Magnetic flux reversal motor assembly including an inner stator assembly

Abstract

Embodiments of the present disclosure relate to a flux reversal electric machine assembly, a stator assembly for a flux reversal electric machine assembly, and an electric machine assembly. The flux reversal electric machine assembly includes a rotor core of a rotor assembly, the rotor core including a plurality of magnets disposed within a rotor support structure, and a modulator surrounding the rotor core. The modulator includes a plurality of modulator teeth extending radially toward the rotor core. The electric machine assembly also includes a stator assembly located radially inward of the rotor assembly, the stator assembly including a stator located radially inward of the rotor core and adjacent to the rotor core. The stator includes a plurality of arm portions extending radially from an interior portion of the stator, and a plurality of exterior portions radially opposite the interior portion and adjacent to the rotor core. Each of the plurality of exterior portions is immediately adjacent to one of the plurality of arm portions and includes a plurality of stator teeth.

Description

Technical Field

[0001] The field of this disclosure generally relates to motor systems, and more specifically, to flux-reversing motor assemblies comprising an inner stator assembly and an outer rotor assembly. Background Technology

[0002] Radial flux motors (such as electric motors or generators) typically include spoke-type permanent magnets disposed within a rotor core. The rotor core is formed of multiple layers of laminations. These laminations define circumferentially spaced magnetic poles within the rotor core. Alternatively, the magnetic poles may comprise discrete members supported by the rotor. In this alternative rotor, slots are formed between adjacent magnetic poles, and the spoke-type magnets are disposed within these slots. To further improve motor efficiency and prevent flux leakage across the laminations, the rotor may include axial magnets disposed adjacent to the ends of the spoke-type rotor magnets.

[0003] In radial flux motors, such as electric motors and generators, the stator is positioned close to the rotor. During operation, the stator remains stationary while the rotor rotates relative to the stator. The stator may be located on the outer periphery of the rotor. The stator comprises a combination of stacked cores and insulated wire coils called windings. When alternating current is applied to the stator windings, a magnetic field is generated, which produces the desired rotor rotation, thereby generating the corresponding motor power.

[0004] To increase the torque rating of a known electric motor, the size of the coil windings can be increased. This can be achieved by increasing the diameter of the coil wires or by increasing the number of turns. Larger coil sizes and geometries result in greater electrical loads, thus producing greater motor power. In such motors, the coil size / winding can be increased without altering the geometry / configuration of the motor assembly or components. Known motor designs allow for the use of larger diameter coils without proportionally increasing the size of the rotor assembly.

[0005] These types of motors are typically symmetrical about the stator opening, rotor shaft, or axis of rotation. For example, windings are arranged diametrically opposite each other on opposite sides of the stator. While the torque of a symmetrically configured motor can be increased by adjusting the coil characteristics, the torque increase is limited at least by the volume that can accommodate the enlarged coil windings and the symmetrical configuration. Generally, it is preferable to keep the motor's footprint constant during use to ensure that the component can be fitted into the system in which the motor will be installed. The tendency to use symmetrical motors can become a design factor limiting the torque that the motor can produce. The need to keep the motor housing dimensions constant limits the available internal space for accommodating conductors, thereby limiting the size and range of conductors that can be accommodated in a particular motor housing, and may also limit the motor's torque output.

[0006] Therefore, there is a need in the art for improved stator and rotor assemblies to enable the motor to provide increased torque. Summary of the Invention

[0007] In one embodiment, a flux-reversing motor assembly is described. The flux-reversing motor assembly includes a rotor assembly comprising a rotor core having a rotor support structure and a plurality of magnets disposed within the rotor support structure. Each of the plurality of magnets is circumferentially spaced from each other within the rotor support structure. The flux-reversing motor assembly also includes a modulator surrounding the rotor core of the rotor assembly. The modulator includes an inner surface disposed adjacent to the rotor core and a plurality of modulator sub-teeth extending radially from the inner surface toward the rotor core of the rotor assembly. In the rotor assembly, the rotor core is configured to rotate relative to the modulator.

[0008] In another embodiment, a stator assembly for a flux-reversing motor assembly is described. The stator assembly includes a stator having an internal portion having an orifice extending axially therethrough, and a plurality of arms extending radially from the internal portion. Each of the plurality of arms is circumferentially spaced from each other to form a plurality of openings. The stator also includes a plurality of external portions radially opposite the internal portion. Each of the plurality of external portions is adjacent to one of the plurality of arms and includes a plurality of stator teeth. The stator assembly also includes a plurality of coils disposed within the plurality of openings in the stator. Each of the plurality of coils surrounds one of the plurality of arms of the stator and is located radially between the internal portion and the plurality of external portions.

[0009] In another embodiment, a motor assembly is described. The motor assembly includes a rotor assembly including a rotor core, the rotor core including a plurality of magnets disposed within a rotor support structure. The motor assembly also includes a modulator surrounding the rotor core, the modulator including a plurality of modulator sub-teeth extending radially toward the rotor core of the rotor assembly from an inner surface adjacent to the rotor core. The motor assembly also includes a stator assembly located radially inward of the rotor assembly. The stator assembly includes a stator located radially inward of and adjacent to the rotor core of the rotor assembly. The stator includes a plurality of arms extending radially from an inner portion of the stator. Each of the plurality of arms is circumferentially spaced from each other to form a plurality of openings. The stator also includes a plurality of outer portions radially opposite to and adjacent to the rotor core of the rotor assembly. Each of the plurality of outer portions is adjacent to one of the plurality of arms and includes a plurality of stator sub-teeth. The rotor core is configured to rotate relative to the modulator and the stator. Attached Figure Description

[0010] Figure 1This is a perspective view of the flux reversing motor assembly;

[0011] Figure 2 yes Figure 1 An exploded perspective view of the flux reversing motor assembly shown.

