Memory machine with multiple magnets with low coercivity

Abstract

Systems comprising a rotor and magnets of an electrical machine, which is a variable flux machine (VFM), such as a memory machine or memory motor (MM), are provided. The rotor of the system comprises: a first set of magnets with higher coercivity, integrated into at least one slot of the rotor and arranged in a V-shape; and a second set of magnets with lower coercivity compared to the first set of magnets, wherein the second set of magnets comprises at least one pair of magnets of different degrees arranged parallel in a radial slot of the rotor, the first set of magnets forming a first magnetic layer and the second set of magnets forming a second magnetic layer of the rotor.

Description

CROSS-REFERENCE TO RELATED REGISTRATIONS

[0001] The present application claims priority over preliminary US application No. 63 / 689,127 entitled “MEMORY MACHINE WITH MULTIPLE LOW COERCIVE FORCE MAGNETS”, which was filed on August 30, 2024. The entire content of the aforementioned application is hereby incorporated by reference for all purposes. TECHNICAL AREA

[0002] The present description relates in general to an electric machine and in particular to a variable flux machine, wherein the arrangement enables the rotor of the electric machine to be free of rare-earth permanent magnets. BACKGROUND AND BRIEF

[0003] Variable flux machines (VFMs) are electrical machines, such as electric motors and / or generators, that can dynamically change the intensity of magnetization by increasing or decreasing the magnetic current and that remember the flux density levels of magnets housed in a rotor of the VFM. VFMs can additionally or alternatively be referred to as electrical memory machines or memory machines (MMs), such as memory motors and / or memory generators. VFMs can be used to generate torque or electrical energy in machines or systems, such as electric vehicles (EVs), including fully electric vehicles (FEVs) and hybrid electric vehicles (HEVs) with multiple torque sources from at least one electric machine. VFMs allow for a wider and more variable selection (e.g.,envelopes) of torques and speeds compared to other electrical machines for driving or electrically powering a system, such as an interior permanent magnet synchronous motor (IPMSM). s ).

[0004] There is a desire to manufacture and use VFMs and MMs that are free of rare earth metals / materials, referred to in this document as rare earths. Rare earths are becoming increasingly scarce, difficult to extract / procure, and subject to fluctuating availability and procurement costs. Furthermore, there is a specific desire to reduce the environmental damage associated with rare earth extraction, such as mining or precipitation extraction, and rare earth refining. Existing MMs and other VFMs that are free of rare earth magnets, such as rare earth permanent magnets, can be subject to demagnetization under stress, leading to degradation or an abrupt cessation of the VFMs' operational processes.Furthermore, existing rare-earth magnets (MMs) and other rare-earth magnet mass transformers (VFMs) may exhibit lower reluctance torque utilization, reducing the efficiency of mechanical-to-electrical energy conversion and vice versa. The problems associated with rare-earth VFMs may be partly due to the low coercivity of the magnets used. Additionally, rare-earth MMs often incorporate a single magnet type. Hybrid magnet VFMs are frequently constructed with high-coercivity and low-coercivity magnets operating side-by-side in the same magnetic circuit (MC). There is a desire for rare-earth hybrid magnet VFMs that utilize both high- and low-coercivity magnets.

[0005] The inventors recognized disadvantages of VFM configurations that are free of rare-earth permanent magnets, such as those described above. The inventors developed an embodiment of a solution comprising a rotor of an electric machine system, which includes: a first set of magnets with higher coercivity, integrated into at least one slot of the rotor and arranged in a V-shape; and a second set of magnets with lower coercivity compared to the first set of magnets, wherein the second set of magnets comprises at least one pair of magnets of different degrees, arranged parallel in a radial slot of the rotor, the first set of magnets forming a first magnetic layer and the second set of magnets forming a second magnetic layer of the rotor.

[0006] It is understood that the foregoing summary serves to present, in simplified form, a selection of concepts that are further explained in the detailed description. It is not intended to identify important or essential features of the claimed subject matter, the scope of which is clearly defined by the claims that follow the detailed description. Furthermore, the claimed subject matter is not limited to implementations that overcome disadvantages mentioned above or in any part of this disclosure. BRIEF DESCRIPTION OF THE FIGURES Fig. Figure 1 shows an exemplary schematic representation of a system that includes an electric drive system; Fig. Figure 2 shows a system of an electrical machine and an end view of an example of an electrical machine of the present disclosure; Fig. Figure 3 shows a schematic representation and a sectional perspective of the electric machine; Fig. Figure 4 shows an expanded view of an assembly comprising a stator, a rotor and a plurality of permanent magnets of the present disclosure; Fig. 5 shows a sectional view of the assembly; Fig. Figure 6 shows a cross-sectional view of the rotor; Fig. Figure 7 shows a sectional view of a cut segment of the assembly; Fig. 8A shows a section view of the cut segment during a first mode; Fig. Figure 8B shows a section view of the cut segment during a second mode; Fig. Figure 8C shows a section view of the cut segment during a third mode; Fig. Figure 9 shows a variety of tracks for a variety of magnetic materials of permanent magnets housed in the assembly, the tracks showing magnetic flux densities at different magnetic field strengths (H); Fig. Figure 10 shows a trace of a demagnetization curve for the electric machine, where the trace shows magnetic flux at different demagnetization currents. Fig. Figure 11 shows a variety of demagnetization curve traces for the magnetic materials, the traces showing demagnetization ratios at different demagnetization currents. Fig. Figure 12 shows a network diagram with a multitude of traces of the magnetic flux density for the magnetic materials under different conditions. Fig. Figure 13 shows a diagram with a multitude of traces showing remagnetization curves for the electric machine. Fig. Figure 14 shows a diagram with a multitude of traces showing remagnetization curves for the magnetic materials, with the traces showing demagnetization ratios at different magnetizing currents. Fig. Figure 15 shows a diagram of a multitude of traces of an opposing electromagnetic force (counter-EMF) over time for magnetization states of the electric motor. Fig. Figure 16 shows a diagram of traces of torque relative to current for different current angles. Fig. Figure 17 shows a diagram of a multitude of traces of torque energy at different current angles for different torques of the electric machine. Fig. Figure 18 shows a diagram of a multitude of traces of torque energy at different current angles for different torques of the electric machine. Fig. Figure 19 shows a diagram of a multitude of traces showing torque energy over time for different magnetization states. DETAILED DESCRIPTION

[0007] The following description concerns systems for a rotor of an electric motor. The rotor comprises a rotor of an electric machine system, which includes: a first set of magnets with higher coercivity, integrated into at least one slot of the rotor, which is to be arranged in a V-shape; and a second set of magnets with lower coercivity compared to the first set of magnets, wherein the second set of magnets comprises at least one pair of magnets of different degrees, arranged parallel in a radial slot of the rotor, the first set of magnets forming a first magnetic layer and the second set of magnets forming a second magnetic layer of the rotor.

