ELECTRICALLY EXCITED MACHINE AND CONTACTLESS ARRANGEMENT FOR AN ELECTRICALLY EXCITED MACHINE
20250096651 · 2025-03-20
Inventors
Cpc classification
H02K11/30
ELECTRICITY
H02K19/12
ELECTRICITY
H02K11/042
ELECTRICITY
H02K11/00
ELECTRICITY
H02K11/012
ELECTRICITY
H02J50/005
ELECTRICITY
H02J50/70
ELECTRICITY
H02K3/04
ELECTRICITY
H02K11/0141
ELECTRICITY
International classification
H02K11/00
ELECTRICITY
H02K7/00
ELECTRICITY
H02K11/30
ELECTRICITY
H02K3/04
ELECTRICITY
Abstract
An electrically excited machine that includes a machine rotor and an exciter device for the electrical excitation of the electrically excited machine. The exciter device can include at least one energy transfer system integrated in and/or arranged inside the machine rotor. The machine rotor can include a rotor winding. The electrically excited machine can also include a machine stator. The machine stator can be arranged outside of the electrically excited machine.
Claims
1. An arrangement for an electrically excited machine, comprising: a machine rotor having a machine rotor shaft designed as hollow shaft having a cavity; and an exciter device for the electrical excitation of the machine, wherein the exciter device comprises at least one energy transfer system, wherein the at least one energy transfer system has a primary side and a secondary side, is configured for the contactless transfer of electrical energy from the primary side to the secondary side, and is arranged inside the cavity of the machine rotor shaft.
2. The arrangement according to claim 1, wherein the at least one energy transfer system of the exciter device is completely arranged inside the cavity of the machine rotor shaft.
3. The arrangement according to claim 1, wherein: the machine rotor shaft has at least one cable bushing from the cavity to the outside; and/or the machine rotor shaft has at least one opening for cooling the at least one energy transfer system.
4. The arrangement according to claim 1, wherein the machine rotor comprises a exciter winding and a laminated core; and the primary side and the secondary side are, viewed in axial direction, arranged inside the laminated core.
5. The arrangement according to claim 1, wherein the at least one energy transfer system of the exciter device comprises a rotating energy transfer device that is an external rotor, wherein the at least one energy transfer system is arranged in the machine rotor such that the external rotor is connected to the machine rotor in a rotatably fixed manner, and wherein a bearing for supporting the machine rotor shaft is arranged inside the cavity of the machine rotor shaft on a non-output side of the machine, the bearing having a stationary inner part and a rotating outer part.
6. The arrangement according to claim 1, wherein the at least one energy transfer system of the exciter device comprises an exciter stator and an exciter rotor, wherein the exciter stator is made of a magnetically as well as electrically non-conductive material, and wherein the exciter stator has a bore for cooling.
7. The arrangement according to claim 1, wherein the machine rotor has an exciter winding, and wherein the secondary side is configured to transfer the energy transferred from the primary side to the secondary side in a contactless manner from the secondary side to the exciter winding of the machine rotor.
8. The arrangement according to claim 7, wherein the secondary side is configured to completely generate a magnetic rotor field by an electric current supplied to the exciter winding.
9. The arrangement according to claim 1, wherein the exciter device further comprises a primary-side electronics device with an inverter and/or a secondary-side electronics device with a rectifier, wherein the primary-side electronics device further has a primary-side compensation unit, wherein the secondary-side electronics device further has a secondary-side compensation unit, and wherein the secondary-side electronics device is arranged on and/or outside the machine rotor shaft.
10. The arrangement according to claim 1, wherein a primary-side compensation unit and/or a secondary-side compensation unit is configured for reactive power compensation.
11. The arrangement according to claim 1, wherein the arrangement further comprises an energy source and/or a converter for controlling the electrically excited machine.
12. The arrangement according to claim 1, wherein an operating frequency of the energy transfer system is independent of a speed of the electrically excited machine.
13. The arrangement according to claim 1, wherein the exciter device comprises two or more energy transfer systems; and/or wherein the exciter device further comprises at least one data transmission system, which is integrated in the machine rotor.
14. The arrangement according to claim 1, wherein an additional electrically conductive material layer is arranged on at least one active part of the energy transfer system, wherein an active part of the energy transfer system is part of the energy transfer system which is at least partially exposed to a magnetic field used for energy transfer, and wherein the electrical conductivity of the additional material layer is greater than the electrical conductivity of the at least one active part.
15. The arrangement according to claim 14, wherein the additional electrically conductive material layer is arranged on a coil system of the energy transfer system, in particular in the region of electrically poorly conductive and at the same time magnetically conductive materials, or in the region of electrically poorly conductive and at the same time magnetically non-conductive materials.
16. The arrangement according to claim 1, wherein the energy transfer system has a stator made of an electrically non-conductive material and/or a magnetically non-conductive material.
17. The arrangement according to claim 1, wherein an operating frequency of the at least one energy transfer system is independent of a speed of the electrically excited machine.
18. The arrangement according to claim 1, wherein the secondary side is arranged concentrically around an axis of rotation of the machine rotor, and wherein the primary side is located inside the secondary side.
