is shown inserted in the rotor 10. It rotates around the axis 200 of rotation.
(41) In the assembled electrical machine, the axis 200 of rotation is also the axis of rotation of the rotor, and the axis around which the excitation coil 40 and the stator 20 are arranged.
(42) The winding 28 of the stator is represented by a single element for schematic purposes and is arranged on the side of the ring 22 of the stator 20.
(43) The rotor 10 is arranged at least partly in the inner zone 30 formed by the denture of the stator. Here, the intermediate portion 14 and the second portion 12b are arranged in the inner zone 30. When the electrical machine 50 is in operation, the stator 20 is stationary and the rotor 10 is rotating with respect to the stator 20. One or more bearings (not shown) arranged between the rotor 10 and the stator 20 can be used to hold the elements in place. Alternatively, in generator operation, the rotating element holds the rotor 10 in place in the stator 20 and no bearings are required.
(44) The excitation coil 40 is arranged in the stator 20 around the intermediate portion 14 of the rotor 10 leaving an air gap 52. When supplied, it causes a continuous magnetic flux in the rotor 10, represented by arrows, by induction. The DC electric flux allows polarization of the rotor, so that the first portion 12a behaves as a north magnetic pole and the second portion 12b behaves as a south magnetic pole. Thus, the electric flux moves from the south pole to the north pole, i.e. from the second portion 12b of the rotor to the first portion 12a of the rotor, is transmitted axially through the denture of the stator via the air gap 54 between the first portion 12a and the stator 20. In other words, the electrical flux flows axially (along the axis 200 of rotation) through the teeth 26 of the stator 20. The magnetic flux then flows to the stator.
(45) Due to its position at the intermediate portion 14, the excitation coil 40 is not influenced by the poles it creates when said poles rotate.
(46) As can be seen in
(47) Another embodiment of this electrical machine is shown in
(48) In particular, as can be seen in
(49) With reference to
(50)
(51) In
(52) The integrated electrical device 300 also comprises a control unit 312 which is electrically connected to the inverter 311 and the DC electric power source 316. This control unit 312 is configured so that the correct set points are generated to the inverter and a chopper described below of the excitation of the electrical machine.
(53) a “rectifier+chopper+filter” assembly of the excitation of the electrical machine.
(54) The integrated electronic device 300 is completed by a chopper+filter 313 which is supplied from the DC power source via two DC terminals. The chopper 313 is also coupled to the excitation coil 40 of the rotor so that the latter is supplied with direct current. The chopper is also electrically coupled to the control unit 312 via two terminals.
(55) In
(56) The rectifier and chopper module then comprises three AC terminals coupled to the power source and two DC terminals coupled to the rotor excitation coil 40 so that the latter is supplied with DC power. This module is also electrically coupled to the control unit 312.
(57) The control unit 312 generates the control commands for the inverter and chopper to ensure the correct operation of the machine.
(58) In
(59) The integrated electrical device 300 also comprises the control unit 312 which is electrically connected to the rectifier+chopper+filter 315 and to the AC power source generated by the generator. This control unit 312 is configured to control the chopper so that the excitation of the generator is adapted to the correct operation.
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(61) In the case of an electrical machine powered by an AC power source, the AC electric flux flows axially (along the axis 200 of rotation) through the teeth 26 of the stator 20. Similarly, the alternating electric flux flows circumferentially in the stator 20 (in particular the ring 22) around the axis 200 of rotation. The magnetic flux then flows to the stator.
(62) To limit eddy current losses, the stator 20′ shown in
(63) In a first embodiment this laminated stator 20′ illustrated in
(64) The laminated stator 20′ in one-piece is produced by a method shown in part in
(65) Several notches 405 are cut in the strip of ferromagnetic sheet metal 400 to form tabs 406. Each tab 406 is defined by two notches on either side of it in the second direction. These are intended to form the teeth 26 of the stator. The notches 405 are arranged in the second direction. Each notch 405 extends from the first side 406 along the first direction and has a width less than that of the strip of ferromagnetic sheet metal. The part of the uncut strip of sheet metal is used to form the ring of the stator.
(66) The strip of ferromagnetic sheet metal 400 is then coiled around a coiling axis 407 in such a way that the tabs 406 are superimposed one above the other radially with respect to this coiling axis. The coiling axis is perpendicular to the second direction and is coaxial with the axis 200 of rotation in an installation situation in the electrical machine.
(67) We then obtain a stator made up of several sheets of this strip of ferromagnetic sheet metal.
(68) According to this embodiment, the gap or distance between each successive notch is defined by the formula
X+n.Math.e [Math 1]
(69) wherein n is an integer from 0 to K−2 and K is the number of notches.
(70) The calculation of e is made by considering that the stacking or superposition of the tabs of the strip of ferromagnetic sheet metal obtained is an Archimedes' spiral whose pitch e is equal to the thickness of the strip of ferromagnetic sheet metal. Its polar equation is therefore expressed by the following formula:
(71) [Math 2]
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(73) wherein Ri is the inner radius of the stator.
(74) It is of course possible to make the notches after coiling the strip of ferromagnetic sheet metal to form the laminated stator.
(75) The notches are made by any type of suitable tool, for example by means of a wire. With such a manufacturing method, there are no geometrical defects in the stator.