[0008] The first set of magnets can be arranged in a V-shaped structure or structures, such as a slot or multiple slots. More specifically, the first set of magnets can comprise multiple subsets, each subset arranged in a V-shape. Each subset can contain at least one pair of magnets. In other words, each subset can contain at least two magnets. The first set of magnets can act as the main / series flux path generator. The first set of magnets consists of higher coercivity (HC) magnets integrated into the rotor.

[0009] The flux from the first set of magnets can flow through at least one parallel hybrid spoke structure with two low-coercivity (LC) magnets, each of which has a different material grade and coercivity. A second set of magnets, comprising the two LC magnets, is also present. The spoke-shaped branching structure incorporates a flux barrier support to minimize the flux shortening effect near the magnet edges. The two LC magnets are connected in parallel to form a magnetic circuit (MC). Furthermore, the two LC magnets exhibit different demagnetizing properties, with the first LC magnet having a lower coercivity than the other. The two LC magnets include a first LC magnet and a second LC magnet, where the first LC magnet is an upper parallel magnet (e.g.The first LC magnet is located radially furthest outward, and the second LC magnet is a lower parallel magnet (e.g., the magnet located radially furthest inward). The first LC magnet is the weaker magnet in the MC, while the second LC magnet is stronger than the first. The proposed parallel structure of the MC enhances flux control by enabling the cross-coupled demagnetization effect of the spoke structures. The parallel hybrid features of a VFM, which includes the rotor system, the first set of magnets, and the second set of magnets, are achieved using magnets without rare-earth materials. The strongest magnets are used for the V-shaped structure and a first set of magnets to achieve the desired ability to withstand demagnetization under load.

[0010] The first set of magnets, arranged in a V-shape for the rotor, can be made of an iron nitride (FeN) magnet material, which can exhibit the desired demagnetization properties compared to magnets made of an aluminum, nickel, cobalt alloy (AINiCo). The second set of magnets, connected in parallel to form the motor core (MC), is made of two different grades of AINiCo magnets, with the first magnet having a different AINiCo grade than the second. Due to its reduced coercivity, the FeN magnets allow the electric machine to utilize a high reluctance torque, which is achievable with AINiCo magnets.

[0011] Fig. Figure 1 shows an exemplary schematic representation of a system that includes an electric drive system. The system of Fig. 1 includes an electrical machine of the present disclosure, wherein the electrical machine can be a variable flux machine (VFM) and a memory machine (MM) that drives the system by mechanical energy. The system of Fig. 1 can be a vehicle. Fig. Figure 2 shows a system of an electric machine and an end view of an example of an electric machine from the present disclosure. The electric machine from Fig. 2 is the electric machine from Fig. 1. Fig. Figure 3 shows a schematic representation and a sectional perspective of the electric machine. Fig. Figure 4 shows an exploded view of an assembly comprising a stator, a rotor, and a plurality of permanent magnets as described in the present disclosure. The configuration of the Fig. The assembly shown in section 4 allows the permanent magnets to be free of rare earth materials. In other words, the configuration of the components shown in Fig. The assembly shown in Figure 4 is a VMF that is free of rare-earth permanent magnets. The permanent magnets comprise a variety of first sets of magnets exhibiting higher coercivity (HC) and a variety of second sets of magnets exhibiting lower coercivity (LC). Each of the second sets of magnets comprises a pair of magnets designed to be connected in parallel as a magnetic circuit (MC), made of a single material, with each magnet in the pair having different coercivity and comprising different material grades. The magnets in the second set of magnets comprise a first LC magnet and a second LC magnet, the first LC magnet having a lower coercivity than the second LC magnet. Fig. Figure 5 shows a sectional view of the assembly. Fig. Figure 6 shows a cross-sectional view of the rotor. Fig. Figures 5-6 show the first sets of permanent magnets arranged in a V-shape and integrated into the rotor via a multitude of slots, with the slots arranged in a V-shaped structure. Similarly, the Fig. 5-6 The magnets of the second sets of magnets are connected in the MC in a parallel configuration and integrated into the rotor via a plurality of other slots, the other slots arranging the magnets of the second sets of magnets in pairs and a spoke shape. Each pair of magnets in the second set includes a lower-coercivity first magnet and a lower-coercivity second magnet, the lower-coercivity first magnet being on top of and radially outside the lower-coercivity second magnet. The lower-coercivity first magnet has a lower coercivity than the lower-coercivity second magnet, and the lower-coercivity second magnet may be magnetically stronger than the lower-coercivity first magnet.

[0012] Fig. Figure 7 shows a sectional view of a cut segment of the assembly. Fig. Figure 8A shows a sectional view of the cut segment during a first mode. Fig. Figure 8B shows a section view of the cut segment during a second mode. Fig. Figure 8C shows a section view of the cut segment during a third mode.

[0013] Fig. Figure 9 shows a variety of tracks for a variety of magnetic materials of permanent magnets housed in the assembly, the tracks showing magnetic flux densities (B) at different magnetic field strengths (H). Fig. Figure 10 shows a trace of a demagnetization curve for the electric machine, where the trace shows magnetic flux at different demagnetization currents. Fig. Figure 11 shows a variety of demagnetization curve traces for the magnetic materials, the traces showing demagnetization ratios at different demagnetization currents. Fig. Figure 12 shows a network diagram with a multitude of traces, showing the change in B for the magnetic materials under different conditions. Fig. Figure 13 shows a diagram with a multitude of traces showing remagnetization curves for the electric machine. Fig. Figure 14 shows a diagram with a multitude of traces showing remagnetization curves for the magnetic materials, with the traces showing demagnetization ratios at different magnetizing currents. Fig. Figure 15 shows a diagram of a multitude of traces of an opposing electromagnetic force (counter-EMF) over time for magnetization states of the electric motor. Fig. Figure 16 shows a diagram of traces of torque relative to current for different current angles. Fig. Figure 17 shows a diagram of a multitude of traces of torque energy at different current angles for different torques of the electric machine. Fig. Figure 18 shows a diagram of a multitude of traces of torque energy at different current angles for different torques of the electric machine. Fig. Figure 19 shows a diagram of a multitude of traces showing torque energy over time for different magnetization states.

