Modular variable pole electric motor system

Abstract

A modular variable pole electric motor system includes a stator, a plurality of modular rotors, and an inverter system. The stator includes a plurality of stator coils. The plurality of modular rotors includes at least one modular wound field rotor, at least one modular induction rotor, at least one modular permanent magnet rotor, and at least one modular synchronous reluctance rotor. Each of the plurality of modular rotors is configured to be removably electrically coupled to the stator. The inverter system includes a plurality of switches, electrically coupled to the plurality of stator coils of the stator, and configured to be electrically coupled to a battery system and convert a direct current (DC) voltage from the battery system to an alternating current (AC) to individually energize each of the plurality of stator coils of the stator.

Description

Technical Field

[0001] The technology field generally relates to vehicles, and more specifically to modular variable pole electric motor systems. Background Technology

[0002] Electric vehicles (EVs) and / or hybrid vehicles typically include a battery system, an inverter system, and an electric motor. The inverter system comprises multiple switches and is electrically coupled to both the electric motor and the battery system. The electric motor typically includes a stator compatible with a specific type of rotor and has a fixed number of poles. A controller manages the routing of current from the battery system to the electric motor via the inverter system.

[0003] Accordingly, it is desirable to provide a modular variable pole electric motor system. Other desired features and characteristics will become apparent from the accompanying drawings and the foregoing technical and background information, as well as from the following detailed description and appended claims. Summary of the Invention

[0004] A modular variable pole electric motor system includes: a stator comprising a plurality of stator coils; a plurality of modular rotors comprising at least one modular wound field rotor, at least one modular induction rotor, at least one modular permanent magnet rotor, and at least one modular synchronous reluctance rotor, wherein each of the plurality of modular rotors is configured to be removably electrically coupled to the stator; and an inverter system comprising: a plurality of switches; a plurality of stator coils electrically coupled to the stator; and configured to be electrically coupled to a battery system and to convert direct current (DC) voltage from the battery system into alternating current (AC) voltage to individually excite each of the plurality of stator coils of the stator.

[0005] In at least one embodiment, at least one modular induction rotor includes a first modular induction rotor and a second modular induction rotor, the first modular induction rotor including a copper induction cage and the second modular induction rotor including an aluminum induction cage.

[0006] In at least one embodiment, at least one modular wound magnetic field rotor includes a first modular wound magnetic field rotor and a second modular wound magnetic field rotor, the first modular wound magnetic field rotor including separately excited windings with alternating teeth, and the second modular wound magnetic field rotor including separately excited windings with all teeth.

[0007] In at least one embodiment, at least one modular permanent magnet rotor includes a first modular permanent magnet rotor, a second modular permanent magnet rotor, and a third modular permanent magnet rotor. The first modular permanent magnet rotor includes a high-energy magnet, the second modular permanent magnet rotor includes a low-energy magnet, and the third modular permanent magnet rotor includes a combination of high-energy magnets and low-energy magnets.

[0008] In at least one embodiment, at least one modular synchronous reluctance rotor includes a first modular synchronous reluctance rotor, a second modular synchronous reluctance rotor, and a third modular synchronous reluctance rotor. The first modular synchronous reluctance rotor includes a first flux barrier having three layers of rotor cavities, the second modular synchronous reluctance rotor includes a second flux barrier having four layers of rotor cavities, and the third modular synchronous reluctance rotor includes a third flux barrier having five layers of rotor cavities.

[0009] In at least one embodiment, a variable pole controller is electrically coupled to an inverter system, wherein: the variable pole controller is configured to implement pole number modulation to define a first stator pole number and a second stator pole number, the first stator pole number being defined based on a first phase shift angle of AC between adjacent stator coils of a plurality of stator coils generated by the manipulation of a plurality of switches of the inverter system, and the second stator pole number being defined based on a second phase shift angle of AC between adjacent stator coils of a plurality of stator coils generated by the manipulation of a plurality of switches of the inverter system; the first phase shift angle is less than the second phase shift angle; the first stator pole number is less than the second stator pole number; the second stator pole number is a multiple of the first stator pole number; the first phase number of AC applied to the plurality of stator coils is based on the first phase shift angle; the second phase number of AC applied to the plurality of stator coils is based on the second phase shift angle; and the first phase number is a multiple of the second phase number.

[0010] In at least one embodiment, the first product of the first stator pole number and the first phase number of the AC applied to the plurality of stator coils is equal to the second product of the second stator pole number and the second phase number of the AC applied to the plurality of stator coils.

[0011] In at least one embodiment, each phase of the stator includes 2 to 4 stator slots per stator pole, wherein the number of poles varies from 4 or 6 to 8 or 12.

