Axial flux switched reluctance and inductive state machine systems, devices, and methods

Abstract

A state machine comprises: a stator assembly arranged to generate a rotating electromagnetic field in response to a control signal; and a rotor assembly positioned adjacent to the stator assembly, arranged to rotate in response to a rotating electromagnetic field. The sensor is arranged to detect an angular position of the rotor assembly and to output sensor data based on the angular position of the rotor assembly. The controller is arranged to receive the sensor data and to adjust the control signal based on the angular position of the rotor assembly to adjust a torque associated with the rotor assembly when the state machine is used as a motor or to adjust a power output from the stator assembly when the state machine is used as a generator.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the validity of and the benefit of U.S. Provisional Patent Application No. 63 / 355,864, filed on June 27, 2022, and entitled “AXIAL FLUX SWITCHED RELUCTANCE MOTOR SYSTEM AND METHOD,” the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present application relates generally to motor or generator control techniques and, more particularly, to the control of switched reluctance or induction motors. Background Art

[0004] Various types of electric motors and generators are currently used in many commercial applications, including electric vehicles (EVs), blowers, tools, pumps, fans, blenders, food processors, and generators, among other applications. A typical motor includes a fixed stator and a rotor that rotates relative to the stator. The rotor is connected to a drive shaft that drives operations associated with a specific application. In a direct current (DC) motor, a DC current is applied to the windings of the rotor to generate an electromagnetic (EM) field. As the rotor rotates, the current applied to the rotor is commutated via mechanical brushes or via electronic control in a brushless configuration. The stator of a DC motor typically includes magnets that provide a magnetic field that interacts with the EM field generated by the rotor, thereby affecting the rotation of the rotor. The stator magnets are typically made of rare earth metals, such as neodymium and dysprosium, which provide a high-density magnetic field to facilitate the relatively high torque of a DC motor.

[0005] Induction motors and reluctance motors are other types of motors. Induction motors use alternating current (AC) or a sinusoidal signal applied to the stator to generate a rotating EM field that drives the rotation of the adjacent rotor. Typically, a three-phase induction motor has a stator with three pole pairs (i.e., six stator poles), where each pole pair includes a series-connected winding that carries one of the three phases of voltage and current applied to the stator of the induction motor. Each phase of the current is offset by 120 degrees, and each corresponding pole pair is physically offset by 120 degrees from each other. This physical and electrical configuration provides a rotating EM field that interacts with the rotor to drive the rotation of the rotor assembly. The rotor can be in a squirrel cage configuration, with current flowing along the conduits of the squirrel cage, thereby generating an EM field that interacts with the EM field generated by the stator to promote the rotation of the rotor. The rotational speed of the rotor can be controlled using various techniques, such as changing the frequency of the current applied to each phase winding or changing the voltage, among other techniques. Reluctance motors are excited by pulses triggered by the rotor position, which is very different from induction motors. While speed regulation of an induction motor is achieved by varying the frequency of the rotating magnetic field, speed regulation of a reluctance motor is achieved by varying the input voltage applied to the stator windings. Reluctance motors operate in a similar manner to stepper motors. The stator of an SRM has windings, but the rotor is typically salient pole (e.g., no windings or magnets) made of steel. Computer control is required to implement the drive waveform (timing and triggering control) based on rotor position and current / voltage feedback. An SRM achieves closed-loop speed control by controlling parameters such as the turn-on angle, turn-off angle, and voltage pulse width modulation (PWM) duty cycle. Depending on the configuration, speed control of an SRM can be based on varying the voltage PWM duty cycle of the input control signal to the stator windings. Because SRMs typically have nonlinear rotational characteristics, accurately modeling speed control is very complex.

[0006] The rotation of a reluctance motor is based on the principle that the rotor and stator poles will move to a position where the EM field lines have a lower or lowest magnetic resistance (i.e., lower EM field resistance). One type of reluctance motor is a three-phase switched reluctance motor (SRM). The SRM is self-starting because it includes three phases and three pole pairs, the three phases are electronically offset by 120 degrees, and the three pole pairs are physically offset by 120 degrees from each other to facilitate the rotation of the rotor assembly under the EM field generated by the stator assembly. The SRM uses an electronic controller that controls the excitation of each phase winding to generate a rotating EM field.

[0007] Existing DC motors or generators for EVs or other applications often use rare earth metals, which have adverse effects on the environment and are becoming less and less in demand. Induction and reluctance motors can provide an alternative to DC motors to reduce the need for rare earth metals, but generally have lower performance capabilities than DC motors. Therefore, there is a need to implement motors that eliminate or reduce the use of rare earth metals while providing adequate performance capabilities relative to DC motors or AC motors that use rare earth metals. Summary of the invention

[0008] In various implementations, the present application addresses deficiencies associated with existing electric motor and generator implementations.

[0009] The present application describes exemplary systems, methods and devices for implementing induction and / or reluctance motors that are capable of providing sufficient power and / or torque to fully operate a drive shaft, such as in an EV. Exemplary induction and / or reluctance motor or generator systems, methods and devices can provide implementations without the use of rare earth metals, while not sacrificing performance relative to other motors that use rare earth metals, such as DC motors. If desired, rare earth magnets and / or copper conductors can still be used to enhance the performance of the induction and / or reluctance motors described herein. However, the motors described herein utilize reluctance and induction to generate torque or power. In addition, innovative electromagnets having magnetic flux characteristics comparable to those of rare earth magnets suitable for integration into electric motors are described. In some implementations, the magnetic circuit comprising the electromagnet utilizes low-cost, readily available steel alloys. The above components can be packaged in a manner that optimizes the magnetic flux path of each phase, thereby reducing power consumption and increasing torque. In various implementations, the heat generation of the electric motor is significantly improved due to the geometric configuration of the electromagnet and the control of the electrical excitation.

