SYSTEM AND METHOD FOR SMOOTHING A SALIENT ROTOR IN ELECTRICAL MACHINES
20170054335 ยท 2017-02-23
Assignee
Inventors
- Tsarafidy Raminosoa (Niskayuna, NY, US)
- James Pellegrino Alexander (Ballston Lake, NY, US)
- Aymam Mohamed Fawzi EL-Refaie (Niskayuna, NY, US)
- David A. Torrey (Ballston Spa, NY)
Cpc classification
H02K1/24
ELECTRICITY
H02K1/146
ELECTRICITY
H02K2205/12
ELECTRICITY
International classification
Abstract
An electrical machine exhibiting reduced friction and windage losses is disclosed. The electrical machine includes a stator and a rotor assembly configured to rotate relative to the stator, wherein the rotor assembly comprises a rotor core including a plurality of salient rotor poles that are spaced apart from one another around an inner hub such that an interpolar gap is formed between each adjacent pair of salient rotor poles, with an opening being defined by the rotor core in each interpolar gap. Electrically non-conductive and non-magnetic inserts are positioned in the gaps formed between the salient rotor poles, with each of the inserts including a mating feature formed an axially inner edge thereof that is configured to mate with a respective opening being defined by the rotor core, so as to secure the insert to the rotor core against centrifugal force experienced during rotation of the rotor assembly.
Claims
1. An electrical machine comprising: a stator; a rotor assembly disposed within the stator and configured to rotate relative to the stator, wherein the rotor assembly comprises: a rotor core constructed of a stack of laminations, the rotor core comprising a plurality of salient rotor poles that are spaced apart from one another around an inner hub such that an interpolar gap is formed between each adjacent pair of salient rotor poles; and a plurality of inserts positioned in the gaps formed between the plurality of salient rotor poles, the inserts each formed as a single piece extending axially through the stack of laminations of the rotor core and each being entirely formed of nonconductive and non-magnetic material.
2. The electrical machine of claim 1 wherein the inserts each comprise a mating feature forming an axially inner edge thereof configured to mate with a corresponding opening in each interpolar gap defined by the rotor core.
3. The electrical machine of claim 2 wherein the mating feature comprises a dovetail feature configured to mate with an opening formed in the inner hub of the rotor core.
4. The electrical machine of claim 1 wherein the rotor assembly further comprises a pair of non-conductive and non-magnetic end plates positioned on axially opposing ends of the rotor core.
5. The electrical machine of claim 4 wherein opposing ends of each insert comprise an additional mating feature formed on each end thereof configured to mate with a corresponding opening on each end plate.
6. The electrical machine of claim 1 wherein the plurality of salient rotor poles comprises a plurality of rotor teeth.
7. The electrical machine of claim 1 wherein each of the plurality of inserts comprises a T-shaped insert comprising: a lengthwise member extending in a radial direction; and a crosswise member extending normally between two adjacent rotor poles.
8. The electrical machine of claim 7 wherein the crosswise member forms a smooth outer surface on the rotor in combination with a pair of adjacent rotor poles.
9. The electrical machine of claim 7 wherein each of the plurality of rotor poles comprises a pair of flange-like protrusions formed at a radially outermost portion thereof, wherein the crosswise member includes a shoulder on each end thereof configured to mate with the pair of flange-like protrusions.
10. The electrical machine of claim 7 wherein each of the plurality of rotor poles comprises a pair of axially-extending notches formed in proximity to the radially outermost portion thereof, wherein the crosswise member includes a shoulder on each end thereof configured to mate with the pair of axially-extending notches.
11. A rotor assembly for an electrical machine comprising: a rotor core constructed of a stack of laminations, the rotor core comprising a plurality of salient rotor poles that are spaced apart from one another around an inner hub such that an interpolar gap is formed between each adjacent pair of salient rotor poles; and a plurality of inserts positioned in the gaps formed between the plurality of salient rotor poles, the inserts each formed as a single piece extending axially through the stack of laminations of the rotor core and each being entirely formed of nonconductive and non-magnetic material.
12. The rotor assembly of claim 11 wherein the rotor assembly further comprises a pair of non-conductive and non-magnetic end plates positioned on axially opposing ends of the rotor core.