[0012] In at least one embodiment, a variable pole controller is electrically coupled to an inverter system, wherein: the variable pole controller is configured to implement pole phase sequence modulation to define a third stator pole number of the stator by generating a fixed number of phases of AC applied to a plurality of stator coils of the stator in a first sequence based on the manipulation of a plurality of switches of the inverter system, wherein each of the fixed number of phases has a first polarity; and to define a fourth stator pole number by generating a fixed number of phases of AC applied to a plurality of stator coils of the stator in a second sequence based on the manipulation of a plurality of switches of the inverter system, wherein a first subsequence in the second sequence has a first polarity, and a second subsequence in the second sequence has a second polarity opposite to the first polarity; and the third stator pole number is twice the fourth stator pole number.

[0013] In at least one embodiment, each phase of the stator includes 2 to 4 stator slots per stator pole, wherein the number of poles varies from 4 or 6 to 8 or 12.

[0014] A vehicle including a modular variable pole electric motor system includes: a stator comprising a plurality of stator coils; a plurality of modular rotors comprising at least one modular wound magnetic field rotor, at least one modular induction rotor, at least one modular permanent magnet rotor, and at least one modular synchronous reluctance rotor, wherein each of the plurality of modular rotors is configured to be removably electrically coupled to the stator; and an inverter system comprising: a plurality of switches; a plurality of stator coils electrically coupled to the stator; and configured to be electrically coupled to a battery system and to convert direct current (DC) voltage from the battery system into alternating current (AC) voltage to individually excite each of the plurality of stator coils of the stator.

[0015] In at least one embodiment, at least one modular induction rotor includes a first modular induction rotor and a second modular induction rotor, the first modular induction rotor including a copper induction cage and the second modular induction rotor including an aluminum induction cage.

[0016] In at least one embodiment, at least one modular wound magnetic field rotor includes a first modular wound magnetic field rotor and a second modular wound magnetic field rotor, the first modular wound magnetic field rotor including an independent excitation winding with alternating teeth, and the second modular wound magnetic field rotor including an independent excitation winding with all teeth.

[0017] In at least one embodiment, at least one modular permanent magnet rotor includes a first modular permanent magnet rotor, a second modular permanent magnet rotor, and a third modular permanent magnet rotor. The first modular permanent magnet rotor includes a high-energy magnet, the second modular permanent magnet rotor includes a low-energy magnet, and the third modular permanent magnet rotor includes a combination of high-energy magnets and low-energy magnets.

[0018] In at least one embodiment, at least one modular synchronous reluctance rotor includes a first modular synchronous reluctance rotor, a second modular synchronous reluctance rotor, and a third modular synchronous reluctance rotor. The first modular synchronous reluctance rotor includes a first flux barrier having three layers of rotor cavities, the second modular synchronous reluctance rotor includes a second flux barrier having four layers of rotor cavities, and the third modular synchronous reluctance rotor includes a third flux barrier having five layers of rotor cavities.

[0019] In at least one embodiment, a variable pole controller is electrically coupled to an inverter system, wherein: the variable pole controller is configured to implement pole number modulation to define a first stator pole number and a second stator pole number, the first stator pole number being defined based on a first phase shift angle of AC between adjacent stator coils of a plurality of stator coils generated by the manipulation of a plurality of switches of the inverter system, and the second stator pole number being defined based on a second phase shift angle of AC between adjacent stator coils of a plurality of stator coils generated by the manipulation of a plurality of switches of the inverter system; the first phase shift angle is less than the second phase shift angle; the first stator pole number is less than the second stator pole number; the second stator pole number is a multiple of the first stator pole number; the first phase number of AC applied to the plurality of stator coils is based on the first phase shift angle; the second phase number of AC applied to the plurality of stator coils is based on the second phase shift angle; and the first phase number is a multiple of the second phase number.

[0020] In at least one embodiment, the first product of the first stator pole number and the first phase number of the AC applied to the plurality of stator coils is equal to the second product of the second stator pole number and the second phase number of the AC applied to the plurality of stator coils.

[0021] In at least one embodiment, each phase of the stator includes 2 to 4 stator slots per stator pole, wherein the number of poles varies from 4 or 6 to 8 or 12.

[0022] In at least one embodiment, a variable pole controller is electrically coupled to an inverter system, wherein: the variable pole controller is configured to implement pole phase sequence modulation to define a third stator pole number of the stator by generating a fixed number of phases of AC applied to a plurality of stator coils of the stator in a first sequence based on the manipulation of a plurality of switches of the inverter system, wherein each of the fixed number of phases has a first polarity; and to define a fourth stator pole number by generating a fixed number of phases of AC applied to a plurality of stator coils of the stator in a second sequence based on the manipulation of a plurality of switches of the inverter system, wherein a first subsequence in the second sequence has a first polarity, and a second subsequence in the second sequence has a second polarity opposite to the first polarity; the third stator pole number is twice the fourth stator pole number; and the stator comprises seventy-two stator slots, the fourth stator pole number is six, and the third stator pole number is twelve.