[0010] In one aspect, the state machine (i.e., a motor and / or generator) includes a stator assembly that is arranged to generate a rotating electromagnetic field in response to a control signal. The state machine also includes a rotor assembly that is positioned adjacent to the stator assembly and is arranged to rotate in response to the rotating electromagnetic field. For an inductive state machine, the rotating electromagnetic field is based on the physical arrangement of the stator poles and a control signal that may include a three-phase AC signal. For a reluctance state machine, the rotating electromagnetic field may be based on the physical arrangement of the stator poles and a varying excitation signal that is applied to the stator poles under the control of a processor so that the electromagnetic field causes the stator to rotate in a desired direction of rotation at a specific torque and / or speed based on the magnetic resistance between the stator and the rotor poles. In some implementations, the controller of the state machine implements an SRM trigger control technique to achieve inductance and resistance changes associated with the rotor position, resulting in a variable inductance time constant. The controller may adjust the triggering energization and de-energization for each phase to achieve maximum torque and / or power output while preventing the rotor assembly from aligning with the energized phase. Depending on the rotor assembly speed, the controller may adjust the trigger to achieve the desired torque and / or power output, and / or rotor assembly acceleration or deceleration rate. This phenomenon with respect to the controller's heavy side timing and trigger control may be referred to as phase trigger advance or delay.

[0011] The first sensor is arranged to detect an angular position of the rotor assembly and output first sensor data based on the angular position of the rotor assembly. The controller is arranged to receive the first sensor data and adjust a control signal based on the angular position of the rotor assembly to adjust a torque associated with the rotor assembly when the state machine is used as a motor or to adjust an electrical output from the stator assembly when the state machine is used as a generator.

[0012] In some implementations, the second sensor is arranged to detect one or more state machine conditions, such as, for example, rotor assembly speed, stator current, stator voltage, and / or state machine temperature. The second sensor may output second sensor data corresponding to the one or more state machine conditions, wherein the controller is further arranged to receive the second sensor data and adjust the control signal based on the second sensor data.

[0013] The control signal may include a pulse waveform and / or a square wave. In the case where the motor includes an induction state machine, the controller may adjust the rotational speed of the rotor assembly by adjusting the frequency associated with the control signal. In the case where the motor includes a reluctance motor, the controller may adjust the speed of the rotor assembly by adjusting the voltage applied to the stator assembly winding. The state machine may include a multi-phase induction motor and / or a multi-phase induction generator. The state machine may include a single-phase, three-phase, five-phase or six-phase induction motor and / or generator. The state machine may include a single-stator induction state machine, an inner-rotation induction state machine, and one of an outer-rotation induction state machine. The state machine may include at least one of a multi-phase switched reluctance motor (SRM) and a multi-phase reluctance generator. In some implementations, the SRM includes a three-phase SRM and a three-phase generator. The state machine may include a single-stator reluctance state machine, a single-stator dual-coil reluctance machine, an inner-rotation reluctance state machine, an outer-rotation dual-rotor reluctance state machine, an outer-rotation single-rotor reluctance state machine, a zero-gradient flux dual-stator state machine, and a zero-gradient flux outer-rotation state machine.

[0014] The state machine is configured to operate as a motor-generator. The state machine may include and / or interface with an energy storage element configured to release magnetic stored energy and / or electrical stored energy based on the angular position of the rotor assembly. The magnetic stored energy may be stored in at least one transformer. The electrical stored energy may be stored in at least one capacitor.

[0015] The stator assembly may be arranged to generate an electrical signal in response to a rotating magnetic field generated by rotation of the rotor assembly. When the state machine is used as a reluctance generator, the controller is further arranged to: i) receive second sensor data from a second sensor, wherein the second sensor data includes a rotor assembly rotational speed, and ii) based on the rotor assembly rotational speed and the rotor angular position, for each phase of the stator, reverse the excitation circuit to generate the electrical signal.

[0016] When the state machine is used as an induction generator, the controller may be further arranged to: i) receive second sensor data from a second sensor, wherein the second sensor data includes a rotor assembly rotational speed, and ii) trigger each phase of the stator assembly prior to the rotor assembly angular position associated with each phase to generate an electrical signal. The electrical signal may be an AC signal. The state machine may include an AC to DC inverter arranged to convert the AC signal to a DC signal. The state machine system may include a power storage and / or power supply including one or more batteries configured to receive the DC signal and store electrical energy based on the received DC signal.

[0017] Another aspect includes a method for operating a state machine, the state machine having a stator assembly arranged to generate a rotating electromagnetic field in response to a control signal and a rotor assembly positioned adjacent to the stator assembly and arranged to rotate in response to the rotating electromagnetic field, wherein the method includes: detecting an angular position of the rotor assembly via a sensor; outputting sensor data based on the angular position of the rotor assembly via the sensor; and receiving the sensor data and adjusting the control signal based on the angular position of the rotor assembly to adjust the torque associated with the rotor assembly when the state machine is used as a motor or to adjust the power output from the stator assembly when the state machine is used as a generator.

[0018] On the other hand, an electric vehicle (EV) includes a power storage device including at least one battery, wherein the power storage device is arranged to output the stored energy as an output DC electrical signal. The EV has a state machine including: a stator assembly arranged to generate a rotating electromagnetic field in response to a control signal; and a rotor assembly positioned adjacent to the stator assembly and arranged to rotate in response to the rotating electromagnetic field. A first sensor is arranged to detect an angular position of the rotor assembly and output first sensor data based on the angular position of the rotor assembly. A controller is arranged to receive the first sensor data and adjust a control signal based on the angular position of the rotor assembly to adjust a torque associated with the rotor assembly when the state machine is used as a motor or to adjust a power output from the stator assembly when the state machine is used as a generator, the power output including an AC electrical signal. The EV also includes a DC to AC inverter arranged to convert an output DC electrical signal from the power storage device into a control signal. The EV also includes an AC to DC converter arranged to convert an AC electrical signal into an input DC electrical signal delivered to the power storage device.

