Biased segmented dual radial gap brushless PMDC motor/generator

Abstract

A multiple radial gap BLPMDC/BLPMAC motor/generator suitable for direct drive wind or other fluid medium driven turbines or other rotary machine application. Each rotor and stator segment are housed in a fixture having an intermediate interior ramp angularly inclined at an angle of from about 10 to about 80 to cause the rotor/stator segments to interact at the axis of rotation of the fluid medium driven rotating machine at the same angle.

Claims

1. In a dual air gap motor/generator of the type having: (a) a rotor including a plurality of rotor segments, each one of the plurality of rotor segments including: a rotor frame having a rotor channel; and (b) a stator forming a circular rotor ring including a plurality of stator segments, forming a circular stator ring, each one of the plurality of stator segments including: (i) a stator frame having a stator channel; (ii) a plurality of bus bars disposed within the stator channel; (iii) a plurality of stator induction modules, the plurality of stator induction modules being seated on the a shoulder of the stator frame, the improvement, comprising: a fixture for each rotor and stator segment, each fixture including an angularly disposed ramp therewithin, each stator segment seating on the ramp at least, in part, the ramp being disposed at an angle ranging from about 10 to about 80 relative to the axis of rotation of a rotating machine.

2. The improvement of claim 1 further comprising: a plurality of lamination stacks, each one of the lamination stacks being disposed within and encircled by at least one turn of a respective coil, the plurality of lamination stacks being formed from a magnetically permeable material, thereby reducing the dual air gap between the coils and the opposing magnets.

3. The improvement of claim 1 further comprising: (a) a wind turbine rotor mechanically connected to the rotor in a direct drive application; and wherein the rotor and wind turbine rotor rotate simultaneously while the stator remains stationary, the rotor and stator being disposed at an angle of about 45 relative to the axis of rotation of the turbine.

4. A wind turbine comprising: the improved motor/generator of claim 1.

5. The wind turbine of claim 4 further comprising: (a) a plurality of turbine rollers secured to the wind turbine rotor; (b) a circular turbine guide rail for stabilizing the plurality of turbine rollers and rotation of the wind turbine rotor, and (c) a plurality of support brackets securing the stator to the guide rail to ensure the stator remains stationary while the rotor and the wind turbine rotor rotate.

6. In a motor/generator of the type having a plurality of rotor segments and stator segments where the motor segments and stator segments form a circular motor/generator, the improvement comprising: the rotor/stator assembly of claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a broken perspective view of a wind turbine incorporating the rotor/stator individual modules of the present invention;

(2) FIGS. 2 and 3 illustrate the constructions associated with a radial and axial dual gap motor, respectively;

(3) FIG. 4 illustrate the advantages associated with a biased dual gap motor;

(4) FIG. 5 is a side view of an individual rotor/stator module;

(5) FIG. 6 is a perspective view showing an individual rotor/stator module; and

(6) FIG. 7 is a perspective view of an assembled rotor/stator segment.

DESCRIPTION OF THE INVENTION

(7) As noted hereinabove the present invention incorporates by reference in its entirety co-pending U.S. patent application Ser. No. 15/450,098 including the drawings. Therefore, for purposes of clarity, much of that description will be omitted herefrom with the focus being on the advantages accruing with the rotor and stator in a biased orientation.

(8) Referring now to the drawing and, as shown, the present invention comprises individual segments or modules 10 being arrayed in a biased angularity with respect to the axis or center line of rotation of a rotating machine or, in the case of a wind turbine, inclined with respect to the axis of rotation, i.e., the Z-axis, as shown in FIG. 6.

(9) It has been found that by incorporating the bias with respect to the Z axis at an angle ranging from about 10 to about 80 greater flexibility is imparted to the structure such that manufacturing tolerance is enhanced.

(10) Preferably, the angular relationship ranges from about 30 to about 60 and, more preferably, about 45. Using the 45 biased angle relative to the Z axis or the axis of rotation, increases the tolerance in the X and Z axis without any change to the gaps or loss of flux density.

(11) Referring to FIGS. 2, 3 and 4, based upon the Pythagorean Theorem, there is shown that the load or tolerance in the Y-axis is increased to 1.41. The same is true with respect to the X axis. Thus, the angularity imparts the requisite desired flexibility.

(12) Again, and as shown in FIGS. 2-4, a dual radial gap 12,14 is provided. One gap 12 exists between the stator and lower loaded magnet and a second gap 14 exists between the stator and upper loaded magnet.

(13) It is to be appreciated that when the rotor and stator are both aligned such that the stator is disposed between the magnets with the module in a substantially vertical or axial array the rotor tolerance is constricted as to the gap while the rotor tolerance is unconstricted in the Z direction. When the module or individual segment is arrayed in a horizontal or radial direction the tolerance is constricted in both the horizontal X axis and unconstrained in the Z axis. The present invention reduces these constrictions by deploying the segments along the bias.

(14) In all other respects the present motor/generator assembly is the same as described in the parent application.

(15) Referring again to the drawing and, in particular, FIGS. 5-7 there is shown therein, an individual module segment 100 comprising a rotor segment 102 and a stator segment 104 being loaded intermediate the rotor 102. The rotor, in turn, is operatively connected to a turbine 106 and the individual blades (not shown).

(16) The rotor and stator segments are housed in a stator fixture or stator frame 120 having an intermediate interior wall or ramp 122. The ramp 122 is used to facilitate assembly of the present rotor/stator segments.

(17) As is known to the skilled artisan, as the blades rotate the rotor, the rotor in turn, rotates and creates a magnetic field to thereby create an electrical current which is transmitted to the stator 104 comprising the segments 100 which stator, in turn, is connected, via coils (not shown), having lead wires 124 electrically connected to bus bars 126 for generating electricity in a manner well known to the skilled artisan.

(18) With more particularity the present rotor/stator motor/generator has each rotor and stator segment 102,104 housed in the fixture 120.

(19) The fixture has an upper portion 128. The upper portion of the fixture houses the rotor/stator segments. The ramp 122 is disposed in the fixture at an angle ranging from about 10 to about 80 with respect to the axis of rotation or center line 130 of a rotary mechanism 120, e.g., the turbine 106. Thus, concomitantly the rotor and stator are biased with respect to the Z axis.

(20) In assembling the present rotor/stator assembly the stators are inserted into the rotor channel 105 between the encapsulated coils as disclosed in the co-pending application and which are disposed between the magnets of the rotor.

(21) The coil wires 124 (FIG. 1) are then connected to the bus bars 126.

(22) It is to be observed that a loading of the stators into their associated rotor channels is facilitated due to the biased configuration.

(23) It is to be readily appreciated that in this configuration and, by the manner in which the assembly is achieved, repair and/or replacement is facilitated.

LIST OF REFERENCE NUMERALS

(24) 100 Individual module segment 102 Rotor segment 104 Stator segment 106 Turbine 108 Turbine blades 110 Segment fixture 112 Ramp 114 Stator 116 Coils 118 Fixture upper portion