19. The arrangement according to claim 1, wherein the primary side of the at least one energy transfer system comprises an exciter stator having an exciter stator winding and the secondary side of the at least one energy transfer system comprises an exciter rotor having an exciter rotor winding, and wherein the exciter stator winding and the exciter rotor winding are arranged coaxially around an axis of rotation of the machine rotor.
20. An electrically excited machine, comprising: a machine stator; and a machine rotor; and an exciter device for the electrical excitation of the machine, wherein the exciter device comprises at least one energy transfer system configured for the contactless transfer of electrical energy and integrated in the machine rotor.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF THE DRAWINGS
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[0097] The exciter device 30 serves for the electrical excitation of the synchronous machine 100 or the synchronous machine rotor 10 of the synchronous machine 100. The exciter device 30 comprises an energy transfer system 20 integrated in the synchronous machine rotor 10. The synchronous machine rotor 10 has a synchronous machine rotor shaft 13 and an exciter winding 15. The energy transfer system 20 of the exciter device 30 is arranged in a cavity of the synchronous machine rotor shaft 10.
[0098] According to the embodiment shown in
[0099] The energy transfer system 20 is arranged in the synchronous machine rotor 10 in particular in such a way that the exciter rotor 4 is connected to the synchronous machine rotor 10 in a rotatably fixed manner. The exciter rotor 4 thus rotates together with the synchronous machine rotor 10. In other words, the exciter rotor 4 and the synchronous machine rotor 10 are arranged and/or coupled or connected to one another in such a way that the rotational movements of the exciter rotor 4 and the synchronous machine rotor 10 are synchronized. The exciter rotor 4 and the synchronous machine rotor 10 consequently have the same angular speed and/or rotational speed in the operating state.
[0100] The exciter device 30 is configured to transfer electrical energy in a contactless manner from the exciter stator 2 to the exciter rotor 4 of the exciter device 30 and finally from the exciter rotor 4 to the exciter winding 15 of the synchronous machine rotor 10. The exciter device 30 further comprises an electronics device 6, which comprises a primary-side electronics device 6a and a secondary-side electronics device 6b (see also
[0101] The synchronous machine rotor 10 further has a magnetic flux carrier element 17. Accordingly, the synchronous machine stator 40 further has a magnetic flux carrier element 47. The magnetic flux carrier element 17 of the synchronous machine rotor 10 is arranged between the magnetic flux carrier element 47 of the synchronous machine stator 40 and the synchronous machine rotor shaft 13. The magnetic flux carrier element 17 serves to carry the magnetic flux on the synchronous machine rotor 10, and the magnetic flux carrier element 47 serves to carry the magnetic flux on the synchronous machine stator 40.
[0102] In order to reduce any losses, e.g. due to eddy currents and/or heating, the exciter stator 2 is preferably formed from a magnetically non-conductive as well as electrically non-conductive material (in particular from a plastic such as POM or PEEK). This is advantageously possible since no particular stability requirements are made of the exciter stator 2 of the energy transfer system 20. It must only be possible to apply windings to the exciter stator 2. Of course, it is also possible to manufacture the exciter stator 2 from steel or aluminum. In this case, it is advantageous to apply an additional, highly conductive electrical layer to the exciter stator 2.
[0103] The exciter stator 2 has a bore forming a cooling channel along its longitudinal axis. In other words, the exciter stator 2 is formed to be hollow or tubular. A coolant such as air, water and/or oil can be fed into the cooling channel via an inlet 12. The coolant can move through the cooling channel of the exciter stator 2 and thus effectively cool the exciter stator 2 from the inside. Advantageously, the synchronous machine rotor 10 is also cooled from the inside as a result. The inlet 12 can at the same time also serve as an outlet for the coolant.
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[0105] A challenge in the construction of the synchronous machine with an integrated energy transfer system is in particular the mechanical mounting of the non-output side (right side in
[0106] The energy transfer system 20 comprises a primary side (stationary part or stator 2) and a secondary side (rotating part or rotor 4). The usual construction, i.e. with an outer stator and an inner rotor, is reversed in this case: The primary side of the energy transfer system 20 is arranged as an extension of the axis of rotation of the output shaft 13 of the synchronous machine 100 and located inside the secondary side of the energy transfer system 20. The cable routing to the primary side can pass through one or more openings in a (bearing) cover 50 on the non-output side (on the right in
[0107] In the case of the rotating secondary side, the windings are on the inside, followed by a magnetic flux carrier (e.g. a deformable mat made of pressed ferritic composite) and an electrically highly conductive material (e.g. copper) for shielding radially outward. The secondary-side electronics 6b in particular comprises capacitors for reactive power compensation and a rectifier. The rectifier can be a passive full-bridge rectifier, an active half-bridge rectifier or a mixed form (comprising an active transistor and a passive diode per branch). Since the electronics components are the most sensitive components in thermal terms, a circuit board containing the electronic components is preferably attached to the edge of the machine rotor 10. It is thus remote from the two thermal hotspots, namely the energy transfer system 20 in the rotor 10 and the rotor windings 15 of the synchronous machine 100. The secondary-side electronics device or circuit board 6b can be cooled by natural or forced convection. In addition, the secondary-side electronics device 6b can be thermally decoupled from the synchronous machine rotor shaft 13 by thermally weakly conductive materials (e.g. plastic such as POM or PEEK), since in electrical machines it typically has temperatures inadmissible for the components. The connection from the secondary side to the secondary-side electronics is preferably made by means of passages or openings in the synchronous machine rotor shaft 13. Additional cooling openings offer the possibility of an air flow within the energy transfer system 20, so that the heat within the synchronous machine rotor 10 or the synchronous machine rotor shaft 13 does not accumulate. In a preferred embodiment, an additional heat sink, in particular in the form of a ring, is attached for the secondary-side electronics device 6b. This heat sink is preferably insulated from the rotor shaft 13 by poorly conducting or thermally insulating materials.