13. The rotor assembly of claim 12 wherein opposing ends of each insert comprise an additional mating feature formed on each end thereof configured to mate with a corresponding opening on each end plate.
14. The rotor assembly of claim 11 wherein each of the plurality of inserts comprises a T-shaped insert comprising: a lengthwise member extending in a radial direction; and a crosswise member extending normally between two adjacent rotor poles.
15. The rotor assembly of claim 14 wherein the crosswise member forms a smooth outer surface on the rotor in combination with a pair of adjacent rotor poles.
16. The rotor assembly of claim 14 wherein each of the plurality of rotor poles comprises a pair of flange-like protrusions formed at a radially outermost portion thereof, wherein the crosswise member includes a shoulder on each end thereof configured to mate with the pair of flange-like protrusions.
17. The rotor assembly of claim 14 wherein each of the plurality of rotor poles comprises a pair of axially-extending notches formed in proximity to the radially outermost portion thereof, wherein the crosswise member includes a shoulder on each end thereof configured to mate with the pair of axially-extending notches.
18. An electrical machine comprising: a stator; a rotor assembly disposed within the stator and configured to rotate relative to the stator, wherein the rotor assembly comprises: a rotor core comprising a plurality of salient rotor poles that are spaced apart from one another around an inner hub such that an interpolar gap is formed between each adjacent pair of salient rotor poles; and a plurality of inserts positioned in the gaps formed between the plurality of salient rotor poles, the inserts each formed as a single piece extending axially through the rotor core and each being entirely formed of nonconductive and non-magnetic material.
19. The electrical machine of claim 19 wherein the rotor core is formed as a single piece of material.
20. The electrical machine of claim 19 wherein the rotor assembly further comprises a pair of non-conductive and non-magnetic end plates positioned on axially opposing ends of the rotor core.
21. The electrical machine of claim 20 wherein opposing ends of each insert comprise an additional mating feature formed on each end thereof configured to mate with a corresponding opening on each end plate.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The drawings illustrate preferred embodiments presently contemplated for carrying out the invention.
[0011] In the drawings:
[0012]
[0013]
[0014]
[0015]
[0016]
[0017]
[0018]
[0019]
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] Embodiments of the invention are to electrical machines incorporating a salient rotor, with inserts being provided for the salient rotor for smoothing the rotor so as to address issues of friction and windage losses without affecting the magnetic performance. While embodiments of the invention are discussed with respect to an electrical machine in which the rotor and stator interact through radial magnetic fields, it will be appreciated by one skilled in the art that embodiments of the invention can also be used for electrical machines that use axial fields for rotor/stator interaction, with the inserts oriented in the radial direction.
[0021] Referring to
[0022] As shown in
[0023] The exact structure of the electrical machine may take one of numerous forms, according to embodiments of the invention. For example, the electrical machine may be configured as a reluctance motor that induces non-permanent magnetic poles, with the phase windings 5 of the stator 3 being driven in a predetermined sequence to cause rotor 3 to rotate. The reluctance motor may be a synchronous reluctance motor having equal numbers of stator and rotor poles or a switched reluctance motor where the number of stator pole pairs exceeds the number of rotor pole pairs by one. As another example, the electrical machine may be configured as a stator permanent magnet machine (e.g., permanent magnet flux switching machine, permanent magnet flux reversal machine, or doubly-salient permanent magnet machine, for example) that includes permanent magnets 9 (shown in phantom) embedded in the stator. In such stator permanent magnet machines, electric current in the windings 5, interacts with magnetic fields associated with the magnets 9 to cause rotation of the rotor 3.
[0024] It is recognized that
[0025] Referring now to
[0026] According to embodiments of the invention, salient rotors 10, 20 such as those shown in
[0027] Referring now to
[0028] As shown in
[0029]
[0030] Referring now to
[0031] According to other embodiments, the area 73 defined by outer shell 72 may be left open (or partially open)such that the mass of the insert 70 is reduced. That is, in one embodiment, the opening 73 may be left entirely unfilled, as shown in
[0032] As shown in
[0033] Referring now to
[0034] According to an exemplary embodiment, the insert 88 is formed as a multi-material insert having an outer shell 90 formed of a first non-conductive, non-magnetic material and an inner filler 92 formed of a second non-conductive, non-magnetic material. According to an exemplary embodiment, the outer shell 90 is formed of a non-conductive, non-magnetic material that provides a high mechanical strength and rigidity to the insert. The inner filler 92 is formed of non-conductive, non-magnetic material having a lower density than the outer shell 90 materialand may be formed, for example, of a dielectric foam that is very light weight. The inclusion of inner filler 92 in the insert in an interior thereof functions to greatly reduce the overall weight of the insert 88, such that the centrifugal forces generated by the inserts 88 are greatly reducedthereby improving the functioning and longevity of the rotor assembly 76. Alternatively, it is recognized that the insert 88 could also be formed as an extrusion with internal features that provide for increased strength, without the weight penalty of being solid, as discussed above.