[0012] Figure 3 It is along Figure 1 The front cross-sectional view of the stator assembly of the flux reversing motor assembly is taken by line CS-CS.

[0013] Figure 4 yes Figure 3 An enlarged front sectional view of a portion of the stator assembly shown;

[0014] Figure 5 It is along Figure 1 The front cross-sectional view of the rotor core and modulator of the flux reversing motor assembly, taken by line CS-CS in the figure;

[0015] Figure 6 yes Figure 5 A front sectional view of the modulator shown;

[0016] Figure 7 yes Figure 1 and Figure 2 An enlarged front sectional view of the stator assembly, rotor assembly, and a portion of the modulator of the flux-reversing motor assembly shown; and

[0017] Figure 8 It is along Figure 1 The image shows a front sectional view of the stator assembly, rotor assembly, and modulator of the flux reversing motor assembly, taken by line CS-CS. Detailed Implementation

[0018] As used herein, the singular forms “a,” “an,” and “the” include plural references unless the context clearly indicates otherwise. The terms “comprising,” “including,” and “having” are intended to be open-ended and mean that additional elements may exist besides those listed. The terms “optional” or “optionally” indicate that the event or situation subsequently described may or may not occur, and the description includes both the possibility that the event occurs and the possibility that it does not.

[0019] In addition, several descriptive terms may be used frequently in this document, and it will be helpful to define these terms at the beginning of this section. Unless otherwise stated, these terms and their definitions are as follows. It is often necessary to describe components in different radial, axial, and / or circumferential positions. The "A" axis indicates an axial orientation. As used herein, the terms "axial" and / or "along the axial direction" refer to the relative position / direction of an object along axis A, which is substantially parallel to the shaft in the motor assembly discussed herein. As further used herein, the terms "radial" and / or "along the radial direction" refer to the object along direction "R" (see... Figure 1 The relative position / direction of the first component to axis A, which is substantially perpendicular to axis A and intersects axis A at only one location. Finally, the term "circumferential" refers to movement or position about axis A (e.g., direction "C"). In such cases, if the first component is closer to the axis than the second component, this document will state that the first component is located "radially inside" the second component. On the other hand, if the first component is farther from axis A than the second component, this document may state that the first component is located "radially outside" the second component.

[0020] Embodiments of this disclosure relate to a stator assembly, a rotor assembly, and a modulator for a flux-reversing motor assembly. The rotor assembly of the motor assembly includes a rotor core comprising a plurality of magnets disposed within a rotor support structure of the rotor. The modulator of the motor assembly surrounds the rotor core and includes a plurality of modulator sub-teeth extending radially from an inner surface of the modulator disposed adjacent to the rotor core. Each of the plurality of modulator sub-teeth extends radially toward the rotor core of the rotor assembly. The stator assembly of the motor assembly is located radially inside the rotor assembly and includes a stator located radially inside and adjacent to the rotor core of the rotor assembly. The stator includes a plurality of arms extending radially from an inner portion of the stator. Each wall portion of the plurality of arms is circumferentially spaced apart from each other to form a plurality of openings within the stator. The stator also includes a plurality of outer portions radially opposite the inner portions and adjacent to the rotor core of the rotor assembly. Each of the plurality of external portions is arranged adjacent to one of the plurality of arms and includes a plurality of stator teeth extending radially toward the rotor core of the rotor assembly. During operation of the motor assembly, the rotor core of the rotor assembly is configured to rotate relative to the modulator of the rotor assembly and the stator of the stator assembly contained therein.

[0021] Figure 1 This is a perspective view of the motor assembly 100. Figure 2 yes Figure 1An exploded perspective view of the motor assembly 100 shown. In an exemplary embodiment, a larger motor system (not shown) receives and / or utilizes the motor assembly 100 therein to provide output (e.g., power, torque) to a drive component. That is, as described herein, the motor assembly 100 is connected to and / or mechanically communicated with a drive component configured to transmit and / or drive various components of additional devices and / or systems coupled to the motor assembly 100. For example, the motor assembly 100 is coupled to a belt drive (not shown) and drives and / or actuates the belt drive during operation using the rotation and / or torque generated by the motor assembly 100. As described herein, the motor assembly 100 includes an inner stator assembly 102, a rotor assembly 104 surrounding the stator assembly 102, and a modulator 112 (see [link to relevant documentation]). Figure 2 ).

[0022] The motor assembly 100 is configured as a flux-reversing motor assembly. In an exemplary embodiment, the motor assembly 100 includes a shaft 20 extending from an end plate 22 and arranged through a housing 24. Furthermore, the end plate 22 is coupled to and / or fixed in at least a portion of the housing 24 to support the inner stator assembly 102 of the motor assembly 100 (see [link to relevant documentation]). Figure 2 For example, end plate 22 is connected to housing 24 surrounding motor assembly 100. As described herein, shaft 20 passes axially through apertures 106 formed in various components of inner stator assembly 102. Shaft 20 of motor assembly 100 defines an axial axis A1 that passes through the entire motor assembly 100 via apertures 106 provided in stator assembly 102. Shaft 20 is also aligned with axial axis A1.

[0023] like Figure 2 As shown, the stator assembly 102 of the motor assembly 100 includes a stator assembly 102 having an axially penetrating aperture 106 therethrough, wherein the aperture 106 receives, engages with, and / or contacts the shaft 20. Furthermore, as described herein, the stator assembly 102 includes a plurality of coils (see...). Figure 3 The plurality of coils extend axially through portions of the stator 108, substantially surround portions of the stator 108, and / or are wound around portions of the stator 108. As further described herein (see...). Figure 3 and Figure 4 The stator assembly 102 includes multiple different parts and / or sections configured to assist the operation of the motor assembly 100.