[0014] Fig. Figure 1 schematically illustrates an electric vehicle 100 with an electric drive system 102 that provides power to and / or is integrated into an axle assembly 104 of the vehicle 100. The vehicle 100 can take a variety of forms in different examples, such as a light, medium, or heavy-duty vehicle. Furthermore, the electric drive system 102 can be designed for use in front and / or rear axles, as well as in steerable and non-steerable axles. To generate power, the electric drive system 102 can include an electric machine 106. In some examples, the electric machine 106 can be an electric motor-generator and can therefore include conventional components such as a rotor, a stator, and the like, housed in a casing 107 of the electric machine to generate mechanical power and, in some cases, electrical power during a regenerative mode.Furthermore, in other examples, the vehicle 100 may include an additional source of motion power, such as an internal combustion engine (ICE) (e.g., a spark-ignition engine and / or a compression-ignition engine), to provide power to another axle. The electric drive system 102 may be used in an electric vehicle (EV), such as a hybrid electric vehicle (HEV) or a battery electric vehicle (BEV).

[0015] In some examples, the housing of the electric machine can be coupled to the housing of a gearbox (e.g., by screws). Furthermore, the electric machine can supply mechanical power to a differential via the gearbox. From the differential 110, mechanical power can be transmitted to drive wheels 112 and 114 via axle shafts 116 and 118 of the axle assembly 104. Thus, the differential 110 can distribute torque received from the electric machine 106 via the power transmission 108 to the drive wheels 112 and 114 of the axle shafts 116 and 118 under certain operating conditions. In some examples, the differential 110 can be a locking differential, an electronically controlled limited-slip differential, or a differential with targeted left-right torque distribution.

[0016] Alternatively, in another example, the drive motors and power transmissions of the vehicle 100, such as the electric motor 106 and the power transmission 108, can deliver torque directly to a wheel of the vehicle 100, such as wheels 112 or 114, preventing rotational force from being transmitted from the electric motor 106 through a differential, such as the differential 110. Such an arrangement of drive motor and power transmission can be referred to in this document as wheel-side drive motors and wheel-side power transmissions. A drive motor and a gear train can couple the wheel-side power transmission in a driving manner and deliver torque to it, with rotational force flowing from the drive motor to the gear train and from the gear train to the wheel-side power transmission. In another example, the drive motor and the gear train can be coupled to one or more of the wheels 112 and 114 in a driving manner.The drive motor and the gear train can drive one or more wheels, with torque flowing from the drive motor to the gear train and from the gear train to the one or more wheels. For example, in a wheel-side configuration, a vehicle 100 may lack an axle assembly 104. In this example, the power transmission 108 can be a wheel-side power transmission and be rigidly coupled to a wheel of the wheels 112, 114 via a shaft, such as a shaft of the axle shafts 116, 118. The power transmission 108 can be housed in a power transmission housing 109.

[0017] The power transmission 108 can be at least one input power transmission, such as an input gearbox, wherein the power transmission 108 operates in one gear ratio. However, other power transmission arrangements have been considered, such as a multi-speed power transmission designed to operate in several independent gear ratios.In other examples, the power transmission 108 can be a 2-speed transmission, a 3-speed transmission, a 4-speed transmission, a 5-speed transmission, a 6-speed transmission, a 7-speed transmission, an 8-speed transmission, a 9-speed transmission, a 10-speed transmission, an 11-speed transmission, a 12-speed transmission, a 13-speed transmission, a 14-speed transmission, a 15-speed transmission, a 16-speed transmission, a 17-speed transmission, an 18-speed transmission, a 19-speed transmission, a 20-speed transmission, or an n-speed transmission.

[0018] In one example, the electric machine 106, the power transmission 108, and the differential 110 can be integrated into the axle assembly 104, forming an electric axle (e-axle) in the vehicle 100. Among other functions, the e-axle provides power to the drive wheels 112 and 114 during operation. Specifically, in the e-axle configuration, the electric machine and the transmission assembly can be coupled to an axle housing and / or otherwise supported by it. In one particular example, the e-axle can be a rigid electric axle, with a fixed piece of material (e.g., a beam, a shaft, and / or a housing) extending between the drive wheels. The e-axle can provide a compact arrangement to deliver power directly to the axle.In other examples, however, the electric machine 106 and the power transmission 108 may be included in an electric power transmission system in which the gearbox and / or the electric motor are spaced apart from the axle. For example, in the electric power transmission example, mechanical components such as a drive shaft, joints (e.g., universal joints), and the like may provide a rotary connection between the electric power transmission and the drive axle.

[0019] The electric drive system 102 may further include a heat exchanger circuit 130. The heat exchanger circuit 130 may circulate a heat exchanger fluid that can absorb and repel heat energy. For example, the heat exchanger circuit 130 may be a coolant / cooling circuit that circulates coolant (e.g., water and / or glycol) through a jacket 131. The jacket 131 may be a coolant jacket that cools the electric machine via the heat exchanger fluid of the heat exchanger circuit 130. The housing 107 of the electric machine may include or accommodate the jacket 131. The heat exchanger circuit 130 may include a coolant inlet 138 and a coolant outlet 132, which are positioned on (or in) the housing 107 of the electric machine.The heat exchanger circuit 130 may further include a filter 133 and a pump 134, which circulates heat from the coolant outlet 132 via a coolant discharge line 136 to the coolant inlet 138. From the coolant inlet 138, the coolant flows into the jacket 131, which is formed in the housing 107 of the electric machine, thereby removing heat from components of the electric machine 106. In some examples, the heat exchanger circuit 130 may also include a heat exchanger (e.g., a radiator) that removes heat from the coolant leaving the housing 107 of the electric machine via the coolant outlet 132.