[0023] A vehicle includes one of a front-wheel drive unit, a rear-wheel drive unit, and an all-wheel drive rear-drive unit, the front-wheel drive unit, the rear-wheel drive unit, and the all-wheel drive rear-drive unit including a modular variable pole electric motor system, the modular variable pole electric motor system including: a stator including a plurality of stator coils; a plurality of modular rotors including at least one modular wound magnetic field rotor, at least one modular induction rotor, at least one modular permanent magnet rotor, and at least one modular synchronous reluctance rotor, wherein each of the plurality of modular rotors is configured to be removably electrically coupled to the stator; and an inverter system, wherein the inverter system includes: a plurality of switches; a plurality of stator coils electrically coupled to the stator; and is configured to be electrically coupled to a battery system and to convert direct current (DC) voltage from the battery system into alternating current (AC) to individually excite each of the plurality of stator coils of the stator. Attached Figure Description

[0024] Exemplary embodiments will now be described in conjunction with the following figures, wherein similar numbers denote similar elements, and wherein:

[0025] Figure 1 It is a functional block diagram of a vehicle configured to implement a modular variable pole electric motor system according to at least one embodiment;

[0026] Figure 2 This is a perspective view of a modular variable pole electric motor system according to at least one embodiment;

[0027] Figure 3 This is a diagram of an exemplary stator of a modular variable pole electric motor system according to at least one embodiment;

[0028] Figure 4 It is a functional block diagram of a vehicle including a modular variable pole electric motor system according to at least one embodiment;

[0029] Figure 5 It includes a functional diagram of an exemplary stator according to at least one embodiment and a table illustrating exemplary implementations of pole phase number modulation; and

[0030] Figure 6 It is a functional diagram of an exemplary stator according to at least one embodiment and a table illustrating exemplary implementations of polar phase sequence modulation. Detailed Implementation

[0031] The following detailed description is merely exemplary in nature and is not intended to limit application and use. Furthermore, it is not intended to be bound by any express or implied theory presented in the foregoing technical field, background art, summary of the invention, or the following detailed description. As used herein, the term module refers to an application-specific integrated circuit (ASIC), electronic circuitry, a processor (shared, dedicated, or grouped) and memory executing one or more software or firmware programs, combinational logic circuitry, and / or other suitable components providing the described functionality.

[0032] This document describes embodiments of the present disclosure in terms of functional and / or logical block components and various processing steps. It should be understood that such block components can be implemented by any number of hardware, software, and / or firmware components configured to perform specified functions. For example, embodiments of the present disclosure can employ various integrated circuit components, such as memory elements, digital signal processing elements, logic elements, lookup tables, etc., which can perform various functions under the control of one or more microprocessors or other control devices. Furthermore, those skilled in the art will understand that embodiments of the present disclosure can be practiced in combination with any number of systems, and the systems described herein are merely exemplary embodiments of the present disclosure.

[0033] For the sake of brevity, conventional techniques related to signal processing, data transmission, signaling, control, and other functional aspects of the system (and its various operating components) are not described in detail herein. Furthermore, the connecting lines shown in the various figures included herein are intended to illustrate exemplary functional relationships and / or physical couplings between various elements. It should be noted that many alternative or additional functional relationships or physical connections may exist in the embodiments of this disclosure.

[0034] refer to Figure 1 This diagram illustrates a functional block diagram of a vehicle 10 including a modular variable pole electric motor system according to at least one embodiment. The vehicle 10 typically includes a chassis 12, a body 14, front wheels 16, and rear wheels 18. While the vehicle 10 is described as a passenger car in the illustrated embodiment, it can be other types of vehicles, including trucks, sport utility vehicles (SUVs), and recreational vehicles (RVs).

[0035] In various embodiments, the body 14 is arranged on the chassis 12 and substantially surrounds the components of the vehicle 10. The body 14 and the chassis 12 may together form a frame. The wheels 16 and 18 are rotatably coupled to the chassis 12 near respective corners of the body 14.

[0036] In various embodiments, vehicle 10 is an autonomous or semi-autonomous vehicle that is automatically controlled to transport passengers and / or goods from one place to another. For example, in an exemplary embodiment, vehicle 10 is a so-called Level 2, Level 3, Level 4, or Level 5 automation system. Level 2 automation means that the vehicle assists the driver in various driving tasks under the supervision of the driver. Level 3 automation means that the vehicle can take over all driving functions under certain conditions. All major functions are automatic, including braking, steering, and acceleration. At this level, the driver can completely let go until the vehicle otherwise informs the driver. Level 4 system indicates “high automation”, referring to the driving mode-specific performance of the automated driving system for all aspects of dynamic driving tasks, even if the human driver does not respond appropriately to intervention requests. Level 5 system indicates “full automation”, referring to the full-time performance of the automated driving system for all aspects of dynamic driving tasks under all roadway and environmental conditions that can be managed by a human driver.

