AXIAL FLUX STATOR

Abstract

The system and method of the invention pertains to an axial flux stator is implemented to replace the drive-end magnets and the drive motor. The axial flux stator comprises a control circuit to control the voltage and current provided to the stator, to measure the torque and speed of rotation, and to measure the magnetic flux and magnetic flux density produced by the axial flux stator and impeller magnets, individually or in combination. The axial flux stator comprises a plurality of current carrying elements to produce magnetic flux in an axial direction and drive the impeller.

Claims

1. A mixing system comprising: a stator comprising a plurality of current carrying elements to produce a magnetic flux in an axial direction; and an impeller capable of rotating around an axis of the axial flux stator; wherein the magnetic flux drives the impeller.

2. The mixing system of claim 1, where the stator is an axial flux stator having a core to affix the current carrying elements, the core including stator teeth.

3. The mixing system of claim 2, wherein the core is magnetic.

4. The mixing system of claim 1, wherein the impeller comprises a plurality of magnets, a back plate to enhance the magnetic coupling, a plurality of current carrying elements, one or more mixing blades, and a fixture to support the impeller from misalignment, alone or in combination.

5. The mixing system of claim 2, wherein the stator teeth include one or more conic shaped teeth.

6. The mixing system of claim 5, wherein the conic shaped teeth are in a configuration around the axis of rotation.

7. The mixing system of claim 6, wherein at least one of the plurality of current currying elements have a conic arrangement around the conic shaped teeth.

8. The mixing system of claim 4, wherein the plurality of magnets are in a conic arrangement around the axis of rotation.

9. The mixing system of claim 1, wherein the plurality of current carrying elements in the stator control any one of impeller speed, impeller torque, and impeller power, alone or in combination.

10. The mixing system of claim 2, wherein a flow of current through the current carrying elements in the stator forms a magnetic field that flows through the stator teeth, across an air gap between the stator and the impeller and back.

11. An axial flux stator comprising: a plurality of current carrying elements to produce a magnetic flux in an axial direction, a core to affix the current carrying elements, such that the core includes a plurality of stationary segments, each segment having height and a width with modulation slots there between, the segments integrated on a plate with a central hollow axis.

12. The axial flux stator of claim 11, wherein the core is magnetic.

13. The axial flux stator of claim 12, wherein the plurality of stationary segments are stator teeth and the current carrying elements are conductive windings wound around the stator teeth.

14. The axial flux stator of claim 13, wherein the conductive windings are divided into phases.

15. The axial flux stator of claim 14, wherein each phase of the individual windings alternates such that application of current to the winding creates a magnetic field that is directed vertically upward in one tooth and vertically downward in another tooth.

16. The axial flux stator of claim 13, wherein the stator teeth are conic shaped teeth.

17. The axial flux stator of claim 11, wherein the plurality of current carrying elements control any one of impeller speed, impeller torque, and impeller power, alone or in combination.

18. A system utilized as bioreactor mixer, the system comprising: a rotating drive; a fixed shaft; an impeller capable of rotating around the fixed shaft; and a plurality of magnets positioned in one or more array formats, a first set of magnets in a first array format positioned at a drive end adjacent the rotating drive and a second set of magnets in a second array format positioned at the impeller; wherein the rotating drive is a drive stator.

19. The system of claim 18, wherein the drive stator is an axial flux stator positioned on an underside of the plurality of magnets.

20. The system of claim 19, wherein the axial flux stator comprises a control circuit to control the voltage and current, individually or in combination, provided to the stator.

21. The system of claim 19, wherein the axial flux stator comprises a control circuit to measure the torque and speed of rotation.

22. The system of claim 19, wherein the axial flux stator comprises a control circuit to measure the magnetic flux and magnetic flux density produced by the axial flux stator and impeller magnets.

23. The system of claim 19, wherein the axial flux stator comprises a plurality of current carrying elements to produce magnetic flux in an axial direction and drive the impeller.

24. The system in claim 19, wherein the axial flux stator comprises a core to fix the current carrying elements on.

25. The system of claim 24, wherein the core is magnetic or non-magnetic.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1A (PRIOR ART) illustrates the magnetic drive for a bioreactor mixer.

[0015] FIG. 1B (PRIOR ART) illustrates a magnetic coupling where the impeller holds a set of magnets that are coupled to the drive end, the set of magnets in the drive end rotated by a separate motor.

[0016] FIG. 2 (PRIOR ART) depicts a cross-sectional view of the magnetic field coupling in a prior art system.

[0017] FIG. 3 depicts a cross-sectional view of the magnetic field coupling when using the individual magnet shapes and configuration as disclosed in embodiments herein.

[0018] FIG. 4A illustrates an embodiment of the invention including a back iron on both ends.