[0019] Any two or more features described in this specification, including in the Summary of the Invention, may be combined to form implementations not specifically described in this specification. In addition, although this specification may refer to examples of systems, methods, and devices related to electric motors, these techniques are also applicable to generators.

[0020] The details of one or more implementations are set forth in the accompanying drawings and the description that follows. Other features and advantages may be apparent from the description, drawings, and claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is a block diagram of a state machine system;

[0022] Figure 2 A schematic diagram of a computer system implemented for a state machine controller is shown;

[0023] Figure 3 shows a schematic diagram of a motor control system including an inductive energy storage;

[0024] Figure 4 shows a schematic diagram of a motor control system including an electrical energy storage device;

[0025] Figure 5 An exploded view of a single stator reluctance state machine is shown;

[0026] Figure 6 An exploded view of a single-stator dual-coil reluctance state machine is shown;

[0027] Figure 7 The inner reluctance state machine is shown;

[0028] Figure 8 An outer-rotor dual-rotor reluctance state machine is shown;

[0029] Fig. 9 An outer-rotor single-rotor reluctance state machine is shown;

[0030] Fig.10 A zero gradient flux dual stator state machine is shown;

[0031] Fig.11 A zero gradient flux out-turn state machine is shown;

[0032] Fig.12 A single stator induction state machine is shown;

[0033] Fig.13 The inner turn sensing state machine is shown;

[0034] Fig.14 The outer rotation sensing state machine is shown;

[0035] Fig.15 shows the process of operating a reluctance and / or induction motor; and

[0036] Fig.16 Such as Figure 5-14 Cross-sectional view of an electromagnet in a reluctance state machine shown in .

[0037] Like reference numbers in different drawings identify similar elements. DETAILED DESCRIPTION

[0038] In various implementations, the present application addresses the deficiencies associated with existing electric motors and / or generators. The present application describes exemplary systems, methods, and devices for providing a drive shaft with sufficient power and / or torque to fully operate in, for example, an EV. Exemplary induction and / or reluctance motor and / or generator systems, methods, and devices can provide implementations without the use of rare earth metals while not sacrificing performance relative to other types of motors such as DC motors that use rare earth metals. The exemplary systems and techniques described herein implement cutting-edge, low-cost electric state machines in an axial flux configuration. The state machine utilizes reluctance or induction phenomena. Both reluctance state machines and induction state machines can act as motors or generators. The state machine may be suitable for many applications, including, but not limited to, electric vehicles, marine transportation, aviation, climate control, blowers, wind power generation, power tools, mixers, pumps, and hydroelectric power generation.

[0039] Figure 1 1 is a block diagram of a state machine system 100. The state machine system 100 includes a state machine controller 102. The controller 102 may include a processor and / or a computer system 110. The system 100 may also include a power source and / or power storage 108, which may include, for example, one or more batteries capable of receiving and storing electrical energy when the motor-generator 104 operates as a generator, or one or more batteries capable of outputting torque power when the motor-generator 104 operates as a motor. The system 100 may include one or more sensors 106 configured to sense one or more operating conditions associated with the motor-generator 104, such as, but not limited to, the motor-generator 104 rotor assembly rotational speed, the motor-generator 104 rotor assembly angular position, the motor-generator 104 temperature, the motor-generator 104 output or input current, and / or the motor-generator 104 voltage. The controller 102 may utilize the processor 110 to receive sensor data from the one or more sensors 106 and control one or more operations of the motor-generator 104 based on the sensor data. Further details regarding the processor 110 will be described below with respect to Figure 2 Give a description.

[0040] The state machine system 100 may include a stator assembly arranged to generate a rotating electromagnetic field in response to a control signal. As previously described, the rotating EM field is based on a control signal, including an AC signal applied to the stator windings of an induction motor. For an SRM, the rotating EM magnetic field may be based on an excitation and / or trigger signal having, for example, a voltage PWM signal, which is applied to the stator windings under the control of the controller 102 based on feedback from the sensor 106, in such a manner as to cause rotation of the rotor assembly. The system 100 may also include a rotor assembly adjacent to the stator assembly, arranged to rotate in response to the rotating electromagnetic field. In some implementations, the controller 102 implements an SRM trigger control technique to achieve inductance and resistance changes associated with a rotor assembly position such as the rotor assembly 504, resulting in a variable inductance time constant. The controller 102 may adjust the trigger energization and de-energization for each phase to achieve maximum torque and / or power output while preventing the rotor assembly 504 from aligning with the energized phase of the stator assembly 502 (see Figure 5 ). Depending on the speed of the rotor assembly 504, the controller 102 may adjust the trigger to achieve the desired torque and / or power output, and / or the rate of acceleration or deceleration of the rotor assembly 504. This phenomenon is related to the heavy-side timing and trigger control of the controller 102 and may be referred to as phase trigger advance or delay.

[0041] In addition to other operating conditions of the motor-generator 104, one or more sensors 106 may be arranged to detect the angular position of the rotor assembly and output sensor data based on the angular position of the rotor assembly. The controller 102 may be arranged to receive the sensor data and adjust the control signal based on the angular position of the rotor assembly to adjust the torque associated with the rotor assembly when the state machine system 100 is used as a motor, or to adjust the power output from the stator assembly when the state machine system 100 is used as a generator. One or more sensors may be arranged to detect one or more additional state machine 100 operating conditions, including, for example, rotor assembly speed, stator current, stator voltage, and state machine temperature. The controller 102 may be configured to adjust the control signal based on the sensor data associated with multiple detected operating conditions of the motor-generator 104, thereby adjusting the operation of the motor-generator 104.