[0020] The heat exchanger circuit 130 can be a water-cooled cooling circuit, in which water is used as the coolant, and the jacket 131 can be a water jacket. However, it is understood that the heat exchanger circuit 130 can use other forms of coolant to cool the electric machine 106, such as oil. The heat exchanger circuit 130 can also include a lubrication circuit, in which the heat exchanger circuit 130 transports lubricant to lubricate internal components of the electric machine, such as windings and bearings. The lubricant can be oil.

[0021] The vehicle 100 may also include a control system 140 with a controller 141. The controller 141 may include a processor 142 and a memory 144. The memory may be non-transient and may contain instructions stored therein which, when executed by the processor, cause the controller 141 to execute various procedures, control techniques, and the like described in this document. The processor 142 may include a microprocessor unit and / or other types of circuitry. The memory 144 may include known data storage media, such as random-access memory, read-only memory, keep-alive memory, combinations thereof, and the like. The controller 141 may receive various signals from sensors 146 located at different points in the vehicle 100 and in the electric drive system 102.The controller 141 can also send control signals to various actuators 148, which are coupled at different points in the vehicle 100 and the electric drive system 102. For example, the controller 141 can send command signals to the pump 134, and in response, the actuator(s) in the pump(s) can be adjusted to change the flow rate of the oil and / or coolant supplied from it. The control system 140 and the electric drive system 102 can thus be communicatively coupled, as indicated by the dotted line 150. In other examples, the controller can send control signals to the electric machine 106, and in response to receiving the command signals, the electric machine can be adjusted to change a rotor speed, such as to increase or decrease the rotor speed.The other controllable components in the system can be operated in a similar manner with regard to sensor signals and actuator settings.

[0022] A set of reference axes 201 is provided as a reference for comparing views that are in the Fig. 2-8C and Fig. Figures 17-18 are shown. The reference axes 201 indicate a y-axis, an x-axis, and a z-axis. In one example, the z-axis can be a vertical axis (e.g., parallel to a gravitational axis), the x-axis can be a transverse axis (e.g., a horizontal axis), and / or the y-axis can be a longitudinal axis. In other examples, however, the axes can have other orientations. The xy-plane can be parallel to a plane on which the electric machine 106 can lie. When referring to a direction, positive can indicate the direction of the arrow of the y-axis, x-axis, and z-axis, and negative can indicate the direction opposite to the arrow of the y-axis, x-axis, and z-axis. A filled circle can represent an arrow and an axis that are directed toward or positive to a viewing direction.An unfilled circle can represent an arrow and an axis that point away from a viewing direction or are negative to it.

[0023] An axle 299 of the electric machine 106 is furthermore for reference in the Fig. 2-8C and the Fig. 17-18 provided. The axis 299 can be a central axis and a rotary axis for the electric machine 106. A section plane 2-2 for the cross-sectional view, which is in Fig. 3 is shown in Fig. 2 provided. The cutting plane 2-2 extends through an axis 299 of the electric machine 106.

[0024] Features described as axial may be approximately parallel to a referenced axis unless otherwise specified. Features described as anti-axial may be approximately perpendicular to the referenced axis unless otherwise specified. Features described as radial may circumferentially surround or extend outward from an axis, such as the referenced axis, or a component or feature previously described as radial to a referenced axis, unless otherwise specified. Unless otherwise specified, the referenced axis may be axis 299.

[0025] Fig. Figure 2 shows an illustration of the electric machine 106. The electric machine 106 can be configured as an electric motor, a generator, or an electric motor-generator and can be contained in a system 202, which can take various forms. For example, in one example, the electric machine 106 can be integrated into an electric drive system of an electric vehicle (EV), such as the vehicle 100 from Fig. 1. Thus, the electric machine 106 can be a traction motor and the electric drive can further include a power transmission (e.g. a gearbox), such as the electric drive system 102 and the power transmission 108 made of Fig. 1. In the EV example, the EV can be a fully electric vehicle (e.g., a battery electric vehicle (BEV)) in one example, or a hybrid electric vehicle (HEV) with an internal combustion engine in another. However, in other examples, the electric machine 106 can be used in other suitable systems (e.g., stationary systems), such as industrial machinery, agricultural machinery, conveyor systems, and the like.

[0026] The electric machine 106 includes a rotor 204 that interacts electromagnetically with a stator 206 to drive the rotation of a rotor shaft 208, which is contained within or rigidly coupled to the rotor 204. In the illustrated example, the electric machine 106 includes the housing 107 with an electrical interface 212 for the stator 206. The electrical interface 212 can be a multi-phase electrical interface with multiple electrical connectors 214. In the illustrated example, the electrical interface 212 can be a three-phase interface. However, it is understood that the configuration of the electrical interface 212 is not limited. For example, in other examples, the electrical interface 212 can be a different multi-phase interface, such as a six-phase or a nine-phase interface.More generally, the electrical machine 106 can be a multiphase alternating current (AC) machine. More specifically, the electrical machine can be a variable flux (VMF) machine, such as a memory machine (MM). MMs can include memory motors, memory generators, and memory motor / generator combinations.

[0027] As in Fig. As illustrated in Figure 2, the electric machine 106 can be electrically coupled to an inverter 216. The inverter 216 is designed to convert direct current (DC) power to alternating current (AC) power and vice versa. Thus, the electric machine 106 can be an AC machine, such as an AC electric motor, as described above. In other examples, however, the electric machine 106 can be a DC electric motor (as described above), and the inverter 216 can therefore be omitted from the system 202. The inverter 216 can receive electrical energy from one or more energy storage devices 218 (e.g., traction batteries, capacitors, combinations thereof, and the like).Arrows 220 signify the transfer of electrical energy between the electrical machine 106, the inverter 216 and the energy storage device(s) 218, which can take place during different operating modes of the system operation.