[0037] As shown in the figure, vehicle 10 typically includes a propulsion system 20, a transmission system 22, a steering system 24, a braking system 26, a sensor system 28, an actuator system 30, at least one data storage device 32, at least one controller 34, and a communication system 36. The controller 34 is configured to implement an automated driving system (ADS). The propulsion system 20 is configured to generate power to propel the vehicle. In various embodiments, the propulsion system 20 may include an electric motor such as a traction motor, a fuel cell propulsion system, and / or any other type of propulsion configuration. In at least one embodiment, the propulsion system 20 includes an electric motor and an internal combustion engine (ICE). In at least one embodiment, the propulsion system 20 includes a modular electric motor. The modular electric motor is a component of a modular variable pole electric motor system.

[0038] The transmission system 22 is configured to transmit power from the propulsion system 20 to the wheels 16, 18 according to a selectable speed ratio. According to various embodiments, the transmission system 22 may include a step-ratio automatic transmission, a continuously variable transmission (CVT), or other suitable transmission. The braking system 26 is configured to provide braking torque to the wheels 16, 18. In various embodiments, the braking system 26 may include a friction brake, a brake-by-wire brake, a regenerative braking system such as an electric motor, and / or other suitable braking systems.

[0039] Steering system 24 is configured to influence the position of wheels 16. Although depicted for illustrative purposes as including a steering wheel and steering column, in some embodiments contemplated within the scope of this disclosure, steering system 24 may not include a steering wheel and / or steering column. Steering system 24 includes a steering column coupled to axle 50 associated with the front wheels 16 via, for example, a rack and pinion or other mechanism (not shown). Alternatively, steering system 24 may include a steer-by-wire system comprising an actuator associated with each of the front wheels 16.

[0040] The sensor system 28 includes one or more sensing devices 40a-40n that sense observable conditions of the external and / or internal environments of the vehicle 10. The sensing devices 40a-40n may include, but are not limited to, radar, lidar, global positioning system, optical camera, thermal imager, ultrasonic sensor, steering wheel sensor, and / or other sensors.

[0041] The vehicle dynamics sensor provides vehicle dynamics data including longitudinal velocity, yaw rate, lateral acceleration, and longitudinal acceleration. The vehicle dynamics sensor may include wheel sensors that measure information relating to one or more wheels of the vehicle 10. In one embodiment, the wheel sensors include wheel velocity sensors coupled to each of the wheels 16, 18 of the vehicle 10. Furthermore, the vehicle dynamics sensor may include one or more accelerometers (provided as part of an inertial measurement unit (IMU)) that measure information relating to the acceleration of the vehicle 10. In various embodiments, the accelerometers measure one or more acceleration values ​​of the vehicle 10, including lateral and longitudinal acceleration and yaw rate. In at least one embodiment, the vehicle dynamics sensor provides vehicle position and vehicle movement data.

[0042] Actuator system 30 includes one or more actuator devices 42a-42n that control one or more vehicle features, such as, but not limited to, one or more wheels 16, 18, propulsion system 20, transmission system 22, steering system 24, and braking system 26. In various embodiments, vehicle features may also include interior and / or exterior vehicle features, such as, but not limited to, doors, trunk, and cabin features, such as air, music, lighting, etc. (not numbered).

[0043] Communication system 36 is configured to wirelessly transmit information to and from other entities, such as, but not limited to, other vehicles (vehicle-to-vehicle, "V2V" communication), infrastructure (vehicle-to-infrastructure, "V2I" communication), remote systems, and / or personal devices. In an exemplary embodiment, communication system 36 is a wireless communication system configured to communicate via a wireless local area network (WLAN) using the IEEE 802.11 standard or by using cellular data communication. However, additional or alternative communication methods (such as dedicated short-range communication (DSRC) channels) are also considered to be within the scope of this disclosure. A DSRC channel refers to a one-way or two-way short-to-medium-range wireless communication channel specifically designed for automotive use and corresponding set of protocols and standards.

[0044] Data storage device 32 stores data for use in the ADS of vehicle 10. In various embodiments, data storage device 32 stores a defined map of the navigable environment. In various embodiments, the defined map may be predefined by and obtained from a remote system. For example, the defined map may be assembled by a remote system and transmitted to vehicle 10 (wirelessly and / or via wire) and stored in data storage device 32. It is understood that data storage device 32 may be part of controller 34, separate from controller 34, or part of controller 34 and a separate system.