[0024] like Figure 2As shown and as described herein, rotor assembly 104 includes a rotor core 110 that substantially surrounds, encloses, and / or accommodates stator assembly 102 via opening 118. During operation, rotor core 110 is configured to move and / or rotate about stator assembly 102. Furthermore, rotor core 110 is also configured to move and / or rotate relative to stationary modulator 112. Modulator 112 also includes a space 120 for receiving rotor core 110 of rotor assembly 104. Thus, as described herein, modulator 112 substantially surrounds, encloses, and accommodates rotor core 110. During operation of motor assembly 100, modulator 112 remains stationary and / or does not rotate with rotor core 110, but remains stationary.

[0025] The motor assembly 100 also includes another shaft 26 disposed within and extending at least partially through the housing 24. This other shaft 26 is disposed within the housing 24 and adjacent to the stator assembly 102 and the rotor assembly 104, respectively. In a non-limiting example, this other shaft 26 is coupled to the rotor core 110 and configured to rotate with the rotor core 110 to transmit torque to another component (not shown) coupled to and / or in mechanical communication with the other shaft 26.

[0026] Furthermore, the motor assembly 100 includes a bearing assembly 28 disposed within a housing 24. The bearing assembly 28 is disposed on and / or substantially around another shaft 26 within the housing 24. During operation, the bearing assembly 28 is configured to facilitate independent and / or rotation within the housing 24 of the other shaft 26 and / or the rotor core 110 of the rotor assembly 104 relative to the housing 24 of the motor assembly 100.

[0027] Figure 3 It is along Figure 1 The front sectional view of the stator assembly 102 of the motor assembly 100, taken by line CS-CS in the figure. Figure 4 yes Figure 3 An enlarged view of a portion of the stator assembly 102 shown. As described herein, the stator 108 includes multiple segments and / or portions. For example, the stator 108 includes an inner portion 122, which includes an axially extending aperture 106 therethrough. That is, the inner portion 122 is the radially innermost portion of the stator 108 and is radially opposite to the rotor assembly 104 of the motor assembly 100 (see [reference]). Figure 7 and Figure 8 During assembly, shaft 20 passes through orifice 106 and / or engages with internal portion 122 of stator 108.

[0028] The stator 108 also includes a plurality of arms 124 extending radially from the inner portion 122. That is, the plurality of arms 124 are arranged circumferentially around the inner portion 122 and extend radially outward from the inner portion 122, and are located on opposite sides of the aperture 106. For example... Figure 3 As shown, each of the plurality of arms 124 is radially toward the rotor assembly 104 from the inner portion 122 (see Figure 104). Figure 7 and Figure 8 As they extend, they are also circumferentially spaced apart from each other. In a non-limiting example, each of the plurality of arms 124 is circumferentially spaced apart from each other at equal intervals. Therefore, a plurality of openings 126 are formed between the plurality of arms 124. More specifically, each opening 126 is formed between two circumferentially adjacent arms 124 of the stator 108. As described herein, the openings 126 in the stator 108 receive at least a portion of the coils in the stator assembly 102. Figure 3 In the exemplary embodiment shown, the stator 108 includes twelve (12) arms 124 extending radially from the inner portion 122. However, it should be understood that the stator 108 of the stator assembly 102 may include more or fewer arms 124.

[0029] In addition, such as Figure 3 As shown, the stator 108 also includes a plurality of outer portions 128 radially opposite the inner portion 122. Each outer portion 128 of the stator 108 is arranged adjacent to one of the plurality of arms 124. More specifically, a single outer portion 128 of the plurality of outer portions 128 is arranged adjacent to a corresponding single arm 124 of the plurality of arms 124 of the stator 108 and is located radially outward therefrom. Thus, each arm 124 is located radially between the inner portion 122 of the stator 108 and the corresponding outer portion 128. Within the motor assembly 100, each of the plurality of outer portions 128 of the stator 108 is also radially adjacent to and / or located radially inward therefrom of the rotor core 110 of the rotor assembly 104 (see [link to motor assembly 100]). Figure 7 and Figure 8 ).

[0030] Each outer portion 128 also extends substantially perpendicularly to a corresponding arm 124 extending radially from the inner portion 122. A segment 130 of each outer portion 128 also extends circumferentially and covers at least a portion of the opening 126 formed between two adjacent openings 126 in the stator 108. As described herein, the segment 130 of the outer portion 128 is positioned and / or located radially outward of the opening 126. Each outer portion 128 is also substantially concentric with the inner portion 122 and / or the aperture 106 of the stator 108. The number of outer portions 128 of the stator 108 is equal to the number of arms 124. For example, the stator 108 includes twelve (12) outer portions 128. However, it should be understood that the stator 108 of the stator assembly 102 may include more or fewer outer portions 128.

[0031] The stator 108 also includes a plurality of stator teeth 132, comprising the plurality of external portions 128 thereof. Figure 3 In the non-limiting example shown, a plurality of stator teeth 132 extend radially from the exposed surfaces 134 of the respective outer portions 128 of the stator 108. More specifically, each stator tooth of the plurality of stator teeth 132 extends radially outward from the exposed surfaces 134 of the outer portions 128 and / or radially away from the arm portion 124 and / or the inner portion 122, respectively. Each stator tooth of the plurality of stator teeth 132 extending radially from the exposed surfaces 134 of the outer portions 128 is also positioned radially adjacent to the rotor core 110 of the rotor assembly 104 and / or located radially inward of the rotor core during operation of the motor assembly 100 (see [link to relevant documentation]). Figure 7 and Figure 8 ).exist Figure 3 In the non-limiting example shown, each outer portion 128 of stator 108 includes three (3) separate stator teeth 132 extending radially from it. However, it should be understood that the stator 108 of stator assembly 102 may include more or fewer stator teeth 132. As described herein, the number of stator teeth 132 in stator assembly 102 at least partially determines the number of magnets included in rotor core 110 of rotor assembly 104.