(76)
(77) As can be seen in
(78) As an advantageous, but not limiting characteristic, the cooling fluid 31 is supplied from an external source so that the fluid circulates in the first housing. In this case, the outer surface 32 of the first housing 29 can act as a heat exchanger. Of course, it is not necessary to circulate the fluid inside the first housing.
(79) With reference to
(80) The seal joints 38 are arranged between each first and second cover 35 and the radially internal and external walls so that the first housing is sealed.
(81) The first cover and the second cover each comprise lights 39 passing through their walls on both sides along the axis 200 of rotation. The lights 39 are distributed evenly and in a circumferential direction.
(82) The second cover comprises passages for power supply cables 49 of the integrated electronic device 300.
(83) In this example of embodiment, the first housing 29 has an external diameter which is larger than that of the stator. The first housing has an inner diameter (defined by the radially internal wall) which is larger than that of the rotating element 100.
(84) Advantageously, the cooling fluid 31 comprises an oil which effectively dampens vibrations which can be detrimental to the connections, for example by soldering the elements composing the integrated electronic device 300.
(85) Advantageously, the oil filling of this housing prevents fire due to an electrical fault.
(86) In an alternative embodiment not shown, the excitation coil 40 is also arranged in a second housing which is filled with a second cooling fluid. This second cooling fluid can also be an oil.
(87) Following an example of the method of assembling of the electronic machine 50 shown in
(88) For this purpose, the radially internal and external annular walls 33, 34 and the first cover 35 are tightly assembled. The radially internal and external walls extend from an internal face 41 of the first cover.
(89) The winding 28 is respectively arranged around several projections 42 extending from the internal face 41 of the first cover along the axis 200 of rotation. Each of these projections 42 has a rectangular cross-section. The winding 28 is then connected to the integrated electronic device 300 by means of current terminals 43. Then, the second cover is assembled in such a way as to seal the first housing.
(90) The cooling fluid (here oil) is then injected inside the first housing 29.
(91) After insertion of the first cover on the stator, the first cover of the first housing is advantageously, but not limited to, in contact with the ring 22 of the stator 20, 20′.
(92) For this purpose, the teeth 26 of the stator fit into the lights 39 of the first and second covers.
(93) The excitation coil 40 is assembled around the rotor 10 and then the latter is inserted at least partly in the inner zone 30 of the stator 20, 20′.
(94) In the event that the excitation coil 40 is arranged inside the second housing according to an alternative embodiment of the electrical machine, the second housing is first inserted around the intermediate portion 14. The rotor 10 equipped with the second housing is then inserted into the stator 20.
(95) The second housing comprising the excitation coil 40 is similarly configured to the first housing.
(96) Another embodiment is shown in
(97) In this example of embodiment, the electrical machine is completed by a rotor module 500 comprising at least a casing 501, a drive shaft 110, an excitation coil 40 and a magnetic circuit of the rotor. In particular, the casing 501 comprises an annular wall 502 extending (along the axis of rotation 200) from a bottom 503. The latter comprises a plurality of orifices 504 passing through the bottom wall on both sides along the axis 200 of rotation. These orifices 504 are distributed evenly and in a circumferential direction. Each orifice 504 is intended to receive one tooth 26 of the stator. The border 505 of the annular wall 502 delimits an opening which is closed by a flange 506.
(98) As an example, the annular wall 501 comprises slots 507 which extend from the border 505 into the annular wall. The slots 507 are arranged along the circumference of the annular wall.
(99) The drive shaft 110 extends along the axis 200 of rotation and between the flange 506 and the bottom 503. As can be seen in particular in
(100) The shaft 110 is rotatably assembled inside the casing. For this purpose rotating guide bearings 509 are assembled upstream and downstream of the drive shaft and inside the casing. The rotating guide bearings 509 comprise in this example bearings with balls 510.
(101) This drive shaft is intended to be coupled to the rotating element 100. Such an arrangement allows to free space for the integrated electronic device 300′. More specifically, the integrated electronic device is full. In other words, it does not comprise a through hole 310 as is the case in the embodiment in
(102) The integrated electronic device 300′ is arranged axially between the bottom 503 of the casing and the rear face 201 of the stator 20, 20′.
(103) The rotor 10 is assembled in the casing 501 and around the drive shaft 110.
(104) In this figure we can see that the maximum length of the first portion 12a of the rotor is smaller than the diameter of the inner zone 30 of the stator 20, 20′ and that the first portion 12a of the rotor is arranged in the inner zone 30 of the stator. In other words, the entire rotor 10 is arranged in the inner zone 30 of the stator. The two magnetic pole sequences of the rotor are positioned radially with respect to the magnetic circuit formed by the stator.
(105) The excitation coil 40 is arranged around the intermediate portion 14.
(106) In addition, the rotor module comprises grooves or accommodations each intended to receive at least part of the free end of the teeth of the stator. In particular, the radially internal wall of the casing 501 comprises a plurality of grooves 511 or accommodations extending in the direction of the axis 200 and distributed evenly around this axis. These grooves allow to receive the teeth of the stator in order to immobilize them. This stiffens the assembly. Alternatively, the flange 506 has accommodations evenly distributed circumferentially around the axis 200. This allows at least the free end of the stator teeth to be trapped so as to stiffen the assembly.