[0028] System 202 can additionally include a control subsystem 280 with a controller 282. The controller 282 includes a processor 284 and a memory 286. The memory 286 can contain instructions stored therein which, when executed by the processor 284, cause the controller 282 to carry out the various procedures, control strategies, and the like described in this document. The processor 284 can include a microprocessor unit and / or other types of circuitry. The memory 286 can include known data storage media, such as random-access memory, read-only memory, keep-alive memory, combinations thereof, and the like.

[0029] The controller 282 can receive various signals from sensors 288 located at different points in the system 202. The sensors 288 may include a speed sensor for the electric machine, a temperature sensor for the energy storage device, a state-of-charge sensor for the energy storage device, a power sensor for the inverter, and the like. The controller 282 can also send control signals to various actuators 290 connected at different points in the system 202. For example, the controller can send signals to the inverter 216 to adjust the speed of the electric machine 106. In another example, the controller 282 can send a command signal to the electric machine 106 and / or the inverter 216, and the motor speed can be adjusted in response. The other controllable components in the system- tem 202 can function in a similar way with regard to command signals and actuator settings.

[0030] The system 202 may also include one or more input devices 292 (e.g., an accelerator pedal, a brake pedal, a console instrument panel, a touch-sensitive user interface, a touch panel, a keyboard, combinations thereof, and the like). The input device(s) 292 may, in response to user input, generate an engine speed setting request.

[0031] System 202 can outsource System 140 Fig. 1. The controller 282 can turn the controller 141 off. Fig. 1 be and the processor 284 and the memory 286 can the processor 142 and the memory 144 from Fig. 1. In addition, the sensors 146 and the various actuators 148 can be from Fig. 1 the sensors 288 or various actuators 290 may be or include.

[0032] An exemplary schematic representation 300 of the electric machine 106 is shown in Fig. Figure 300 is a simplified schematic illustration of a cross-section of the electric machine 106. The schematic illustration 300 can be an exemplary schematic representation of a sectional perspective of the electric machine 106 on the section plane 2-2. It should be noted that the cross-section represents a section of the electric machine 106. It is understood that the electric machine 106 includes various additional components, which are omitted for clarity. Fig. 3 are omitted. The electric machine 106 includes a stator 206, which includes a stator core 302, with a plurality of end windings 304 that project axially (e.g. along the central axis of rotation: axis 299) from each end of the stator core 302.

[0033] The stator core 302 can completely surround a rotor 204 of the electric machine 106 and can be spaced from the rotor 204 by an air gap 308 (e.g., a radial air gap). The air gap 308 can be a distance represented by a plurality of arrows 309. The rotor 204 has a rotor core 310, which can contain permanent magnets to generate magnetic flux fields and enable the rotor 204 to rotate at synchronous speeds in response to an applied current. The rotor core 310 is rigidly coupled to a shaft 208 of the rotor 204, so that the rotor core 310 and the shaft 208 rotate as a single unit. In one example, the length of the shaft 208, as defined along the central axis of rotation (e.g. axis 299), may be greater than the length of the rotor core 310, which may be similar to the length of the stator core 302.The rotor 204 can be made of various materials depending on the application and the rotor section. For example, the shaft 208 can be made of steel or a similar metal capable of transmitting torque and possessing the desired stiffness. The rotor core 310 of the rotor 204 can, for example, comprise a high-permeability steel with embedded permanent magnets. Similarly, the stator core 302 can comprise a high-permeability steel.

[0034] The stator 206 and the rotor 204 can be enclosed within the housing 107, which may include a jacket for heat exchanger fluid, such as the jacket 131 made of Fig. 1. The housing 107 comprises a sleeve section 316, a first end plate 318, and a second end plate 320, the sleeve section 316 and the end plates being described further below. The housing 107 can completely surround the stator core 302 and can be made of a rigid, thermally conductive material, such as aluminum, which is lightweight and inexpensive while being mechanically strong and durable. By positioning the housing 107 in direct contact with the stator core 302, heat generated at the stator core 302 can be conducted away from the stator core 302 and into the housing 107, as indicated by the arrows 307. In some cases, the housing 107 can be air-cooled and transfer heat from the housing 107 to air flowing over the electric machine 106. In other examples, the housing 107 can be liquid-cooled and allow heat exchange via a coolant flowing through one or more coolant channels of the housing 107.

[0035] For example, the sleeve section 316 of the housing 107 can circumferentially surround the stator core 302 along a direction parallel to the central axis of rotation (e.g., axis 299). If the housing 107 is configured to be liquid-cooled, the sleeve section 316 of the housing 107 can include at least one coolant channel fluidically coupled to the heat exchanger circuit 130, for example, a vehicle, as indicated by arrows 305. Cooling the stator 206 therefore does not require a separate additional cooling system, such as an oil-based cooling system, which would increase the complexity and cost of implementing the electric motor. The housing 107 can also have the first end plate 318 and the second end plate 320, the end plates being arranged perpendicular to the central axis of rotation (e.g., axis 299) and coupled at the ends of the sleeve section 316 of the housing 107.The end plates can be made of the same or a different material than the housing 107. In some examples, the end plates can be made of aluminum to provide high thermal conductivity while keeping the weight of the end plates low. The first end plate 318 has a central opening 322 (e.g., an opening centered around the axis 299) to accommodate an arrangement of components coupled to the rotor 204, such as bearings, seals, etc. (in . Fig. 3 not shown).

[0036] The inner surfaces of the first and second end plates 318, 320 can accommodate the end windings 304 at the respective ends of the electric machine 106. However, due to a grooved configuration of the inner surfaces, the end windings 304 can be spaced apart from the inner surfaces of the end plates, as described below with reference to Fig. 4 is described. For example, grooves or indentations in the inner surfaces of the end plates can be aligned with the end windings 304 so that the tips of the end windings 304 can be inserted into the grooves without making contact with the end windings 304 and therefore without exerting any mechanical forces on the end windings 304. Spaces between the end plates and the end windings 304 within the grooves can be filled with a flexible, thermally conductive potting material to provide mechanical support for the end windings 304 while simultaneously allowing conductive heat transfer from the end windings 304 to the end plates.