[0042] The implementation of the system 100 and various rotor-stator configurations eliminates, for example, the need for rare earth magnets and copper conductors in the motor-generator 104. However, rare earth magnets and / or copper conductors can still be used to enhance the performance of the motor-generator 104. However, the motor-generator 104 differs from conventional systems in that it utilizes reluctance and induction to generate torque or power. The systems, devices, and methods of the present invention described herein include electromagnets having magnetic flux characteristics comparable to rare earth magnets suitable for integration into electric motors and / or generators. A magnetic circuit, including the electromagnets of the present invention, utilizes low-cost and readily available steel alloys, such as, but not limited to, stainless steel, duplex stainless steel, maraging steel, carbon steel vanadium, high-speed steel, titanium, molybdenum steel, HSLA steel, alloy 20, manganese iron, nickel iron, chrome steel, chrome vanadium steel, electrical steel, Damascus steel, AL-6XN, spring steel, Bulat steel, ANSI 4145, micro-alloyed steel, and molybdenum. The above components can be packaged in a manner that optimizes the magnetic flux path of each phase, thereby reducing power consumption and increasing torque. In various implementations, for example, heat generation of the motor-generator 104 has been significantly improved due to the geometry of the electromagnets and the method of electrical excitation. Figure 5-14 Exemplary rotor-stator assembly geometries are shown in relation to reluctance and induction type motor generators and will be discussed in greater detail later.

[0043] Figure 2 1 shows a diagram of a processor and / or computer system 200 that may be implemented, for example, in the state machine 102. The processor system 200 may represent a processing system in a motor and / or generator controller, such as Figure 1 1, for example, a processor 110 of a state machine controller 102. The processor and / or computer system 200 may include a microcontroller, a processor, a system on a chip (SoC), a client device, and / or a physical computing device, and may also include hardware and / or virtual processors. In some implementations, the processor system 200 and its components may include: Figure 2 As shown, each element is associated with physical hardware, and in some implementations, one, more or all elements can be implemented using a simulator or a virtual machine. In any case, the processor system 200 can be implemented on physical hardware.

[0044] like Figure 2As shown, the processor system 200 may include a user interface 212, for example, having a keyboard, keypad, touchpad or sensor readout (e.g., a biometric scanner) and one or more output devices, such as a display, audio speakers, LED indicators, and / or indicator lights. The processor and / or computer system 200 may also include a communication interface 210, such as a network communication unit, which may include a wired communication component and / or a wireless communication component that may be communicatively coupled to one or more components of the controller 102. The network communication unit may utilize any of a variety of proprietary or standardized network protocols, such as Ethernet, TCP / IP, etc. to name a new number of protocols, to enable communication between the processor 202 and another device, network, or system. The network communication unit may also include one or more transceivers that utilize Ethernet, power line communication (PLC), Wi-Fi, cellular, and / or other communication methods.

[0045] The processor and / or computer system 200 may include a processing element, such as a controller and / or processor 202, which includes one or more hardware processors, each of which may have a single or multiple processor cores. In one implementation, the processor 202 includes at least one shared cache that stores data (e.g., computing instructions) that is used by one or more other components of the processor 202. For example, the shared cache may be a local cache of data stored in a memory for faster access by the components that make up the processing element of the processor 202. Examples of processors include, but are not limited to, a central processing unit (CPU) and / or a microprocessor. The controller and / or processor 202 may use a processor based on, but not limited to, 8051 architecture, 68HCX, 80X86 and other computer architectures. Processor 202 may include, but is not limited to, 8-bit, 12-bit, 16-bit, 32-bit, or 64-bit architectures. Figure 2 As described in the figure, the processing elements making up the processor 202 may also include one or more other types of hardware processing components, such as a graphics processing unit (GPU), an application specific integrated circuit (ASICs), a field programmable gate array (FPGA), and / or a digital signal processor (DSP).

[0046] Figure 2It is shown that the memory 204 can be operably and communicatively coupled to the processor 202. The memory 204 can be a non-transitory medium configured to store various types of data. For example, the memory 204 can include one or more storage devices 208, which include non-volatile storage devices and / or volatile memory. Volatile memory, such as random access memory (RAM), can be any suitable non-permanent storage device. The non-volatile storage device 208 can include one or more disk drives, optical drives, solid-state drives (SSDs), tape drives, flash memory, read-only memory (ROM), and / or any other type of memory designed to retain data for a duration after power is lost or shutdown operations. In some configurations, if the allocated RAM is not large enough to accommodate all working data, the non-volatile storage device 208 can be used to store overflow data. The non-volatile storage device 208 can also be used to store such programs that are loaded into the RAM when a program is selected for execution. The data storage and / or storage device 208 can be arranged to store multiple motor control instruction programs associated with operating the motor. Such control instruction programs may include instructions for the controller and / or processor 202 to: operate, adjust speed, start or stop one or more motors 104 and / or 214 (eg, drive motors for an electric vehicle).

[0047] As is known to those skilled in the art, software programs may be developed in various computing languages, coded and compiled for various software platforms and / or operating systems, and then loaded and executed by the processor 202. In one implementation, the compilation process of the software program may convert program code written in one programming language into another computer language so that the processor 202 can execute the programming code. For example, the compilation process of the software program may generate an executable program that provides coded instructions (e.g., machine code instructions) to the processor 202 to perform specific, non-general, special computing functions.

[0048] After the compilation process, the encoded instructions may be loaded into the processor 202 from the storage device 208, the memory 204, and / or embedded into the processor 202 (e.g., via a cache or onboard ROM) as computer-executable instructions or processing steps. The processor 202 may be configured to execute the stored instructions or processing steps so that the execution of the instructions or processing steps transforms the processor and / or computer system 200 into a non-general purpose, special, specially programmed machine or device. Stored data, such as data stored in the data storage and / or storage device 208, may be accessed by the processor 202 when executing the computer-executable instructions or processing steps to instruct one or more components in the processor system 200 and / or other components or devices external to the system 200.