[0032] Temporarily transferred to Figure 4 Each stator tooth 132 disposed on and / or extending radially from the outer portion 128 of the stator 108 is equidistant from each other. That is, each stator tooth 132 on the respective outer portion 128 of the stator 108 is circumferentially spaced from each other by a first circumferential distance D1. Furthermore, adjacent circumferentially spaced stator teeth 132 extending radially from different outer portions 128 of the stator 108 are also separated from each other by a first circumferential distance D1. For example, as... Figure 4As shown, stator teeth 132A extending from the outer portion 128A of the stator 108 and stator teeth 132B extending from the outer portion 128B are circumferentially spaced apart and / or separated from each other by a first circumferential distance D1. The outer portion 128, and more specifically the segment 130 of the outer portion 128, extends circumferentially and / or is sized such that the distance between stator teeth 132 of adjacent different outer portions 128 is equal to the distance between adjacent stator teeth 132 on the same single outer portion 128 (e.g., the first circumferential distance D1).

[0033] like Figure 3 and Figure 4 In the non-limiting example shown, the stator 108 is constructed as a single integral component. More specifically, the stator 108 and its various portions (e.g., internal portion 122, arm 124, external portion 128, stator teeth 132, etc.) are constructed as a single integral component. In other non-limiting examples, the stator 108 is composed of multiple independent portions that are connected, joined, linked, and / or mated together to form the stator 108. Furthermore, the stator 108 and its various portions are formed of any suitable magnetic material and / or material having magnetic properties to allow or facilitate the flow of magnetic flux therethrough. For example, the stator 108 and its included portions (e.g., internal portion 122, arm 124, external portion 128, stator teeth 132, etc.) are formed of laminated steel.

[0034] exist Figure 3 and Figure 4 In the non-limiting example shown, the stator assembly 102 also includes a plurality of coils 136 disposed within the plurality of openings 126 of the stator 108. More specifically, each of the plurality of coils 136 (or windings) covers one of the plurality of arms 124 of the stator 108 and passes axially through two circumferentially adjacent openings 126 disposed on two circumferential sides of the corresponding arm 124. Each coil of the plurality of coils 136 is formed of a conductive wire (e.g., copper) wound and / or wrapped around the respective arm of the plurality of arms 124 of the stator 108. Furthermore, as shown, each coil of the plurality of coils 136 of the stator assembly 102 is also radially disposed and / or positioned between the inner portion 122 and the outer portion 128 of the stator 108. Figure 3 and Figure 4 As shown, a segment 130 of each of the plurality of external portions 128 of the stator 108 extends radially outward of at least a portion of the coil 136 covering the corresponding arm 124 and / or is located radially outward of at least a portion of the coil 136 covering the corresponding arm 124.

[0035] In a non-limiting example, coil 136 may include a single coil covering arm 124 of stator 108; or, coil 136 of motor assembly 100 may include a predetermined number of repeating units disposed therein. The predetermined number of repeating units is determined and / or defined by the phase windings or system of coil 136. The number of repetitions of coil 136 included in the phase system, and consequently in stator assembly 100, is predetermined and / or based on characteristics of motor assembly 100, including but not limited to the number of arms 124 in stator 108, the size of motor assembly 100, etc. Furthermore, the number of repetitions of coil 136 refers to the number of times a coil group is repeated within stator 108. For example, in a three (3) phase system, the number and / or number of repetitions of coil 136 in this coil group is three (3), wherein each coil in each group of coil 136 is powered by a different phase of the three-phase system, as described herein. As described herein, the predetermined number of repeating units of coil 136 at least partially affects the number of magnets included in rotor core 110 of rotor assembly 104. Figure 3 , Figure 4 And the content described in this article Figure 8 In the non-limiting example shown, stator assembly 102 includes a three-phase system. Therefore, the coils 136 of stator assembly 102 include four (4) repetitions. However, it should be understood that stator assembly 102 may include any suitable phase system and therefore any corresponding number of repetitions.

[0036] During operation, as described herein, current flows through the coil 136 of the stator assembly 102. When current is applied to the coil 136, the current flows to the stator 108, and when magnetic flux is applied to the rotor core 110 through the stator teeth 132 and the modulator 112, the magnetic flux causes the rotor core 110 of the rotor assembly 104 to rotate.

[0037] Figure 5 It is along Figure 1 The front sectional view of the rotor assembly 104 and modulator 112 of the motor assembly 100, taken by line CS-CS, is shown in the figure. Figure 6 yes Figure 5 An enlarged view of a portion of the modulator 112 shown. The rotor core 110 of the rotor assembly 104 of the motor assembly 100 (see...) Figure 2 The motor assembly 100 includes a rotor support structure 138 that substantially surrounds and / or encloses the stator 108 of the stator assembly 102 within the motor assembly 100 (see [link to motor assembly 100]). Figure 2 , Figure 7 and Figure 8In a non-limiting example, the rotor support structure 138 includes a plurality of slots 140 extending axially therethrough. Each of the plurality of slots 140 is circumferentially spaced apart from each other about the rotor support structure 138. As described herein, each slot 140 formed axially through the rotor support structure 138 is configured to receive one or more magnets such that the magnets are embedded within the rotor support structure 138. In an exemplary embodiment, the slots 140 of the rotor support structure 138 are generally rectangular. Alternatively, the plurality of slots 140 formed through and / or within the rotor support structure 138 may have any suitable shape corresponding to the shape of a permanent magnet to enable the motor assembly 100 to operate as described herein. The rotor support structure 138 is formed of any suitable magnetic material and / or a material having magnetic properties. For example, the rotor support structure 138 is formed of laminated steel.