[0037] The first and second end plates 318, 320 can, in one example, be coupled to the sleeve section 316 of the housing 107 such that the first and second end plates 318, 320 and the housing 107 form a single, cohesive unit. Alternatively, the end plates can be separate units from the sleeve section 316 and can be attached to the sleeve section 316 by welding, fasteners, etc. The end plates can facilitate heat dissipation from the end windings 304 by conducting heat from the end windings 304 to the sleeve section 316 of the housing 107, as indicated by arrows 307. Compared to heat dissipation through the rotor core 310 to the housing 107, heat transfer via the end plates provides additional heat transfer paths for heat generated at the end windings 304.The thermal management of the developments can be faster and more efficient due to the high thermal conductivity of the end plate material.

[0038] In some examples, the end plates each have at least one coolant channel that is fluidically coupled to the at least one coolant channel of the sleeve section 316, as indicated by arrows 305, thereby enabling coolant circulation from the heat exchanger circuit 130 to the end plates and increasing the cooling capacity of the end plates. In other examples, only one of the end plates may have the at least one coolant channel, and the other end plate may not have any coolant channels. In particular, the end plate coupled to the welded set of end windings may be configured with at least one coolant channel, since there is a tendency to generate hotspots at the welded set of end windings.Hotspots can form as a result of a greater length of the welded set of end windings compared to the set of crown windings, if the conductive windings are hairpin windings.

[0039] By configuring the housing 107 with the first and second end plates 318, 320, each configured to accommodate the end windings 304 of the stator 206, an additional heat flow path for the stator 206 can be provided. For example, without the end plate configuration described in this document, heat generated at the end windings 304 can instead be dissipated at the ends of the stator core 302 to the stator core 302 and through the stator core 302 to the sleeve end. The heat is conducted through section 316 of the housing 107. This can increase the cooling load on the sleeve section 316, thereby reducing the cooling efficiency of the housing 107. Since the end plates are coupled to the sleeve section 316 of the housing 107, the heat from the end windings 304 can instead be conducted away from the stator core 302, thus increasing the overall heat dissipation from the stator 206.

[0040] In some cases, the rotor 204 can also be configured to allow coolant flow through it if the housing 107 is liquid-cooled. As in Fig. As shown in Figure 3, the shaft 208 of the rotor 204 can, for example, include a plurality of first channels 324 extending along a section of the length of the rotor core 310. The first channels 324 can be arranged in a section of the rotor 204 that remains stationary and does not rotate. Additionally, the shaft 208 can include a plurality of second channels 326 extending along a section of the length of the shaft 208. The first and second channels 324, 326 can be fluid channels and, in particular, heat exchanger channels, such as cooling channels. A heat exchanger fluid, such as coolant, can flow through the first and second channels 324, 326 to absorb thermal energy from the rotor 204 and the shaft 208.

[0041] The first channels 324 and the second channels 326 can be connected to at least one coolant channel from one of the end plates, so that coolant is supplied from the end plate to the first channels 324 and / or the second channels 326. In this way, coolant from the vehicle's heat exchanger circuit 130 can be circulated to the sleeve section 316 of the housing 107, into one or more of the first and / or second end plates 318, 320, and into the shaft 208 of the rotor 204, before flowing back to a heat sink of the heat exchanger circuit 130, such as a heat exchanger. Heat extraction via a coolant flow at the end plates and the rotor shaft makes it possible to keep the temperatures of the end windings, the rotor, and bearings and seals coupled to the rotor below a temperature threshold, such as 100 °C.

[0042] To maximize cooling of the end windings by the end plates, it may be desirable to position the end windings as close as possible to the end plates while still providing sufficient clearance to allow for thermal expansion. This can be achieved by configuring inner surfaces of the end plates, such as those facing the end windings, with grooves or notches to accommodate them. For example, the tips of the welded set of end windings can be at least partially recessed into the notches, thus reducing the amount of extra length added due to the stator being capped by the end plates at each end.

[0043] With reference to Fig. Figure 4 shows a view 400 of an assembly 402, which includes the stator 206, the rotor 204, and a plurality of magnets 414 centered radially around the axis 299. View 400 is an expanded view of the assembly 402. The stator 206 and the stator core 302 can comprise a plurality of first coatings 410. The rotor 204 of the rotor core 310 can comprise a plurality of second coatings 412. The first coatings 410 and the second coatings 412 can be non-restrictive representations, with fewer or more of the first coatings 410 and / or second coatings 412 than shown in Figure 4. Fig. 4 shown may be present. Likewise, the first coatings 410 and / or the second coatings 412 may have different dimensions than shown. Fig. 4 shown. Furthermore, the coatings 410, 412 can be shown schematically relative to the other components and features of the assembly 402. Alternatively, it is understood that in another example the stator 206 and the rotor 204 may not have any coatings. For example, the stator core 302 may be a single and uniform structure without coatings and / or subdivisions. Likewise, in this or another example, the rotor core 310 may have a single and uniform structure without coatings and / or subdivisions.

[0044] A gap of air, referred to in this document as the air gap, may be enclosed between the stator and the rotor. The air gap may be represented by arrows 409 and the air gap from Fig. 4. The air gap 308 can be measured with the distance indicated by the arrows 309 in Fig. The air gap, represented by arrows 409, is approximately to scale. More specifically, the air gap represented by arrows 409 can be arranged approximately radially between the stator 206 and the rotor 204.

[0045] The stator 206 and the rotor 204, and in particular the stator core 302 and the rotor core 310, can comprise a type of high-permeability steel, such as a steel alloy containing iron and nickel. The first coatings 410 of the stator and the second coatings 412 can also comprise high-permeability steel. The stator 206 and the stator core 302 are hollow and can include a first hole 406.

[0046] Furthermore, the rotor 204 and the rotor core 310 can be hollow and include a second hole 408. The first and second holes 406, 408 can be through holes. The rotor 204 can be received via the rotor core 310 through the first hole 406, whereby the rotor 204 can be positioned concentrically to the first hole 406. A shaft, such as the shaft 208 from the Fig. 2-3 can be housed in the rotor core 310 and firmly coupled to it via the second hole 408. The first hole 406 and the second hole 408 can be radially centered around the axis 299.