[0049] The user interface 212 may include a display, a position input device (such as a mouse, a touchpad, a touch screen, etc.), a keyboard, a keypad, one or more buttons, or other forms of user input and output devices. The user interface components may be communicatively coupled to the processor 202. When the user interface output device is or includes a display, the display may be implemented in various ways, including via a liquid crystal display (LCD) or a cathode ray tube (CRT) or a light emitting diode (LED) display, such as an OLED display. The sensor 206 may include one or more sensors that detect and / or monitor operating conditions within or around the system 200 and / or within or around a motor (such as motors 104 and / or 214). The operating conditions may include (but are not limited to) rotation, rotational speed and / or movement of a device or component (such as a motor), temperature, pressure, current, position of a device or component (such as an angular position of a rotor). It is known to those having ordinary skill in the art that an electronic processing system such as the system 200 may include other components well known in the art, such as a power supply such as the power supply 108, and / or an analog-to-digital converter, but not described herein. Figure 2 Clearly shown in.

[0050] In some implementations, the processor and / or computer system 200 and / or processor 202 includes a SoC having multiple hardware components including, but not limited to:

[0051] Microcontrollers, microprocessors or digital signal processor (DSP) cores and / or multi-processor SoCs (MPSoC) with multiple processor cores;

[0052] Memory blocks including a selected one of read-only memory (ROM), random access memory (RAM), electronically erasable programmable read-only memory (EEPROM), and flash memory;

[0053] a timing source including an oscillator and a phase-parking loop;

[0054] Peripherals, including count timer, real-time timer, and power-on reset generator;

[0055] External interfaces, including industry standards such as Universal Serial Bus (USB), FireWire, Ethernet, Universal Synchronous / Asynchronous Receiver / Transmitter (USART), Serial Peripheral Interface (SPI), etc.

[0056] Analog interfaces, including analog-to-digital converters (ADCs) and digital-to-analog converters (DACs); and

[0057] Voltage regulators and power management circuits.

[0058] SoC includes the above hardware and software that controls microcontrollers, microprocessors and / or DSP cores, peripherals and interfaces. Most SoCs are developed from pre-qualified hardware blocks of hardware elements (e.g., called modules or components, representing IP cores or IP blocks), and software drivers that control their operation. The above list of hardware elements is not exhaustive. SoCs can include protocol stacks that drive industry standard interfaces such as Universal Serial Bus (USB).

[0059] After the overall architecture of the SoC is defined, the individual hardware elements can be described in an abstract language called RTL (register-transfer level). RTL is used to define circuit behavior. Hardware elements are connected together using the same RTL language to create a complete SoC design. In digital circuit design, RTL is a design abstraction that models synchronous digital circuits based on the flow of digital signals (data) between hardware registers and the logical operations performed on these signals. RTL abstraction is used in hardware description languages ​​(HDLs) such as Verilog and VHDL to create a high-level representation of the circuit, from which low-level representations and final actual wiring can be derived. RTL-level design is a typical practice in modern digital design. Verilog, standardized as the Institute of Electrical and Electronics Engineers (IEEE) 1364, is an HDL for modeling electronic systems. Verilog is most commonly used for the design and verification of digital circuits at the abstract RTL level. Verilog can also be used for the verification of analog circuits and mixed-signal circuits, as well as the design of genetic circuits. In some implementations, various components of the processor system 200 are implemented on a printed circuit board (PCB).

[0060] Pulse re-side timing and triggering controller

[0061] The systems, methods, and devices described herein include reluctance state machines and induction state machines that utilize unique geometries and flux generating components. In various implementations, a state machine controller, such as controller 102, is configured and / or operated to complement and optimize the performance of a reluctance / induction state machine, such as state machine system 100. Depending on the application of the state machine, the reluctance / induction state machine can generate a mechanical output (torque) or an electrical output (power).

[0062] Traditionally, reluctance machines have been difficult to control when operated as motors due to a phenomenon known as torque ripple. Torque ripple is the difference between the maximum and minimum torque during one rotation. During motor operation, torque ripple can cause vibrations and audible noise.

[0063] Pulse heavy-side trigger and timing controller, magnetic field energy storage configuration (MFESC)

[0064] Figure 3A schematic diagram of a motor control system 300 including an inductive energy storage device is shown, wherein the controller 102 and / or the control system 300 operates a pulse heavy side trigger and timing controller using an MFESC to compensate for torque pulsation. The system 300 can be coupled to each phase of the motor stator, such as stator windings 318, 320, and 322. The system 300 can include sensors 324, 326, and 328, which are arranged to detect the working conditions of the motor, such as the rotor assembly rotation speed, the rotor assembly angular position, and / or the motor temperature. The processor 304 and / or the processor 110 can control switches 306, 308, and 310, each of which is in electrical communication with the corresponding stator windings 318, 320, and 322 and transformers 312, 314, and 316. When the corresponding switches 306, 308, and / or 310 are closed, the power supply 302 provides a control signal including an electrical signal to the transformers 312, 314, and 316, respectively, to store magnetic energy in their primary windings. When the corresponding switches 306 , 308 , and / or 310 are opened, the magnetic fields in the transformers 312 , 314 , and 316 collapse, and current is discharged from the secondary windings to the corresponding stator windings 318 , 320 , and 322 .