[0038] The rotor core 110 also includes a plurality of magnets 142 disposed within the rotor support structure 138. More specifically, such as Figure 5 As shown, a plurality of magnets 142 are disposed within, placed in, and / or pass through axially through a plurality of slots 140 formed in the rotor support structure 138. The slots of the plurality of magnets 142 disposed within the rotor support structure 138 are equidistant from each other circumferentially within the rotor support structure 138. For example, as... Figure 5 As shown, any two circumferentially adjacent magnets among the plurality of magnets 142 are spaced apart by a second circumferential distance D2. In other non-limiting examples (not shown), the distance between two adjacent magnets 142 included in the rotor support structure 138 of the rotor assembly 104 varies throughout the rotor support structure 138. In an exemplary embodiment, the magnets 142 are arranged perpendicular to the rotation axis R (see... Figure 1 and Figure 2 Rare earth magnets that are oriented to be magnetized. However, it should be understood that the plurality of magnets 142 in the rotor core 110 may be made of any suitable material to enable the motor assembly 100 to operate as described herein, such as bonded NdFeB, AlNiCo, sintered NdFeB, bonded and ceramic ferrites and / or Samarium Cobalt.

[0039] exist Figure 5In the non-limiting example shown, the plurality of magnets 142 includes a first magnet group 144 having a first polarity, and a second magnet group 146 having a second polarity different from the first polarity of the first magnet group 144. The magnets of the first magnet group 144 and the second magnet group 146 are alternately spaced within the rotor support structure 138 of the rotor core 110. That is, the magnets of the first magnet group 144 and the second magnet group 146 constituting the plurality of magnets 142 are alternately spaced within the rotor support structure 138 such that any two circumferentially adjacent magnets 142 include a single magnet from the first magnet group 144 and a single magnet from the second magnet group 146.

[0040] like Figure 5 As shown and as described herein, the modulator 112 substantially surrounds and / or encloses the rotor core 110 of the rotor assembly 104 within the motor assembly 100 (see [link to motor assembly 100]). Figure 2 , Figure 7 and Figure 8 The modulator 112 includes an inner surface 148 disposed adjacent to the rotor core 110. More specifically, the modulator 112 includes an inner surface 148 disposed radially adjacent to the rotor support structure 138 and the plurality of magnets 142 constituting the rotor core 110 of the rotor assembly 104, and / or located radially outward of the rotor support structure 138 and the plurality of magnets 142. As described herein, the modulator 112 remains stationary during operation of the motor assembly 100, such that the rotor core 110 is configured to rotate relative to the modulator 112 and the stator 108 of the stator assembly 102.

[0041] exist Figure 5 and Figure 6 In the non-limiting example shown, the plurality of modulator teeth 150 extend radially inward from the inner surface 148 of the modulator 112 and / or radially toward the rotor support structure 138 of the rotor core 110 and / or the plurality of magnets 142. Figure 5 In the non-limiting example shown, modulator 112 includes thirty-six (36) different modulator sub-teeth 150. However, it should be understood that modulator 112 may include more or fewer modulator sub-teeth. As described herein, the number of modulator sub-teeth 150 disposed in and / or on modulator 112 at least partially determines the number of magnets 142 included in the rotor core 110 of rotor assembly 104.

[0042] Temporarily transferred to Figure 6The modulator sub-teeth 150 of the plurality of modulator sub-teeth are equidistant from each other. That is, the modulator sub-teeth 150 of the plurality of modulator sub-teeth on modulator 112 are circumferentially spaced from each other by a third circumferential distance D3. As described herein, in a non-limiting example, the third circumferential distance D3 separating the individual modulator sub-teeth 150 on modulator 112 may be substantially equal to the first circumferential distance D1 separating the individual stator sub-teeth 132 of stator 108 from each other.

[0043] like Figure 5 and Figure 6 In the non-limiting example shown, modulator 112 is constructed as a single integral component. More specifically, modulator 112 and modulator teeth 150 extending radially therefrom are constructed as a single integral component. In other non-limiting examples, modulator 112 is composed of multiple independent parts that are connected, joined, linked, and / or mated together to form modulator 112. Furthermore, modulator 112 and modulator teeth 150 are formed of any suitable magnetic material and / or material having magnetic properties to allow or facilitate the flow of magnetic flux therethrough. For example, modulator 112 and modulator teeth 150 extending radially therefrom are formed of laminated steel.

[0044] Figure 7 and Figure 8 It shows along Figure 1 The image shows an enlarged front sectional view of at least a portion of the motor assembly 100, taken by line CS-CS. It should be understood that components with the same number and / or name may function in substantially the same manner. For clarity, repeated descriptions of these components have been omitted.

[0045] Figure 7 An enlarged forward sectional view of a portion of the stator assembly 102, rotor assembly 104, and modulator 112 constituting the motor assembly 100 is shown. As illustrated in this non-limiting example and as described herein, the plurality of stator teeth 132 extend radially outward from each outer portion 128 and radially toward and / or adjacent to the rotor core 110 of the rotor assembly 104. Furthermore, the rotor core 110, including rotor support structures 138 and a plurality of magnets 142, is located radially outward of the stator 108 of the stator assembly 102, adjacent to and surrounding the stator 108. The rotor core 110 is also radially disposed between the modulator 112 and the stator 108 of the stator assembly 102. During operation, as described herein, when current is applied to the coil 136 of stator assembly 102, the current flows to stator 108, while magnetic flux is applied to rotor core 110 through stator teeth 132 and modulator teeth 150 of modulator 112, respectively, causing rotor core 110 of rotor assembly 104 to rotate relative to stationary stator 108 and stationary modulator 112.