[0045] The controller 34 includes at least one processor 44 and a computer-readable storage device or medium 46. The processor 44 may be any custom or commercially available processor, central processing unit (CPU), graphics processing unit (GPU), auxiliary processor among several processors associated with the controller 34, semiconductor-based microprocessor (in the form of a microchip or chipset), macroprocessor, any combination thereof, or any device generally used for executing instructions. The computer-readable storage device or medium 46 may include volatile and non-volatile memory such as read-only memory (ROM), random access memory (RAM), and keep-alive memory (KAM). KAM is a persistent or non-volatile memory that can be used to store various operational variables when the processor 44 is powered off. The computer-readable storage device or medium 46 may be implemented using any of several known memory devices such as PROM (programmable read-only memory), EPROM (electrical PROM), EEPROM (electrically erasable PROM), flash memory, or any other electrical, magnetic, optical, or combined memory device capable of storing data (some of which represent executable instructions used by the controller 34 to control the vehicle 10). In at least one embodiment, vehicle 10 includes controller 34 configured as a variable pole controller.

[0046] The instructions may include one or more separate programs, each comprising an ordered list of executable instructions for implementing logical functions. When executed by processor 44, the instructions receive and process signals from sensor system 28, execute logic, calculations, methods, and / or algorithms for automatically controlling components of vehicle 10, and generate control signals to actuator system 30 based on the logic, calculations, methods, and / or algorithms to automatically control components of vehicle 10. Although in Figure 1 Only one controller 34 is shown, but embodiments of vehicle 10 may include any number of controllers 34 that communicate via any suitable communication medium or combination of communication media and cooperate to process sensor signals, perform logic, calculations, methods and / or algorithms, and generate control signals to automatically control the features of vehicle 10. In various embodiments, the controllers(s) 34 are configured to implement ADS.

[0047] refer to Figure 2 A perspective view of a modular variable pole electric motor system 200 according to at least one embodiment is shown. The modular variable pole electric motor system 200 includes a modular electric motor 202, an inverter system 204, and a variable pole controller 206. The modular electric motor 202 includes a stator 208 and a modular rotor 210. The stator 208 includes a plurality of stator coils. The modular electric motor 202 includes a shaft 212. The inverter system 204 is configured to be electrically coupled to a battery system 214 and includes a plurality of switches. The inverter system 204 is electrically coupled to the plurality of stator coils of the stator 208. In at least one embodiment, the inverter system 204 is a traction power inverter module (TPIM). The variable pole controller 206 is electrically coupled to the inverter system 204. The inverter system 204 is configured to convert a direct current (DC) voltage from the battery system 214 into alternating current (AC) suitable for exciting the respective stator coils of the plurality of stator coils of the stator 208. In at least one embodiment, the battery system 214 is a multi-cell rechargeable battery pack.

[0048] Inverter system 204 and stator 208 are configured to operate with multiple modular rotors 210. The modular rotors 210 are removably coupled to stator 208. Different modular rotors 210 include modular wound field rotors, modular induction rotors, modular permanent magnet rotors, and modular synchronous reluctance rotors. In at least one embodiment, the modular induction rotor includes a copper induction cage. In at least one embodiment, the modular induction rotor includes an aluminum induction cage. In at least one embodiment, the modular wound field rotor with separately excitable windings employs alternating stator tooth windings. In at least one embodiment, the modular wound field rotor with separately excitable windings employs full stator tooth windings. In at least one embodiment, the modular permanent magnet rotor includes high-energy magnets. In at least one embodiment, the modular permanent magnet rotor includes low-energy magnets. In at least one embodiment, the modular permanent magnet rotor includes a combination of high-energy and low-energy magnets. In at least one embodiment, the modular synchronous reluctance rotor has a flux barrier and includes three to five layers of rotor cavities.

[0049] Inverter system 204 and stator 208 can be used with different modular rotors 210 on different vehicle platforms with different power specifications. In at least one embodiment, modular variable pole electric motor system 200 is used in a multi-axle vehicle. In at least one embodiment, modular variable pole electric motor system 200 is integrated into a front-wheel drive unit. In at least one embodiment, modular variable pole electric motor system 200 is integrated into a rear-wheel drive unit. In at least one embodiment, modular variable pole electric motor system 200 is integrated into an all-wheel drive rear-drive unit. Each of these different drive units is associated with a different vehicle platform with different power specifications, which are supported by different modular rotors 210.

[0050] refer to Figure 3 The diagram illustrates an exemplary stator 208 of a modular variable pole electric motor system 200 according to at least one embodiment. The stator 208 includes a central cavity 216 and has an outer diameter OD. The stator 208 includes a plurality of radially projecting stator teeth 218. Adjacent stator teeth 218 are separated from each other by corresponding stator slots 220. Each stator slot 220 is filled with an electrical conductor 222. In at least one embodiment, the electrical conductor 222 is copper wire. In at least one embodiment, the electrical conductor 222 is a copper bar / hairpin. The electrical conductor 222 forms a stator winding W that defines stator coils surrounding the periphery of the stator 208. When the stator coils are sequentially excited by the inverter system 204, the stator coils individually act as electromagnets. When current flows through the winding W of the stator coils defining the stator 208, the stator 208 rotates the modular rotor 210 by generating a rotating magnetic field.