[0035] Referring now to
[0036] Beneficially, embodiments of the invention thus provide non-conductive, non-magnetic rotor inserts that provide smoothing for various types of salient rotors. The rotor inserts enable significant reduction of friction and windage losses, as the rotor surface becomes mechanically smooth based on the positioning of the inserts between adjacent pairs of rotor poles, so as to provide a significant efficiency improvement (i.e., better efficiency than a non-smooth rotor), especially for high-speed applications. The non-conductive, non-magnetic rotor inserts are assembled with the salient rotor in a mechanically robust way, such as via the use of mating (e.g., dovetail) features on the inserts, that enable the inserts to withstand centrifugal forces at high speeds. The non-conductive, non-magnetic rotor inserts are further constructed to minimize the mass that is added to the rotor, with the inserts being formed to fill only a portion of an interpolar between adjacent rotor poles and/or being formed partially of a low-density material.
[0037] Therefore, according to one embodiment of the invention, an electrical machine includes a stator and a rotor assembly disposed within the stator and configured to rotate relative to the stator, wherein the rotor assembly comprises a rotor core comprising a plurality of salient rotor poles that are spaced apart from one another around an inner hub such that an interpolar gap is formed between each adjacent pair of salient rotor poles, with an opening being defined by the rotor core in each interpolar gap, and a plurality of inserts positioned in the gaps formed between the plurality of salient rotor poles, the plurality of inserts being formed of electrically non-conductive and non-magnetic material. Each of the plurality of inserts comprises a mating feature formed an axially inner edge thereof that is configured to mate with a respective opening being defined by the rotor core, so as to secure the insert to the rotor core against centrifugal force experienced during rotation of the rotor assembly.
[0038] According to another embodiment of the invention, a method for manufacturing an electrical machine includes providing a stator and providing a rotor assembly that is positionable within the stator and is mountable for rotation about a central axis, wherein providing the rotor assembly comprises providing a salient rotor core comprising a plurality of salient rotor poles that are spaced apart from one another around an inner hub such that an interpolar gap is formed between each adjacent pair of salient rotor poles, with a dovetail-shaped opening being defined by the rotor core in each interpolar gap. Providing the rotor assembly further comprises providing a plurality of inserts formed of electrically non-conductive and non-magnetic material and securing the plurality of inserts in the interpolar gaps formed between the plurality of salient rotor poles, wherein, in securing each of the plurality of inserts in an interpolar gap formed between an adjacent pair of salient rotor poles, a mating feature of the insert is mated with a respective opening being defined by the rotor core, so as to secure the insert to the rotor core against centrifugal force experienced during rotation of the rotor assembly.
[0039] According to yet another embodiment of the invention, a rotor assembly for an electrical machine includes a salient rotor comprising a plurality of salient rotor poles that are spaced apart from one another around an inner hub such that an interpolar gap is formed between each adjacent pair of salient rotor poles and a plurality of inserts positioned in the interpolar gaps formed between the plurality of salient rotor poles and being constructed such that the plurality of inserts in combination with the plurality of salient rotor poles forms a smooth outer surface on the rotor assembly. The plurality of inserts comprise one of T-shaped inserts formed of an electrically non-conductive and non-magnetic material, hollow inserts having an outer shell formed of an electrically non-conductive and non-magnetic material, or dovetail-shaped inserts formed of an electrically non-conductive and non-magnetic material. Each of the plurality of inserts is configured to mate with the salient rotor so as to secure the insert to the salient rotor against centrifugal force experienced during rotation of the rotor assembly.
[0040] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.