[0046] In addition, such as Figure 7 As shown, a plurality of modulator sub-teeth 150 of modulator 112 are circumferentially offset from a plurality of stator sub-teeth 132 of stator 108 of stator assembly 102. That is, each modulator sub-teeth 150 of modulator 112 is radially misaligned and / or not radially aligned with the plurality of stator sub-teeth 132 of stator 108. In this non-limiting example, the plurality of modulator sub-teeth 150 of modulator 112 are radially aligned at an intermediate position between two adjacent stator sub-teeth 132 of stator 108 and / or are circumferentially equidistant between two adjacent stator sub-teeth 132 of stator 108. Furthermore, as... Figure 7 As shown, one of the plurality of modulator teeth 150 of modulator 112 is radially aligned between two adjacent outer portions 128 of stator 108 and / or circumferentially equidistantly distributed between two adjacent stator teeth 132 on different outer portions 128 of stator 108. Furthermore, the plurality of stator teeth 132 of stator 108 are also radially aligned at an intermediate position between two adjacent modulator teeth 150 of modulator 112 and / or circumferentially equidistant between two adjacent modulator teeth 150 of modulator 112. This equidistant circumferential offset arrangement of the plurality of stator teeth 132 and the plurality of modulator teeth 150 within motor assembly 100 improves operating performance during operation, and more specifically, improves magnetic flux flow between stator 108, rotor core 110, and modulator 112.

[0047] Figure 8 A front sectional view of the entire motor assembly 100, including stator assembly 102, rotor assembly 104, and modulator 112, is shown. In this non-limiting example, the rotor support structure 138 and the plurality of slots 140 formed therein are configured and / or formed such that, at a certain moment of operation of the motor assembly 100, only specific portions or groups of the plurality of magnets 142 are substantially radially aligned with the stator teeth 132 and / or the modulator teeth 150. Furthermore, during this moment of operation of the motor assembly 100, the remaining portions or groups of the plurality of magnets 142 are not substantially aligned with the stator teeth 132 and / or the modulator teeth 150, and / or are substantially circumferentially located between the stator teeth 132 and / or the modulator teeth 150.

[0048] For example, Figure 8The diagram illustrates a motor assembly 100 at a certain moment of operation as the rotor core 110 rotates relative to the stator 108 and modulator 112. In this non-limiting example, a first group 152 of the plurality of magnets 142 is indicated. The first group 152 of the plurality of magnets 142 includes a predetermined number (e.g., three (3)) of magnets from a first group 144 of the rotor core 110, which are substantially radially aligned with a certain proportion or a portion of the stator teeth 132 of the stator 108 at a certain moment of operation of the motor assembly 100. Furthermore, the first group 152 of the plurality of magnets 142 also includes a predetermined number (e.g., three (3)) of magnets from a second group 146 of the rotor core 110, which are substantially radially aligned with a certain proportion or a portion of the modulator teeth 150 of the modulator 112 at a certain moment of operation of the motor assembly 100. In the example shown, the first group 152 of the plurality of magnets 142 includes six (6) magnets that are circumferentially adjacent and are respectively composed of magnets in the first group of magnets 144 and magnets in the second group of magnets 146 in an alternating manner.

[0049] Furthermore, in this non-limiting example, the second group 154 ​​of the plurality of magnets 142 includes magnets from a predetermined number (e.g., three (3)) of the first magnet group 144 in the rotor cores 110, which are substantially radially aligned with a certain proportion or a portion of the modulator sub-teeth 150 of the modulator 112 at a certain moment of operation of the motor assembly 100. The second group 154 ​​of the plurality of magnets 142 also includes magnets from a predetermined number (e.g., three (3)) of the second magnet group 146 in the rotor cores 110, which are substantially radially aligned with a certain proportion or a portion of the stator sub-teeth 132 of the stator 108 at a certain moment of operation of the motor assembly 100. Similar to the first group 152, the second group 154 ​​of the plurality of magnets 142 includes six (6) magnets that are circumferentially adjacent and are respectively composed of magnets from the first group 144 and magnets from the second group 146 in an alternating manner.

[0050] Although the plurality of magnets 142 discussed herein comprises six (6) magnets arranged circumferentially adjacent and alternately, it should be understood that the identified groupings of the plurality of magnets 142 radially aligned with the stator teeth 132 and modulator teeth 150 in the motor assembly 100 may have any predetermined number of magnets. Although Figure 8Only a single first group 152 and a single second group 154 ​​of the plurality of magnets 142 are shown herein. However, it should be understood that at any point in operation of the motor assembly 100, the rotor core 110 may include a plurality of magnet groups that are substantially radially aligned with the modulator sub-teeth 150 of the modulator 112 and / or the stator sub-teeth 132 of the stator 108, respectively. However, it should be understood that at any point in operation of the motor assembly 100, not all of the plurality of magnets 142 are radially aligned with the modulator sub-teeth 150 of the modulator 112 and / or the stator sub-teeth 132 of the stator 108, respectively. As described herein, the predetermined number of magnets included in the identified groups (e.g., first group 152, second group 154) of the plurality of magnets 142 is at least partially based on the number of the plurality of magnets 142 in the rotor core 110, the number of stator sub-teeth 132 of the stator 108, and / or the number of modulator sub-teeth 150 of the modulator 112.

[0051] At least the magnets of the third group or another group 156 of the plurality of magnets 142 are not radially aligned with any part of the stator teeth 132 of the stator 108 or any part of the modulator teeth 150 of the modulator 112. That is, the other group 156 includes a predetermined number (e.g., two (2)) of the magnets of the first magnet group 144 in the rotor core 110, which at a certain moment of operation of the motor assembly 100 are substantially circumferentially offset from and / or located radially between a part of the modulator teeth 150 of the modulator 112 and a part of the stator teeth 132 of the stator 108. In addition, another group 156 includes a predetermined number (e.g., two (2)) of magnets in the second magnet group 146 of the rotor core 110, which, at a certain moment of operation of the motor assembly 100, are also substantially offset circumferentially from a portion of the modulator sub-teeth 150 of the modulator 112 and a portion of the stator sub-teeth 132 of the stator 108 and / or located radially between the two. Although Figure 8 Only a single one of the plurality of magnets 142 is shown in another group 156, but it should be understood that at any point during operation of the motor assembly 100, the rotor core 110 includes a plurality of magnet groups that are substantially offset circumferentially from a portion of the modulator sub-teeth 150 of the modulator 112 and a portion of the stator sub-teeth 132 of the stator 108 and located radially between them. As described herein, the predetermined number of magnets included in the other group (e.g., the other group 156) is at least in part based on the number of the plurality of magnets 142 in the rotor core 110, the number of stator sub-teeth 132 of the stator 108, and / or the number of modulator sub-teeth 150 of the modulator 112.