[0065] Processor 304 and / or 110 receives sensor data from sensors 324, 326, and 328 and controls the operation of switches 312, 314, and 316 based on the sensor data to determine when additional current must be provided to each stator winding 318, 320, and 322. Figure 3 As shown in , the processor 304 and / or 110 can also control aspects of the control signal from the power supply 302 to adjust the frequency of the control signal and thereby adjust the rotational speed of the rotor assembly. The operating principle of the MFESC pulse re-side timing and triggering controller 300 is to store electrical energy in the primary coil of a step-down transformer, such as transformers 312, 314 and 316. The energy stored in the primary coil exists in the form of a magnetic field. When the current flowing to the primary coil of the step-down transformer 312, 314 or 316 is cut off by the disconnect switch 310, 308 or 306, the magnetic field collapses, causing a large current and voltage in the secondary coil of the step-down transformer. The electrical energy induced in the secondary coil is delivered to one of the three phases of the reluctance motor via the stator windings 318, 320 and 322. The angular position of the rotor detected by the sensors 324, 326 and / or 328 triggers the release of the stored magnetic energy. When the rotor assembly reaches a predetermined angular position, the current flowing to the primary side coil is cut off, that is, the switch 310, 308 or 310 is opened, causing the corresponding motor phase windings 318, 320 and 322 to be energized, thereby causing magnetic flux to be generated. This magnetic flux generation causes torque generation, which drives the rotation of the rotor assembly. This technology can reduce torque ripple by providing an increase in electrical energy in instances where the excitation drops due to the angular position of the rotor during rotation.

[0066] Pulse heavy side trigger and timing controller, electric field energy storage configuration (EFESC)

[0067] Figure 4 A schematic diagram of a motor control system 400 including an electrical energy storage device is shown, wherein the controller 102 and / or the control system 400 operates a pulse re-side triggering and timing controller using an EFESC to compensate for torque pulsation. The system 400 can be coupled to each phase of the motor stator, such as stator windings 418, 420, and 422. The system 400 can include sensors 424, 426, and 428, arranged to detect the operating conditions of the motor, such as rotor assembly rotation speed, rotor assembly angular position, and / or motor temperature. The processor 404 and / or the processor 110 can control switches 406, 408, and 410, each of which is in electrical communication with the corresponding stator windings 418, 420, and 422 and capacitors 412, 414, and 416. The working principle of the EFESC pulse re-side timing and triggering controller 404 and / or 110 is to store electrical energy in a capacitor. The energy stored in the capacitor, such as capacitors 412, 414, and 416, exists in the form of an electric field. When a capacitor, such as capacitor 412, is triggered, a large current and voltage pulse is delivered to one of the three phases of the reluctance motor, such as motor phase winding 418. The release of the stored electrical energy is triggered by the processor 404 and / or 110 to open switch 410 based on the angular position of the rotor. When the rotor reaches a predetermined angular position, the processor 404 opens switch 410 and the capacitor 412 discharges, causing the motor phase winding 418 to be energized, thereby causing flux generation. This flux generation results in torque generation to drive the rotor assembly. This technique can reduce torque ripple by providing a boost in electrical energy in instances where the excitation drops due to the angular position of the rotor during rotation.

[0068] Pulse heavy side trigger and timing controller, non-sinusoidal rotating magnetic field

[0069] Induction motors operate on the principle of a rotating magnetic field. As the field rotates, the rotor attempts to align itself with the rotating field, resulting in rotation. Typically, this is accomplished using a sinusoidal input for each phase, where the current and voltage alternate between positive and negative values, resulting in a rotating magnetic field. The inventive systems, devices, and methods herein include a technique for creating a rotating magnetic field using a DC input, where each half-phase is either negatively or positively excited, resulting in a rotating magnetic field.

[0070] Pulse heavy-side triggering and timing controller, Torque Optimization Algorithm (TOA)

[0071] For a reluctance motor, a controller such as controller 102 can implement TOA to adjust the excitation of each phase based on rotor position, rotor speed, mechanical load, and / or heat generation. The above inputs are monitored via sensors such as sensor 106, which output corresponding sensor data. Controller 102 can generate an optimal output excitation for each phase based on the sensor data. For an induction motor, controller 102 implementing TOA adjusts the rotating magnetic field by monitoring rotor speed and position to generate torque.

[0072] Pulse heavy-side triggering and timing controller, Power Generation Optimization Algorithm (PGOA)

[0073] For a reluctance generator, the controller 102 may implement a PGOA, wherein the sensor 106 detects and / or monitors the speed and position of the rotor assembly, and the controller 102 controls the inversion of the excitation circuit for each phase based on the sensor data from the sensor 106 to allow current to be generated. The output power may be filtered by an external DC-DC regulator to provide the desired DC power to an energy storage device, such as a power storage 108. For DC power generation, an AC to DC inverter may be implemented. The mechanical input required to rotate a reluctance generator is often nonlinear with significant speed variations. The controller 102 implementing the PGOA algorithm may closely monitor the internal temperature via sensor data from the sensor 106, and then adjust the power output as needed to prevent the generator from overheating. For an induction generator, the controller 102 implementing the PGOA monitors the speed and position of the rotor via sensor data from the sensor 106, and may trigger each phase prior to the rotor assembly position to generate current. The output power may be filtered by an external DC-DC regulator to provide the desired DC power to an energy storage device, such as a power storage 108. For DC power generation, an AC to DC inverter may be implemented. The mechanical input required to rotate an induction generator is often non-linear with significant speed variations. The controller 102 implements a PGOA algorithm that closely monitors the internal temperature based on sensor data from the sensor 106 and adjusts the power output as needed to prevent the generator from overheating.

[0074] Depending on the speed of the rotor assembly, the energization of the motor phases will need to be advanced or delayed in timing. As the speed of the rotor assembly increases, the amount of electrical energy to excite the motor phases will need to be increased in intensity and decreased in duration, for example, by the controller 102. As the speed of the rotor assembly decreases, the amount of electrical energy to excite the motor phases will need to be decreased in intensity and increased in duration. In some implementations, the controller 102 can modulate the energy intensity and duration as required by the motor phases. Controlling the intensity and duration of phase excitation can also be used to balance the phases and mitigate vibration and noise caused by torque ripple.

[0075] Conventionally, this type of control strategy has been used for ignition timing in internal combustion engine applications for over 50 years. The battery voltage is amplified by many orders of magnitude using capacitance or induction to ignite the combustion gases in the cylinder at top dead center of the compression stroke. In various implementations, the controller 102 can implement this type of control technique, except that current is amplified instead of voltage. The amplified current is then used to generate magnetic flux in the electromagnet of the motor. The above-mentioned motor control technique improves motor operation by: reducing the complexity of power timing and control circuits; reducing motor power consumption; improving the motor thermal profile (i.e., reducing heat generation; reducing mean time to repair (MTTR); reducing mean downtime (MDT).