[0051] In at least one embodiment, the variable pole controller 206 is configured to achieve pole phase number modulation by changing the number of stator poles of stator 208, which is done by changing the phase shift angle of the alternating current (AC) applied to adjacent stator coils of stator 208. When the number of phases of the AC applied to the stator coils changes, the number of stator poles changes. This results in a relatively ideal magnetomotive force (MMF) distribution. The length of winding W is based on the lowest stator pole count.

[0052] In at least one embodiment, the variable pole controller 206 is configured to achieve pole phase sequence modulation by changing the number of stator poles of the stator 208, which is done by changing the polarity and phase sequence of the AC applied to adjacent stator coils of the stator 208. While the number of phases remains the same, the number of stator poles changes. Using the same number of phases allows for the use of relatively short winding lengths W.

[0053] In at least one embodiment, the stator pole-slot combination of stator 208 includes 72 stator slots with six stator poles, which can be changed to twelve stator poles. A variable pole controller 206 is configured to operate multiple switches of inverter system 204 to enable operation of modular electric motor 202 with either six or twelve stator poles. In at least one embodiment, stator 208 has four layers with 24 turns per phase, having two parallel paths when modular electric motor 202 operates with six stator poles and one parallel path when modular electric motor 202 operates with twelve stator poles. Higher stator pole count operation of modular variable pole electric motor system 200 is generally desired at lower vehicle speeds to generate higher torque levels. Lower stator pole count operation of modular variable pole electric motor system 200 is generally desired at higher vehicle speeds to generate higher power levels and higher efficiency.

[0054] refer to Figure 4 A vehicle 10 including a modular variable pole electric motor system 200 according to at least one embodiment is shown. The vehicle 10 includes a modular electric motor 202, an inverter system 204, a variable pole controller 206, and a battery system 214. The variable pole controller 206 includes at least one processor 400 and at least one memory 402. The at least one processor 400 is a programmable device including one or more instructions stored in or associated with the at least one memory 402. The at least one memory 402 includes instructions that the at least one processor 400 is configured to execute. The at least one memory 402 includes a variable pole management system 406.

[0055] In at least one embodiment, at least one processor 400 is configured to execute instructions in a variable pole management system 406 to achieve pole phase number modulation by changing the number of stator poles of stator 208, which is done by changing the phase shift angle of the alternating current (AC) applied to adjacent stator coils of stator 208 via inverter system 204. Reference will be made below. Figure 5 The implementation of pole phase number modulation is described in more detail.

[0056] In at least one embodiment, at least one processor 400 is configured to execute instructions in a variable pole management system 406 to achieve pole phase sequence modulation by changing the number of stator poles of stator 208, which is done by changing the polarity and phase sequence of AC applied to adjacent stator coils of stator 208. Reference will be made below. Figure 6 The implementation of polar phase sequence modulation is described in more detail.

[0057] refer to Figure 5 A functional diagram of an exemplary stator 208 according to at least one embodiment and tables 500 and 502 illustrating exemplary implementations of pole number modulation are shown. The stator 208 includes a plurality of stator coils. A variable pole controller 206 is configured to implement pole number modulation to define the stator pole number of the stator 208 by generating phase shift angles of the AC between adjacent stator coils of the plurality of stator coils of the stator 208 based on manipulation of a plurality of switches of the inverter system 204. The phase number of the AC applied to the plurality of stator coils is based on the phase shift angle. The variable pole controller 206 is configured to change the stator pole number by changing the phase shift angles of the AC between adjacent stator coils of the plurality of stator coils via the inverter system 204.

[0058] An exemplary stator 208 includes six stator coils. When the variable pole controller 206 generates a first phase shift angle of 30° for the AC and applies it to the six stator coils via the inverter system 204, the inverter system 204 generates six phases A, B, C, X, Y, and Z of the AC and defines N stator poles. For example, referring to the first table 500, at a certain moment, the first phase A of the AC with a 0° phase angle is applied to the first stator coil, the second phase X of the AC with a 30° phase angle is applied to the second stator coil, the third phase C of the AC with a 60° phase angle is applied to the third stator coil, the fourth phase Z of the AC with a 90° phase angle is applied to the fourth stator coil, the fifth phase B of the AC with a 120° phase angle is applied to the fifth stator coil, and the sixth phase Y of the AC with a 150° phase angle is applied to the sixth stator coil.