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[0113] As already explained above, it can be advantageous to arrange an additional electrically conductive material layer 8 (in particular made of copper) at various points of the arrangement according to the invention or the synchronous machine 100 according to the invention, in particular in the region of the exciter device 30, such as e.g. at least one active part of the energy transfer system 20a or 20b. An active part of the energy transfer system is understood to mean a part of the energy transfer system that is at least partially exposed to a magnetic field used for energy transfer. The electrical conductivity of the additional material layer 8 is greater than the electrical conductivity of the at least one active part. If the exciter stator 2 is made of steel, it is advantageous to arrange such an additional electrically conductive material layer 8 on the exciter stator 2, for example. This is because in this case undesired eddy current losses and/or thermal losses can be reduced or avoided. Alternatively or in addition, an additional electrically conductive material layer 8 can also be arranged on the exciter rotor 4 (see
[0114] As can also be seen in
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[0117] Thus, the arrangement according to the invention serves in particular for rotor excitation of an electrical machine 100 in order to build up a static magnetic field and thus to cause a rotation of the machine rotor 10. With the aid of the arrangement according to the invention, in particular all four quadrants of an electrical machine as a motor and generator can be controlled without external forces. In other words, four-quadrant operation is possible with the arrangement described here. The electrical machine 100, which is excited with the aid of the exciter device 30, can therefore in particular be used both as a motor and as a generator. The coil system 28 is preferably single-phase and its operating frequency is independent of the speed of the machine 100.
[0118] Even if a three-phase machine is shown in
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[0120] In particular, the rotating energy transfer system 20, of which the coil system 28 is located in the cavity of the machine rotor 10, has the electrical single-phase structure shown in
[0121] The compensation can take various forms.
[0122] In summary, the present invention provides in particular a new solution for the construction of an electrically excited synchronous machine, the electrical energy transfer to the rotor preferably being carried out without contact. In particular, the energy transfer system is integrated into the hollow rotor shaft of the electrical machine. The hollow shaft of the machine rotor can also be lined with a highly electrically conductive material in order to minimize losses when using an inductively contactless transfer system, in particular in the high-frequency range. The transmission system is advantageously wear-free and a motor can take up less space (especially in the axial area). Furthermore, the electrically excited synchronous machine described in the context of the present invention offers a higher level of reliability and less heat development compared to conventional electrically excited synchronous machines, without the power density suffering thereby. One possible application of the present invention is e.g. in the field of electromobility.
REFERENCE NUMERAL LIST
[0123] 1 stator winding of the energy transfer system [0124] 2 stationary primary system or stator of the energy transfer system (exciter stator) [0125] 3 rotor winding of the energy transfer system [0126] 4 rotatable secondary system or rotor of the energy transfer system (exciter rotor) [0127] 5 cooling channel [0128] 6 electronics device [0129] 6a primary-side electronics device (electronics board) [0130] 6b secondary-side electronics device (electronics board) [0131] 7 magnetic flux-carrying material [0132] 8 additional electrically conductive material layer [0133] 9 plastics [0134] 10 machine rotor [0135] 11 laminated core of the machine rotor [0136] 12 inlet and outlet for coolant [0137] 13 machine rotor shaft [0138] 14 opening/air hole [0139] 15 rotor winding of the machine (exciter winding) [0140] 16 air gap [0141] 17 magnetic flux carrier element of the machine rotor [0142] 18 bearing [0143] 19 bearing [0144] 20 energy transfer system [0145] 20a first energy transfer system [0146] 20b second energy transfer system [0147] 22 air gap [0148] 24 inverter for the energy transfer system [0149] 25 primary-side compensation unit [0150] 26 rectifier for the energy transfer system [0151] 27 secondary-side compensation unit [0152] 28 coil system [0153] 30 exciter device [0154] 40 machine stator [0155] 42 grooves [0156] 45 stator winding of the machine [0157] 47 magnetic flux carrier element of the machine stator [0158] 50 cover [0159] 52 inverter for the electrically excited machine [0160] 54 energy or voltage source (battery) [0161] 60 adhesive [0162] 62 plastic holder with integrated flow-carrying material [0163] 64 recess [0164] 66 plastic cover [0165] 68 bandage [0166] 70 return element for the winding of the exciter stator [0167] 100 electrically excited machines