[0019] FIG. 4B illustrates an embodiment including pie-shaped magnets, individually positioned, angled, and spaced in a magnetic arrangement around a central axis.

[0020] FIG. 4C illustrates the rotor side constructed with a Halbach array in another embodiment, the individual magnets adjacent one another without spacing to form a concentric magnetic arrangement.

[0021] FIG. 5 depicts a cross-sectional view showing the magnetic coupling in embodiments disclosed herein when using the pie-shaped magnets and back iron.

[0022] FIG. 6 provides a comparison of magnets as utilized in embodiments of the invention.

[0023] FIG. 7 depicts a comparison of maximum torque for cylindrical magnets using different materials in one embodiment.

[0024] FIG. 8 depicts a comparison of maximum torque for cylindrical magnets with back iron.

[0025] FIG. 9 depicts a comparison of maximum torque for pie-shaped magnets and Halbach array

[0026] FIG. 10 depicts a graphic illustration of the relationship of torque versus current density for the axial flux stator in one embodiment.

[0027] FIG. 11 illustrates an embodiment of the invention from a perspective side view.

[0028] FIG. 12 illustrates an embodiment of the invention from a perspective side view.

[0029] FIG. 13(a), (b), (c) shows analyses of varying the stator length.

[0030] FIG. 14(a), (b), (c) shows an analyses of varying the current density.

[0031] FIG. 15(a), (b), (c) demonstrates analyses of varying the slot pitch, and resulting torque.

[0032] FIG. 16A illustrates a perspective view of an embodiment of a tooth wound axial flux stator.

[0033] FIG. 16B depicts a perspective top view of the axial flux stator of FIG. 16A.

[0034] FIG. 16C depicts a perspective side view of the axial flux stator of FIG. 16A.

[0035] FIG. 16D depicts a perspective side view of the tooth height of the axial flux stator of FIG. 16A.

[0036] FIG. 16E depicts an embodiment of a stator core described herein.

DETAILED DESCRIPTION

[0037] Various embodiments will be better understood when read in conjunction with the appended drawings. It should be understood that the various embodiments are not limited to the arrangements and instrumentality shown in the drawings.

[0038] The system and method of the embodiments disclosed pertain to a magnetic drive for a bioreactor mixer or pump that strengthens the magnetic coupling to provide higher torque and replace the drive-end magnets and/or drive motor, as desired. Embodiments include magnetic shapes and arrangements as well, including pie-shaped magnets (“pie” shaped in the sense of a wedge shape and wedged format (i.e., triangular/trapezoidal have a wider outer edge and smaller inner dimension), such that the wedges fit together to increase the volume utilization and hence provide higher torque, and further allow the use of less expensive material (e.g. ferrites). In one embodiment, the rotor side is constructed with a Halbach array which increases the torque. Embodiments disclosed may utilize a back iron on one or both ends to strengthen the magnetic coupling. With the Halbach array, torque is increased without a back iron piece. Another embodiment implements an axial flux stator to replace the drive-end magnets and the drive motor. Embodiments are disclosed as follows.

[0039] Pie-Shaped Magnet Configuration

[0040] For comparison purposes, FIG. 2 depicts a cross-sectional view of the magnetic field coupling 201 in a prior art system between a drive end magnet 202 and an impeller end magnet 204; The magnetic field density 203 is the area represented there between. An embodiment disclosed herein is shown in FIG. 3 where pie-shaped magnets are utilized in the mixer 300. A cross-sectional view shows a large increase in the magnetic field coupling 301, the increased magnetic field density 303 between the drive end magnet 302 and impeller end magnet 304.

[0041] FIG. 4A depicts the rotor side of a mixer 400 with a Halbach array 402 in one embodiment. The individual magnets 403 are adjacent one another without spacing to form a concentric magnetic arrangement of the Halbach array 402. The pie-shaped impeller end magnets 404 are spaced apart and positioned on a magnetic plate 405. The magnetic plate may be a back iron, any magnetic material, including but not limited to any material of magnetic permeability greater than air. In one aspect, the magnetic plate may be a high magnetic permeability allow such as cobalt, iron, or other magnetic material. A magnetic field density 401 is created by the space remaining where the individual magnets 403 of the Halback array 402 levitate above the impeller end magnets 404.

[0042] Back Iron at Impeller and Drive Ends

[0043] FIG. 4B illustrates an embodiment of a magnetic drive 410 including wedged (pie-shaped) magnets 412 at a drive end 411 and wedged (pie-shaped) magnets 414 at an impeller end 413, each magnet 412, 414 individually positioned, angled, and spaced in a magnetic arrangement around a central axis 415. A magnetic plate 405 is positioned at the impeller end 413 while a second magnetic plate 406 is positioned at the drive end 411. The magnetic plates 405, 406 are a back iron, in one embodiment, and may be any magnetic material, including but not limited to any material of magnetic permeability greater than air. A magnetic field density 417 is created between the drive end magnets 412 and impeller end magnets 414, thus increasing the magnetic coupling. In another aspect, the magnetic plate is a high magnetic permeability including materials including, but not limited to, cobalt, iron, or other magnetic material.