[0059] When the variable pole controller 206 generates a second phase shift angle of 60° for the AC and applies it to the six stator coils via the inverter system 204, the inverter system 204 generates three phases A, B, and C of the AC and defines 2N stator poles. For example, referring to the second table 502, at a certain moment, the first phase A of the AC with a 0° phase angle is applied to the first stator coil, the second phase C of the AC with a 60° phase angle is applied to the second stator coil, the third phase B of the AC with a 120° phase angle is applied to the third stator coil, the first phase A of the AC with a 180° phase angle is applied to the fourth stator coil, the second phase C of the AC with a 240° phase angle is applied to the fifth stator coil, and the third phase B of the AC with a 150° phase angle is applied to the sixth stator coil.

[0060] In this example, the first phase shift angle of 30° is less than the second phase shift angle of 60°. The first stator pole number associated with the first phase shift angle of 30° is N, and the second stator pole number associated with the second phase shift angle of 60° is 2N. The first stator pole number N is less than the second stator pole number 2N. The second stator pole number 2N is a multiple of the first stator pole number N. The first phase number (six phases A, B, C, X, Y, Z) of the AC applied to the six stator coils is based on a phase shift angle of 30°. The second phase number (three phases A, B, C) of the AC applied to the six stator coils is based on a phase shift angle of 60°. The product of the first stator pole number (N) and the first phase number (six) associated with a phase shift angle of 30° is equal to the product of the second stator pole number (2N) and the second phase number (three) associated with a phase shift angle of 60°.

[0061] In an alternative embodiment, the number of stator poles can be a different multiple of the first stator pole number N, due to the different number of phases of AC applied according to the associated phase shift angle.

[0062] Figure 6 A functional diagram of an exemplary stator 208 according to at least one embodiment and a table 600 illustrating an exemplary implementation of pole phase sequence modulation are shown. The stator 208 includes a plurality of stator coils. A variable pole controller 206 is configured to implement pole phase sequence modulation to define the stator pole number of the stator 208 by generating several phases of AC applied in a specific sequence to the plurality of stator coils of the stator 208 based on manipulation of a plurality of switches of the inverter system 204, wherein a specific polarity is associated with each phase of the AC in a specific sequence. The variable pole controller 206 is configured to change the stator pole number of the stator 208 by changing the sequence and polarity of the phases of the AC. When the stator pole number changes, the number of phases of the AC does not change.

[0063] An exemplary stator 208 includes six stator coils. A first stator pole number 2N is generated when the variable pole controller 206 generates three phases A, B, and C of an AC via the inverter system 204 and applies them to the six stator coils in a first sequence, each of the three phases A, B, and C having a specific polarity. For example, referring to Table 600, at a certain moment, the first phase A of the positive AC is applied to the first stator coil, the second phase B of the positive AC is applied to the fourth stator coil, the third phase C of the positive AC is applied to the fifth stator coil, the first phase A of the positive AC is applied to the second stator coil, the second phase B of the positive AC is applied to the third stator coil, and the third phase C of the positive AC is applied to the sixth stator coil.

[0064] When the variable pole controller 206 generates three phases A, B, and C of the AC via the inverter system 204 and applies them to the six stator coils in a second sequence with each of the three phases A, B, and C having a specific polarity, the second stator pole number N is generated. For example, referring to Table 600, at a certain moment, the first phase A of the positive AC is applied to the first stator coil, the third phase C of the positive AC is applied to the fourth stator coil, the second phase B of the positive AC is applied to the fifth stator coil, the first phase A of the negative AC is applied to the second stator coil, the third phase C of the negative AC is applied to the third stator coil, and the second phase B of the negative AC is applied to the sixth stator coil.

[0065] In both cases, the number of phases (three phases) remains the same. The sequence of the three phases A, B, and C of AC applied to the six stator coils changes, and the polarity of some phases changes. The number of stator poles 2N under the first sequence is twice the number of stator poles N under the second sequence. In alternative embodiments, different numbers of phases (which remain the same in both cases) can be used to generate stator poles. In at least one embodiment, each stator phase per stator pole comprises 2 to 4 stator slots, wherein the number of poles varies from 4 or 6 to 8 or 12.

[0066] In at least one embodiment, the plurality of modular rotors 210 include modular wound magnetic field rotors, modular induction rotors, modular permanent magnet rotors, and modular synchronous reluctance rotors with different rotor pole numbers. The modular rotor 210 selected for use with stator 208 has a rotor pole number equal to the generated stator pole number of stator 208.

[0067] In vehicle 10, for peak low-speed torque applications, a first stator pole count is desirable, and for peak power or high-speed torque applications, a second stator pole count is desirable, wherein the first stator pole count is higher than the second stator pole count. In high-speed applications in vehicle 10, a second, lower stator pole count is desirable to achieve maximum efficiency.