[0047] The magnets 414 are permanent magnets and can, in particular, be permanent magnets free of rare-earth materials. In other words, the magnets 414 can be free of rare-earth permanent magnets (e.g., not contain them). The rotor 204 can include and accommodate two magnetic layers, with the magnets 414 encompassing the magnets of two magnetic layers. A first magnetic layer is responsible for torque generation, which can be formed by the strongest magnet (highest coercive force) in the magnetic circuit. Another function of the first magnetic layer is to maximize the utilization of the reluctance torque. The second magnetic layer is responsible for facilitating flux regulation. In the present embodiment, the uppermost layer (e.g.,The first magnetic layer (the layer furthest radially outward) of magnets contains iron nitride (FeN) magnets with higher coercivity and relatively lower residual flux density compared to other magnets of rotor 204. The HC magnets, such as the first and second magnets 416a and 416b, which are arranged in a V-shape, may also contain FeN. The magnets of the first magnetic layer can be referred to as HC magnets.

[0048] The magnets of the second magnetic layer can be made of a material with lower coercivity, such as different grades of Alnico alloys (AINiCo). The different grades of AlNiCo materials exhibit varying magnetic properties, including coercivity. A first-grade AINiCo magnet may have a higher or lower coercivity compared to a second-grade AlNiCo magnet.

[0049] The magnets of the second magnetic layer can receive current and magnetic flux via magnetic flux paths through the first magnetic layer to reach the air gap. Therefore, under load conditions, a multitude of magnets in the first magnetic layer protects a further multitude of magnets in the second magnetic layer from demagnetization.

[0050] For example, the magnets 414 include a first set of magnets enclosed by a first ellipse 415 of dashed lines. The first set of magnets may be configured to form the first magnetic layer. A second set of magnets may be enclosed by a second ellipse 417 of dashed lines. The second set of magnets may be configured to form the second magnetic layer. The first set of magnets may be arranged radially inward from the second set of magnets relative to the axis 299. There are multiple first sets of magnets enclosed by the first ellipse 415 and multiple second sets of magnets enclosed by the second ellipse 417.Each of the second sets of magnets enclosed by the second ellipse 417 includes at least one pair of magnets, each magnet of the pair having a different grade of AlNiCo with a different coercive force.

[0051] Furthermore, the magnets of the second magnetic layer can be divided into a plurality of upper magnets and a plurality of lower magnets, with upper and lower being radial to axis 299. The upper and lower magnets of the second magnetic layer can be electrically and magnetically coupled in a parallel arrangement to form a magnetic circuit (MC). Each of the upper parallel magnets exhibits a lower coercive force compared to each of the lower parallel magnets. This difference in coercive force between the upper and lower parallel magnets facilitates control of the operating point of each of the upper parallel magnets by demagnetization or remagnetization. In other words, the upper parallel magnets exhibit the lowest coercive force of the LC magnets.

[0052] Each of the first sets of magnets, represented by the first ellipse 415, can include a variety of first magnets 416a and a variety of second magnets 416b. The first magnets 416a and the second magnets 416b can be of the same type, containing the same material and having the same dimensions. The first magnets 416a and the second magnets 416b can be the permanent magnets with the highest coercivity of the rotor 204 (e.g., the HC magnets of the rotor 204). For example, each of the first magnets 416a and the second magnets 416b can be made of iron nitride (FeN). However, it is understood that the composition of the first magnets 416a and the second magnets 416b is not a limiting factor. For example, a different configuration of the first and second magnets 416a, 416b may have a different grade of FeN, such as a higher grade with lower impurities.In another example, a different configuration of the first and second magnets 416a, 416b can be different grades of magnets with Alnico (AlNiCo) alloy with a higher coercive force compared to the other magnets of magnets 414.

[0053] Each of the first magnets 416a can be positioned to mirror the second magnets 416b, for example, to be arranged in a V-shape. The first magnets 416a and the second magnets 416b can be received and integrated into the stator via at least a plurality of slots, wherein at least one slot can receive a pair of the first magnets 416a and the second magnets 416b, such that the pair is arranged in the V-shape. However, it is understood that a plurality of slots can be present, with specific slots being able to receive the first magnets 416a and other specific slots being able to receive the second magnets 416b.

[0054] Every second set includes a pair of magnets. The second sets of magnets, represented by the second ellipse 417, can include a variety of third magnets 418 and a variety of fourth magnets 420. The third magnets 418 can be adjacent to and touching the fourth magnets 420. The fourth magnets 420 can be oriented radially inward from the third magnets 418 relative to the axis 299. In other words, the third magnets 418 can be positioned in a radially outward direction from the fourth magnets 420 and arranged radially on them. The third magnets 418 and the fourth magnets 420 can comprise different grades of an AlNiCo alloy, the different grades of AlNiCo having different amounts of the compound (e.g., molecularly) of aluminum (Al), nickel (Ni), or cobalt (Co). For example, the different grades of AlNiCo can have different amounts of Co.In this example, the third magnets can be partially made of or contain AlNiCo5, and the fourth magnets can be partially made of or contain AlNiCo9. The third magnets 418 and the fourth magnets 420 can be weaker compared to the first and second magnets 416a and 416b (e.g., exhibit a lower coercive force). The third magnets 418 and the fourth magnets 420 can be the LC magnets of the rotor 204. Furthermore, the third magnets 418 can have a lower coercive force compared to the fourth magnets 420. Conversely, the fourth magnets 420 can have a higher coercive force than the third magnets 418. The third magnets 418 can be the weaker of the LC magnets.

[0055] Each pair of magnets of every second set of magnets enclosed by the second ellipse 417 can be magnetically coupled in a parallel configuration to form an MC. More specifically, a third magnet of the third magnets 418 and a fourth magnet of the fourth magnets 420 can be magnetically coupled to form the MC, the MC being a parallel MC.

[0056] The stator core 302 can include a plurality of teeth 422 extending radially inwards from the stator core. Between the pairs of teeth 422 is a cavity, or a plurality of cavities 424. A plurality of stator windings 426 can be integrated into the stator 206 and, more specifically, the stator core 302. For example, the stator windings 426 can be rigidly coupled to the stator 206 and the stator core 302 by being housed in the cavities 424 and between the teeth 422. The stator windings 426 can be connected to the end windings 304 to provide electrical and thermal coupling. The stator windings 426 can provide the electromagnetic forces and torque to act on the permanent magnets 414 and rotate the rotor 204.