[0044] In one embodiment, as shown in FIG. 4C, a magnetic drive 420 includes an impeller end back iron 405 and drive end back iron 406. The cylindrical shaped magnets 418 are spaced around a central axis 419, and positioned at each end such that a magnetic field density 421 is created therebetween. The back irons enhance the magnetic coupling of the magnetic drive, thereby increasing torque.

[0045] As illustrated in FIG. 4C, back iron is placed in the shape of the impeller above the drive end magnets and below the impeller end magnets. The back iron reduces the overall magnetic path in air, the magnetic field density 421, between the drive end and the impeller end magnets. As a result, the magnetic field density that couples the two ends increases.

[0046] FIG. 5 depicts a cross-sectional view of a mixing system 500 showing the magnetic coupling 501 in embodiments disclosed herein when using the pie-shaped magnets and back irons, as described in FIG. 4B.

[0047] A comparison of magnets is shown in FIG. 6. Baseline torque is at about 5.8 Nm with cylindrical shaped magnets as shown in FIG. 4C. Note that . . .

[0048] FIG. 6 illustrates that the cost of non-rare earth materials, e.g., Alnico 9 and C8B/AC12 (ceramic) are cheaper and have beneficial characteristics that align with the desired magnetic compositions, characteristics, and configurations described.

[0049] FIG. 7 is a comparison of maximum torque for cylindrical magnets (φ=0.75×0.75). By replacing Neodymium (Sintered NdFeB) magnets, and using other non-rare earth magnets, while keeping the cylindrical shapes and arrangement, the torque production is greatly reduced.

[0050] In another aspect, back iron may be added on one of the impeller end or the drive end. Back iron added at impeller and drive ends improves torque production, as illustrated in FIG. 8. Specifically, FIG. 8 demonstrates the comparison of maximum torque for cylindrical magnets with back iron, as represented in FIG. 4C. FIG. 8 shows that maximum torque produced by different types of magnets (e.g., N 38/15, SmCo 28/7, etc.) as a function of magnet geometry. The ferrite magnet grade FB12H gives twice the amount of the torque produced without the back plate, while eliminating the use of rare earth magnets. Three of the magnet grades are not able to produce the baseline torque of the rare earth magnets.

[0051] Embodiments of the invention modify the shape of the magnets from cylindrical to pie-shaped configurations. As shown in FIG. 9, the improved impeller-drive design provides 2.5 times the torque without the need for expensive Neodymium magnets. Ferrite magnet grade FB12H gives 2.5 times the amount of torque produced without the back plate and the magnet pie shape. As demonstrated in FIG. 4B, and referenced in FIG. 9, a comparison is shown of maximum torque for pie-shaped magnets.

[0052] Halbach Magnet Array

[0053] As shown in FIG. 9, an embodiment of the Halbach impeller-drive design of FIG. 4A provides the desired torque without the need for expensive Neodymium magnets. This arrangement of Halbach array and pie shaped increases the torque produced by a factor of 3 which delivers the baseline torque.

[0054] Axial Flux Stator

[0055] Embodiments of the invention provide an axial flux stator to reduce the drive end size, as well as reducing the number of components, and increase its reliability. FIG. 11 depicts an embodiment of the axial flux stator 110 without the shaft and bearing, and without the lever mechanism as utilized in the prior art. The drive stator 111 is positioned on an underside of the magnets 112 and has a control circuit 113.

[0056] The electrical and mechanical components of the axial flux stator 110 are adjusted to address challenges in the modified design. In embodiments of the axial flux stator, the electrical components comprise: high current density (cooling), a higher number of slots to allow high count of slots per pole and hence the ability to choose various coil span (to suppress harmonics), longer slots resulting in higher leakage inductance and lower power factor, and higher current results in higher flux thus accommodating a bigger tooth to avoid saturation.

[0057] The construction of the axial flux stator 120 is depicted in FIG. 12 as an axial-type magnetic gear. A magnetic core 121 is positioned between a high speed rotor 125 (stator with high frequency) and a low speed rotor 126. The magnetic core 121 has a number of slots 122 depending on the arrangement of the impeller magnets and windings. The magnetic core may be laminated, powder type, or a taped core, as desired. A set of windings are shown in FIG. 12 as stationary steel segments 123, or stator teeth, with modulation slots 122. The set of windings may be tooth-wound, distributed, or fractional windings, as well. Windings can also be single or multi-layer, wave or lap windings, full or short pitched windings. The stationary steel segments can have additional slotting to accommodate magnetic gearing (e.g., Vernier type machine) with single or multi-stage gearing. The stator can also have additional magnets when using a Vernier type machine.