[0076] Figure 5-14 Exemplary rotor-stator assembly geometries are shown in connection with reluctance and induction type motor generators, which can increase torque and power generation with or without the use of rare earth metals.

[0077] Figure 5 An exploded view of a single stator reluctance state machine 500 is shown including a stator assembly 502 having six motor winding poles 508 (ie, three phases), a rotor assembly 504 having four poles 510 , and a cover plate 506 .

[0078] Figure 6 An exploded view of a single stator dual coil reluctance state machine 600 is shown, including a rotor assembly 604 surrounded by six coil assemblies (eg, stator poles 602), and a stator support 606. The stator has six poles 602, each with two coils.

[0079] Figure 7 An inner rotor reluctance state machine 700 is shown including a rotor assembly 704 surrounded by a stator assembly 702 and a stator assembly 706 .

[0080] Figure 8 An outer rotor dual rotor reluctance state machine 800 is shown including a stator assembly 804 surrounded on opposite sides by a rotor assembly 802 and a rotor assembly 806. The outer rotor configuration has two outer rotors 802 and 806 and an omphalos stator 804 mechanically connected along a rotating axis.

[0081] Fig. 9 An outer rotor single rotor reluctance state machine 900 is shown including a stator assembly 902 adjacent to a rotor assembly 904. The outer rotor configuration has two outer rotors mechanically connected along a rotating axis and a center stator 902. The stator 902 has six poles with two coils per pole.

[0082] Fig.10A zero gradient flux dual stator state machine 1000 is shown including a stator assembly 1004, a rotor assembly 1002, and a cover plate 1006. The inner rotor configuration has two outer stators and a center rotor 1002 mechanically connected along a rotating axis.

[0083] Fig.11 A zero gradient flux outer rotor state machine 1100 is shown including a stator assembly 1102 and a rotor assembly 1104. The inner rotor configuration has two outer rotors and a central stator mechanically connected along a rotating axis. The stator 1102 has six poles, each with two coils symmetrically along the center line of the stator 1102.

[0084] Fig.12 A single stator inductive state machine 1200 is shown, which includes a stator assembly 1202, a rotor assembly 1204, and a cover plate 1206. The rotor 1204 has an inductive bar assembly encapsulated in magnetic steel.

[0085] Fig.13 An inner rotor induction state machine 1300 is shown, which includes a rotor assembly 1304 surrounded on opposite sides by a stator assembly 1302 and a stator assembly 1306. The inner rotor configuration has two outer stators 1302 and 1306, and a central rotor 1304. The rotor 1304 has two electrically isolated induction bar assemblies, encapsulated in magnetic steel.

[0086] Fig.14 An outer rotor induction state machine 1400 is shown, which includes a stator assembly 1404 surrounded by a rotor assembly 1402 and a rotor assembly 1406. The outer rotor configuration has two outer rotors 1402 and 1406 mechanically connected along a rotation axis and a central stator 1404. Each outer rotor 1402 and 1404 has an induction rod assembly encapsulated in magnetic steel.

[0087] Fig.15 A process 1500 for operating a reluctance and / or induction motor is shown. The process 1500 includes detecting an angular position of a rotor assembly, such as the rotor assembly 504 or 1204, via a sensor, such as the sensor 106 (step 1502). Sensor data is output by the sensor 106 based on the angular position of the rotor assembly 504 or 1204 (step 1504). The sensor data is then received by a controller, such as the controller 102, and a control signal is adjusted based on the angular position of the rotor assembly 504 or 1204 to adjust the torque associated with the rotor assembly 504 or 1204 when the state machine 500 or 1200 is used as a motor, or to adjust the power output by the stator assembly when the state machine is used as a generator (step 1506).

[0088] Fig.16 is Figure 4500. The electromagnet 1600 may be implemented within one or more poles 508 or within the stator assembly 502. The electromagnet 1600 may include a plurality of conductor loops 1602 wound around a metal core 1604. The core 1604 may include a metal such as steel, 10x19 steel, M-19 electrical steel, and / or other magnetic core materials. In various implementations, heat generation of an electric state machine and / or motor such as the reluctance state machine 500 is significantly improved due to the geometric construction of the electromagnet 1600 and the control of electrical excitation by, for example, the controller 102.

[0089] There are several ways to control the heat generation caused by the operation of the motor. First, the vertical and horizontal placement of each conductor loop 1602 in the coil 1606 is geometrically defined with respect to a local Cartesian coordinate system. This ensures defined and repeatable thermal characteristics for each coil 1606. Second, there are no internal air gaps between the conductors 1602 within the coil 1606. This results in an internal conductive heat path, rather than a mixture of conductive and convective heat paths. Third, the geometry of the axial flux SRM provides a shortened direct path for the generated heat to reach the ambient air and be removed via convection. In addition, the wind generated by the rotation of the rotor, for example, the rotor assembly 504, creates a forced convection phenomenon on the heat generating geometry of the coil 1606. The hot air can be exhausted from the inside of the motor (e.g., the state machine 500). Finally, the heat generation is controlled by the controller 102 using, for example, a heavy-side timing and triggering program and / or function. Heat generation within an electric motor (e.g., the state machine 500) is a form of input energy that is not used for torque / power generation, known as motor inefficiency. Heat generation caused by motor operation is closely monitored by the heavy-side timing and triggering control algorithms and / or routines executed by the controller 102. Except for the case where the operator demands an intermediate condition of maximum torque / power generation, an upper limit on heat generation is set by the controller 102. In some implementations, the controller 102 adjusts the motor control signal based on the angular position of the rotor assembly and the detected motor temperature to adjust the torque associated with the rotor assembly (e.g., rotor assembly 504) to prevent the temperature of the motor from exceeding the upper temperature limit and / or limit. The upper temperature limit and / or limit can be preset in memory, and the controller 102 can compare the sensed motor temperature to the stored temperature limit to determine how close the motor temperature is to the limit and adjust the motor control signal accordingly to prevent an over-temperature condition.