[0052] By arranging different groups (first group 152, second group 154, third group, or another group 156) in the motor assembly 100, noise and / or unwanted movement (referred to herein as "pulsation") of the rotor core 110 during operation can be reduced. That is, by aligning only a portion or one group of the plurality of magnets 142 radially with the stator teeth 132 and / or modulator teeth 150 at a certain moment during operation, the rotor core 110 rotates more uniformly around the stator 108, and reduces uneven magnetic pull or flux in certain areas of the motor assembly 100, which can cause unwanted pulsation effects and noise during operation.

[0053] In addition to the circumferential spacing of the plurality of magnets 142, the number of magnets 142 included in the rotor core 110 also contributes to improved operation of the motor assembly 100. As described herein, the number of magnets 142 included in the rotor core 110 is at least partially based on the number of stator teeth 132, the number of modulator teeth 150, and a predetermined number of repetitions of the coils 136. More specifically, in a non-limiting example, the number of magnets 142 included in the rotor core 110 is a range calculated at least partially based on the number of stator teeth 132, the number of modulator teeth 150, and the predetermined number of repetitions of the coils 136. An example equation for calculating the range of the number of magnets 142 that should be included in the rotor core 110 is as follows:

[0054]

[0055]

[0056] Equation (1) represents the lower limit of the calculated number of magnets 142 to be included in the rotor core 110, and Equation (2) represents the upper limit of the calculated number of magnets 142 to be included in the rotor core 110. (Refer to...) Figure 8 In the non-limiting example shown, where the stator assembly 102 includes thirty-six (36) stator teeth 132, thirty-six (36) modulator teeth 150, and four (4) repetitions of the coil 136, the example equation is:

[0057]

[0058]

[0059] like Figure 8 As shown, the rotor core 110 includes sixty-four (64) magnets 142. In another non-limiting example, the rotor core 110 may include up to eighty (80) magnets 142. Alternatively, the rotor core 110 of the rotor assembly 104 may include any even number of magnets 142 between sixty-four (64) and eighty (80) during operation of the motor assembly 100.

[0060] It should be understood that the number of magnets 142 included in the rotor core 110 of rotor assembly 104 may be more or less than the number determined by equations (1) and (2) as defined herein. However, if the number of magnets 142 included in rotor core 110 exceeds the lower or upper limit defined by equations (1) and (2), noise and / or pulsation effects may increase during operation, and / or its operating efficiency may be lower than that of motor assemblies 100 with rotor core 110 having a number of magnets 142 equal to or within the lower or upper limit defined by equations (1) and (2).

[0061] As described herein, the motor assembly 100, and more specifically, the stator assembly 102, the rotor assembly 104, and the modulator 112, may include a variety of numbers of features. For example (not shown), the stator 108 of the stator assembly 102 includes nine (9) arms 124 extending radially from an inner portion 122, and nine (9) outer portions 128 extending from the arms 124. Furthermore, in this example (not shown), each outer portion 128 of the stator 108 includes four (4) stator teeth 132 extending radially outward and / or radially from thereto. A predetermined number of repetitions of the coils 136 included in the stator assembly 102 is also determined and / or limited to three (3) repetitions. Finally, the modulator 112 includes thirty-six modulator teeth 150 extending radially inward and / or toward the rotor core 110 from an inner surface 148.

[0062] Using the equation (1) defined herein, in this other example (not shown), the lower limit of the number of magnets 142 included in the rotor core 110 of the motor assembly 100 is equal to sixty-six (66) magnets 142. Furthermore, in a non-limiting example (not shown), the rotor core 110 may include up to (e.g., the upper limit, equation (2)) seventy-eight (78) magnets 142.

[0063] Exemplary embodiments of rotor and stator assemblies for electric motor assemblies and systems have been described in detail above. This motor assembly and its components are not limited to the specific embodiments described herein, but rather, components of these systems may be utilized independently of and separate from other components described herein. For example, these components may also be used in conjunction with other motor systems, methods, and apparatuses, and are not limited to implementations only with the systems and apparatuses described herein. Conversely, the exemplary embodiments described can be implemented and utilized in many other applications.

[0064] While specific features of the various embodiments of this disclosure may be shown in some figures and not in others, this is merely for convenience. According to the principles of this disclosure, any feature of any figure may be referenced and / or claimed in conjunction with any feature of any other figure.

[0065] This written description uses examples to disclose the invention, including the best mode of implementation, and also enables those skilled in the art to practice the invention, including making and using any apparatus or system and performing any incorporated methods. The patentable scope of the invention is defined by the claims and may include other examples that would occur to those skilled in the art. Such other examples should fall within the scope of the claims if they have structural elements that are not different from those expressed in the claims, or if they include equivalent structural elements that are only non-substantially different from those expressed in the claims.

Claims

1. A magnetic flux reversing motor assembly, comprising: Rotor assembly, the rotor assembly comprising: Rotor core, the rotor core comprising: Rotor support structure; and A plurality of magnets are disposed within the rotor support structure, wherein each magnet is circumferentially spaced from the others within the rotor support structure; and A modulator surrounding the rotor core of the rotor assembly, the modulator comprising: The inner surface adjacent to the rotor core; and Multiple modulator sub-teeth extending radially from the inner surface toward the rotor core The rotor core of the rotor assembly is configured to rotate relative to the modulator.