[0058] An analysis of the axial flux stator with distributed windings (e.g., an 18 slot example) demonstrates that by increasing the stator length, a higher current path results per slot; saturation of the teeth occurs and causes increased harmonics (See FIG. 13). Increasing the stator current density results in higher torque; again, saturation of the teeth occurs and causes increased harmonics (See FIG. 14). And, by increasing the stator slot pitch, higher torque results while placing mechanical constraints on the innermost tooth width (See FIG. 15).

[0059] FIG. 16A illustrates an embodiment of a tooth wound axial flux stator 160 with nine (9) slots 165 (See FIG. 16C), for exemplary purposes, and not limitation. FIGS. 16B, 16C, and 16D depict perspective views to more clearly illustrate the details of the axial flux stator 160. The stator core comprises pie-shaped magnetic stator teeth 163 that extend vertically from the stator back iron 162. The stator core 170 can be formed from sintered powdered iron, ferrite, or machined from a coil of magnetic steel. Conductive windings 164 are wound around the stator teeth 163. The conductive windings are divided up into phases. Within each phase winding, the sense, field direction, of the individual coils alternates so that the application of phase current to the phase winding creates a magnetic field that is directed vertically upward in one tooth and vertically downward in another tooth. The flow of current through the conductive windings forms a magnetic field that flows through the stator teeth, across the air gap between the stator 160 and a rotor 161, interacts with the magnets 166 on the rotor, travels through the rotor 161, and returns through a rotor magnet of opposite magnetic polarity, across the air gap between the stator and rotor, through an oppositely-excited stator tooth, closing through the stator back iron 162.

[0060] As shown in FIG. 16B, the exemplary stator has nine slots 165 of width of about 0.470 in; the inside diameter (a hollow core 171 with central axis 172) of the stator core 170 is about 1.575 in, and the outside diameter of the stator core is about 3.250 in. The width of the slots, the core inside diameter, and core outside diameter are parameters that determine the performance of the motor. FIG. 16C depicts the magnetic stator core 170 including stator teeth 163 in combination with the base back iron 162 and shows that the stator core is about 2.750 in height, but can vary in size, shape and dimension, as desired for a particular mixer. FIG. 16D depicts the height of the magnetic pie-shaped stator teeth 163, the height of which is shown here as about 2.500 in. The height of the stator teeth and the thickness of the stator back iron are additional parameters determined during the design of the motor, and so may be varied in shape and dimension.

[0061] In another embodiment, as shown in FIG. 16E, the stator core 175 is defined with conic teeth 176 and including a back iron 177. As such, the stator core may be modified and designed to provide operational efficiency of a mixer.

[0062] FIG. 10 compares torque versus current density of the axial flux stator 160 for gaps of about 0.32 inches and about 0.265 inches between the stator and rotor. More torque is produced for a given current density with the smaller gap. The efficiency is slightly greater for the smaller gap since the current is smaller.

[0063] As demonstrated, the embodiments thus described address the problems presented in the art. The cheaper impeller as described comprises a magnetic coupling improved by increasing the magnetic field density. Higher torque density is produced by optimizing the impeller magnet by way of material, shape, and back iron, individually or in combination. The rare earth magnets can be replaced by less expensive and environmentally friendly non-rare earth materials, such as Alnico and Ferrite, for example. In addition, the large and oversized drive assembly used prior now can run a much smaller impeller. Further, the moving parts on the drive side, near the user have been repositioned to provide a safer device overall.

[0064] Additional technical and commercial advantages are provided with the more reliable system that includes the axial flux stator; the axial flux stator has a smaller drive, no moving parts, and reduced magnetic force during bag installation. While cost and availability of the magnets is an advantage with improving magnet shape and material, the efficiency of the magnetic coupling that increase torque is very useful for further intensification of the bioreactor, various mixing systems, and overall efficiency.

[0065] In use, for example, microbial fermentations utilize more agitation for sufficient mixing, gas mass transfer and heat transfer at the reactor wall. An improved device of the invention including the axial flux stator improves user experience due to a less complex design. Not only is the design more compact than a drive with permanent magnets, but the installation and removal of the bag is improved as there are no permanent magnetic forces that have to be overcome. Moving parts are avoided with consequences on machinery directive requirements, sealing and ingress protection to avoid prior standard design that utilized a lever mechanism to separate the drive from the impeller such that the bag can be pulled out of the reactor bottom end piece.

[0066] It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.

[0067] This written description uses examples to disclose the various embodiments, and also to enable a person having ordinary skill in the art to practice the various embodiments, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the various embodiments 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 the examples have structural elements that do not differ from the literal language of the claims, or the examples include equivalent structural elements with insubstantial differences from the literal languages of the claims.