[0090] The elements or steps of the different implementations described may be combined to form other implementations not previously specified. In the above-described system or process, certain elements or steps may be omitted without adversely affecting the operation of those elements or steps or the general operation of the system. In addition, various independent elements or steps may be combined into one or more independent elements or steps to perform the functions described in this specification.

[0091] Other implementations not specifically described in this specification are also within the scope of the following claims.

Claims

1. A state machine comprising: a stator assembly arranged to generate a rotating electromagnetic field in response to a control signal; a rotor assembly, positioned adjacent the stator assembly, arranged to rotate in response to the rotating electromagnetic field; a first sensor arranged to detect an angular position of the rotor assembly and to output first sensor data based on the angular position of the rotor assembly; as well as A controller is arranged to receive the first sensor data and adjust the control signal based on the angular position of the rotor assembly to adjust the torque associated with the rotor assembly when the state machine is used as a motor or to adjust the power output from the stator assembly when the state machine is used as a generator.

2. The state machine of claim 1, comprising a second sensor arranged to detect one or more state machine conditions, the one or more state machine conditions comprising one or more of a rotor assembly speed, a stator current, a stator voltage, and a state machine temperature, the second sensor outputting second sensor data corresponding to the one or more state machine conditions, wherein the controller is further arranged to receive the second sensor data and adjust the control signal based on the second sensor data.

3. The state machine of claim 1, wherein: The control signal includes at least one of an alternating current signal, a pulse width modulation waveform, and a square wave.

4. The state machine of claim 1, wherein: The controller adjusts the rotational speed of the rotor assembly by one of adjusting a frequency associated with the control signal and adjusting a voltage of the control signal.

5. The state machine of claim 1, wherein: The state machine includes at least one of a multi-phase induction motor and a multi-phase induction generator.

6. The state machine of claim 5, wherein: The state machine includes one of a single-stator induction state machine, an inner-rotation induction state machine, and an outer-rotation induction state machine.

7. The state machine of claim 1, wherein: The state machine includes at least one of a multi-phase switched reluctance motor (SRM) and a multi-phase reluctance generator.

8. The state machine of claim 7, wherein: The state machine includes one of a single stator reluctance state machine, a single stator dual coil reluctance machine, an inner rotor reluctance state machine, an outer rotor dual rotor reluctance state machine, an outer rotor single rotor reluctance state machine, a zero gradient flux dual stator state machine, and a zero gradient flux outer rotor state machine.

9. The state machine of claim 1, wherein: The state machine is configured to operate as a motor-generator.

10. The state machine of claim 1, comprising an energy storage element configured to release one of magnetically stored energy and electrically stored energy based on an angular position of the rotor assembly.

11. The state machine of claim 10, wherein: The magnetically stored energy is stored in at least one transformer.

12. The state machine of claim 10, wherein: The electrical energy storage is stored in at least one capacitor.

13. The state machine of claim 1, wherein: The stator assembly is arranged to generate an electrical signal in response to a rotating magnetic field generated by rotation of the rotor assembly.

14. The state machine of claim 13, wherein: The state machine operates as a reluctance generator, and the controller is further arranged to: i) receive second sensor data from a second sensor, the second sensor data including the rotor assembly rotational speed, and ii) based on the rotor assembly rotational speed and the rotor assembly angular position, reverse the excitation circuit for each phase of the stator to generate the electrical signal.

15. The state machine of claim 13, wherein: The state machine operates as an induction generator, and the controller is further arranged to: i) receive second sensor data from a second sensor, the second sensor data comprising a rotor assembly rotational speed, and ii) trigger each phase of the stator assembly prior to a rotor assembly angular position associated with each phase to generate the electrical signal.

16. The state machine of claim 13, wherein: The electrical signal is an AC signal.

17. A state machine as claimed in claim 16, comprising an AC to DC inverter arranged to convert the AC signal into a DC signal.

18. The state machine of claim 17, comprising a power source including one or more batteries configured to receive the DC signal and store electrical energy based on the received DC signal.

19. A method for operating a state machine, the state machine comprising a stator assembly arranged to generate a rotating electromagnetic field in response to a control signal and a rotor assembly positioned adjacent to the stator assembly and arranged to rotate in response to the rotating electromagnetic field, the method comprising: detecting, via a sensor, an angular position of the rotor assembly; outputting, by the sensor, sensor data based on the angular position of the rotor assembly; as well as The sensor data is received and a control signal is adjusted based on the angular position of the rotor assembly to adjust torque associated with the rotor assembly when the state machine is used as a motor or to adjust power output from the stator assembly when the state machine is used as a generator.

20. An electric vehicle comprising: a power storage comprising at least one battery, the power storage being arranged to output stored energy as an output DC electrical signal; as well as State machine, including: a stator assembly arranged to generate a rotating electromagnetic field in response to a control signal; a rotor assembly, positioned adjacent the stator assembly, arranged to rotate in response to the rotating electromagnetic field; a first sensor arranged to detect an angular position of the rotor assembly and to output first sensor data based on the angular position of the rotor assembly; and a controller arranged to receive the first sensor data and adjust the control signal based on the angular position of the rotor assembly to adjust the torque associated with the rotor assembly when the state machine is used as a motor or to adjust the power output from the stator assembly when the state machine is used as a generator, the power output comprising an AC power signal; and a DC to AC inverter arranged to convert the output DC electrical signal from the power storage into the control signal; and An AC to DC converter is arranged to convert the AC electrical signal into an input DC electrical signal which is delivered to the power storage.

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