2. The magnetic flux reversing motor assembly according to claim 1, wherein, The first group of the plurality of magnets of the rotor core is radially aligned with a portion of the modulator sub-teeth of the plurality of modulator sub-teeth of the modulator.

3. The magnetic flux reversing motor assembly according to claim 2, wherein, The second group of the plurality of magnets of the rotor core is not radially aligned with a portion of the plurality of modulator sub-teeth of the modulator.

4. The magnetic flux reversing motor assembly according to claim 1, wherein, The individual modulator teeth of the plurality of modulator teeth are circumferentially spaced apart from each other and equidistant from each other on the inner surface of the modulator.

5. The magnetic flux reversing motor assembly according to claim 1, wherein, The plurality of magnets in the rotor core include: A first group of magnets having a first polarity; and A second magnet group having a second polarity different from the first polarity of the first magnet group. The magnets of the first magnet group and the magnets of the second magnet group are alternately spaced within the rotor support structure of the rotor core.

6. The magnetic flux reversing motor assembly according to claim 1, wherein, The number of the plurality of magnets in the rotor core is based on the number of the plurality of modulator sub-teeth in the modulator.

7. A stator assembly for a flux-reversing motor assembly, the stator assembly comprising: Stator, the stator comprising: An internal portion, the internal portion including an opening extending axially through it; A plurality of arms extending radially from the inner portion, each of the plurality of arms being circumferentially spaced from each other to form a plurality of openings; and A plurality of outer portions radially opposite the inner portion, each of the plurality of outer portions being adjacent to one of the plurality of arms and including a plurality of stator teeth; and Multiple coils are disposed within the plurality of openings in the stator, each of the plurality of coils surrounding one of the plurality of arms of the stator and located radially between the inner portion and the plurality of outer portions.

8. The stator assembly for a flux-reversing motor assembly according to claim 7, wherein, The plurality of stator teeth extend radially from the surface of each of the plurality of outer portions of the stator toward the rotor core of the flux-reversing motor assembly.

9. The stator assembly for a flux-reversing motor assembly according to claim 8, wherein, The number of the plurality of magnets in the rotor core is based on the number of the plurality of stator teeth in the stator.

10. The stator assembly for a flux-reversing motor assembly according to claim 7, wherein, The stator teeth of the plurality of stator teeth are circumferentially spaced apart from each other on the respective outer portions of the plurality of outer portions of the stator.

11. An electric motor assembly, comprising: A rotor assembly, the rotor assembly including a rotor core, the rotor core including a plurality of magnets disposed within a rotor support structure; A modulator surrounding the rotor core, the modulator comprising a plurality of modulator sub-teeth extending radially toward the rotor core from an inner surface disposed adjacent to the rotor core of the rotor assembly; as well as A stator assembly located radially inside the rotor assembly, the stator assembly comprising: A stator located radially inside the rotor core of the rotor assembly, the stator comprising: An internal portion and a plurality of arms extending radially from the internal portion of the stator, wherein each of the plurality of arms is circumferentially spaced from each other to form a plurality of openings; and A plurality of outer portions of the rotor core, radially opposite to and adjacent to the inner portion and the rotor assembly, each of the plurality of outer portions being immediately adjacent to one of the plurality of arms and including a plurality of stator teeth. The rotor core is configured to rotate relative to the modulator and the stator.

12. The motor assembly according to claim 11, wherein, The stator assembly also includes a plurality of coils disposed within the plurality of openings in the stator, each of the plurality of coils surrounding one of the plurality of arms of the stator and located radially between the inner portion and the plurality of outer portions of the stator.

13. The motor assembly according to claim 11, wherein, The plurality of magnets includes: A first group of magnets having a first polarity; and A second magnet group having a second polarity different from the first polarity of the first magnet group. The magnets of the first magnet group and the magnets of the second magnet group are arranged alternately at intervals within the rotor support structure of the rotor core.

14. The motor assembly according to claim 13, wherein, The first group of the plurality of magnets includes: A predetermined number of magnets from the first magnet group of the rotor core are radially aligned with a portion of the plurality of stator teeth of the stator; and A predetermined number of magnets in the second magnet group are radially aligned with a portion of the modulator sub-teeth among the plurality of modulator sub-teeth.

15. The motor assembly according to claim 14, wherein, The second group of the plurality of magnets includes: A predetermined number of magnets in the first magnet group, which are radially aligned with another portion of the modulator sub-teeth in the plurality of modulator sub-teeth; and A predetermined number of magnets in the second magnet group are radially aligned with another portion of the stator teeth in the plurality of stator teeth.

16. The motor assembly according to claim 15, wherein, The third group of the plurality of magnets includes: A predetermined number of magnets in the first magnet group are not radially aligned with any of the plurality of modulator sub-teeth and any of the plurality of stator sub-teeth; and The predetermined number of magnets in the second magnet group are not radially aligned with any of the plurality of modulator sub-teeth and any of the plurality of stator sub-teeth.

17. The motor assembly according to claim 11, wherein, The plurality of modulator sub-teeth are circumferentially offset from the plurality of stator sub-teeth.

18. The motor assembly according to claim 11, wherein, The individual modulator sub-teeth of the plurality of modulator sub-teeth are circumferentially spaced apart from each other and equidistant from each other on the inner surface of the modulator.

19. The motor assembly according to claim 11, wherein, The stator teeth of the plurality of stator teeth are circumferentially spaced apart from each other on the respective outer portions of the plurality of outer portions of the stator.

20. The motor assembly according to claim 11, wherein, The number of the plurality of magnets is based on: The number of the plurality of modulator sub-teeth; and The number of stator teeth.

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