[0068] While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be understood that numerous variations exist. It should also be understood that the exemplary embodiments or multiple exemplary embodiments are merely examples and are not intended to limit the scope, applicability, or configuration of this disclosure in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient roadmap for implementing the exemplary embodiments or multiple exemplary embodiments. It should be understood that various changes can be made to the function and arrangement of the elements without departing from the scope of this disclosure as set forth in the appended claims and their legal equivalents.

Claims

1. A modular variable pole electric motor system, comprising: Stator, the stator comprising a plurality of stator coils; Multiple modular rotors, the multiple modular rotors including at least one modular wound magnetic field rotor, at least one modular induction rotor, at least one modular permanent magnet rotor and at least one modular synchronous reluctance rotor, wherein each of the multiple modular rotors is configured to be removably electrically coupled to the stator; as well as Inverter system, wherein the inverter system: Includes multiple switches; The plurality of stator coils electrically coupled to the stator; as well as It is configured to be electrically coupled to the battery system and to convert the direct current (DC) voltage from the battery system into alternating current (AC) to individually excite each of the plurality of stator coils of the stator.

2. The system according to claim 1, wherein the at least one modular induction rotor comprises a first modular induction rotor and a second modular induction rotor, the first modular induction rotor comprising a copper induction cage and the second modular induction rotor comprising an aluminum induction cage.

3. The system according to claim 1, wherein the at least one modular wound magnetic field rotor includes a first modular wound magnetic field rotor and a second modular wound magnetic field rotor, the first modular wound magnetic field rotor includes an independent excitation winding with alternating teeth, and the second modular wound magnetic field rotor includes an independent excitation winding with all teeth.

4. The system according to claim 1, wherein the at least one modular permanent magnet rotor comprises a first modular permanent magnet rotor, a second modular permanent magnet rotor, and a third modular permanent magnet rotor, wherein the first modular permanent magnet rotor comprises a high-energy magnet, the second modular permanent magnet rotor comprises a low-energy magnet, and the third modular permanent magnet rotor comprises a combination of a high-energy magnet and a low-energy magnet.

5. The system according to claim 1, wherein the at least one modular synchronous reluctance rotor comprises a first modular synchronous reluctance rotor, a second modular synchronous reluctance rotor, and a third modular synchronous reluctance rotor, the first modular synchronous reluctance rotor comprising a first flux barrier having three layers of rotor cavities, the second modular synchronous reluctance rotor comprising a second flux barrier having four layers of rotor cavities, and the third modular synchronous reluctance rotor comprising a third flux barrier having five layers of rotor cavities.

6. The system of claim 1, further comprising a variable pole controller electrically coupled to the inverter system, wherein: The variable pole controller is configured to implement pole number modulation to define a first stator pole number and a second stator pole number, the first stator pole number being defined based on a first phase shift angle of the AC between adjacent stator coils of the plurality of stator coils generated by the operation of the plurality of switches of the inverter system, and the second stator pole number being defined based on a second phase shift angle of the AC between adjacent stator coils of the plurality of stator coils generated by the operation of the plurality of switches of the inverter system. The first phase shift angle is smaller than the second phase shift angle; The number of poles in the first stator is less than the number of poles in the second stator; The second stator pole number is a multiple of the first stator pole number; The first number of phases of the AC applied to the plurality of stator coils of the stator is based on the first phase shift angle; The second phase number of the AC applied to the plurality of stator coils of the stator is based on the second phase shift angle; and The first phase number is a multiple of the second phase number.

7. The system of claim 6, wherein the first product of the first stator pole number and the first phase number of the AC applied to the plurality of stator coils is equal to the second product of the second stator pole number and the second phase number of the AC applied to the plurality of stator coils.

8. The system of claim 6, wherein each phase and each stator pole of the stator comprises 2 to 4 stator slots, wherein the number of poles varies from 4 or 6 to 8 or 12.

9. The system of claim 1, further comprising a variable pole controller electrically coupled to the inverter system, wherein: The variable pole controller is configured to implement pole phase sequence modulation to define a third stator pole number of the stator by generating a fixed number of phases of AC applied to the plurality of stator coils of the stator in a first sequence based on the manipulation of the plurality of switches of the inverter system, wherein each of the fixed number of phases has a first polarity, and to define a fourth stator pole number by generating the fixed number of phases of AC applied to the plurality of stator coils of the stator in a second sequence based on the manipulation of the plurality of switches of the inverter system, wherein a first subsequence in the second sequence has the first polarity, and a second subsequence in the second sequence has a second polarity opposite to the first polarity; as well as The third stator pole number is twice the fourth stator pole number.

10. The system of claim 9, wherein each phase of the stator per stator pole comprises 2 to 4 stator slots, wherein the number of poles varies from 4 or 6 to 8 or 12.

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