[0057] The rotor core 310 and the second hole 408 can form a surface 432. The surface can be radially curved about the axis 299. The surface 432 can have a cylindrical shape. A shaft, such as the shaft 208 from the Fig. 2-3, can be adjacent to the rotor core 310 via the surface 432 and be firmly coupled to it.

[0058] The rotor core 310 can have a plurality of first holes 440, a plurality of second holes 442, and a plurality of third holes 444. The first holes 440, the second holes 442, and the third holes 444 can extend through the second coatings 412 in an axial direction, such as with respect to the axis 299. The first holes 440, the second holes 442, and the third holes 444 can extend from a first end to a second end of the rotor 204, with the first end opposite the second end. In other words, the first holes 440, the second holes 442, and the third holes 444 can extend along a length 472 of the rotor 204 and the rotor core 310. The first holes 440, the second holes 442 and the third holes 444 can be positioned radially around the second hole 408 with respect to the axis 299.The first holes 440 and the second holes 442 can have approximately the same dimensions; each of the first holes 440 can mirror a hole of the second holes 442; and the first holes 440 and the second holes 442 can be grouped in pairs. For example, the first holes 440, the second holes 442, and the third holes 444 can accommodate or form a fluid passage. The fluid passages can be fluid channels and, more specifically, heat exchanger channels, such as the first channels 324. Fig. 3. The heat exchanger channels of the rotor core 310 can be used to remove or add thermal energy to the rotor 204 and its integrated components, such as the magnets 414. The fluid passages received in or formed by the first holes 440, the second holes 442, and the third holes 444 can transport coolant or other heat exchanger fluid and be fluidically coupled to components or be part of a cooling system, such as the heat exchanger circuit 130, or fluidically coupled to it. The fluid passages received in or formed by the first holes 440, the second holes 442, and the third holes 444 can be fluidically connected to a jacket, such as the jacket 131. Fig. 1, be coupled or be cooled via this. The fluid passages that are received in or formed by the first holes 440, the second holes 442 and the third holes 444 can cool the rotor 204 therein.

[0059] The rotor 204 includes a plurality of first slots 462, a plurality of second slots 464, a plurality of third slots 466, and a plurality of fourth slots 468. The first slots 462, the second slots 464, the third slots 466, and the fourth slots 468 can be arranged radially around the second hole 408 and can extend along the length 472 of the rotor 204 and the rotor core 310. The third slots 466 and the fourth slots 468 can also extend outwards in a radial direction with respect to the axis 299, and each of the third slots 466 and the fourth slots 468 can be designated as a radial slot. The first and second slots 462, 464 can be radially farther from the axis 299 than the third slots 466. Each of the fourth slots 468 can be radially farther from the axis 299 than the third slots 466.In other words, every fourth groove of the fourth grooves 468 can be an upper groove relative to a third groove of the third grooves 466, and the fourth grooves 468 are located radially outwards from the third grooves 466 with respect to the second hole 408.

[0060] The first and second slots 462, 464 can be arranged in sets, such as pairs. Each of the first slots 462 can be separated at an angle 470 from a second slot of the second slots 464, wherein the first slot of the first slots 462 and the second slot of the second slots 464 are of the same pair. The angle 470 is such that the first and second slots 462, 464 are positioned to form a V-shape. In other words, each pair of first slots 462 and second slots 464 is arranged in a V-shape to extend through the material of the rotor core 310. The first slots 462 and second slots 464 can have approximately the same dimensions, and each of the first slots 462 can be arranged to mirror a second slot of the second slots 464. More specifically, each first groove can mirror a second groove belonging to a pair of first and second grooves 462, 464.Each of the first slots 462 and each of the second slots 464 can be separated by an internal rib 465. However, it is understood that the separation of the first and second slots 462, 464 by a structure cannot be restrictive. In another example of a different configuration of the rotor 204, each of the first slots 462 and each of the second slots 464 can lack a structure such as the internal rib 465. In this example, each of the first slots 462 and each of the second slots 464 can be a single, volumetrically continuous slot.

[0061] The third and fourth slots 466, 468 can be arranged in sets, such as pairs. Each fourth slot of a set of third and fourth slots 466, 468 can be located outside and above the third slot of the set. The third slots 466 can be volumetrically connected to the fourth slots 468, with each of the third slots 466 being volumetrically connected to a fourth slot of the fourth slots 468 of the same set, such as via a passage or other volume enclosed between the third slot and the fourth slot of the set.

[0062] The first magnets 416a and the second magnets 416b can be integrated into the rotor 204 and the rotor core 310 via the first and second slots 462 and 464, respectively. More specifically, the first slots 462 and the second slots 464 can each accommodate and partially enclose the first magnets 416a and the second magnets 416b, respectively. The third magnets 418 and the fourth magnets 420 can be integrated into the rotor 204 and the rotor core 310 via the third slots 466. More specifically, the third slots 466 can each accommodate and partially enclose one third magnet and one fourth magnet of the third magnets 418 and the fourth magnets 420, respectively.

[0063] The stator 206 and the stator core 302 can have a first diameter 482 and a second diameter 484. The first diameter 482 is an outer diameter and the second diameter 484 is an inner diameter of the stator 206 and the stator core 302. The second diameter 484 can be the diameter of the first hole 406. The rotor 204 and the rotor core 310 can have a third diameter 486 and a fourth diameter, where the third diameter 486 is an outer diameter and the fourth diameter 488 is an inner diameter of the rotor 204 and the rotor core 310. The fourth diameter 488 can be the diameter of the first hole 406. The second diameter 484 is larger than the third diameter 486, so the rotor 204 can be accommodated within the first hole 406.

[0064] With reference to Fig. Figure 5 shows a view 500 of assembly 402, in which the magnets 414 are made of Fig. 4 are integrated into the rotor 204. View 500 is a cross-sectional view of the rotor 204 and the stator 206, with the stator 206 receiving the rotor 204 via the first hole 406. View 500 is viewed from a plane perpendicular to the axis 299 and the y-axis of the reference axes 201.

[0065] When the magnets are accommodated, the first slots 462, the second slots 464, the third slots 466, and the fourth slots 468 can form magnetic poles. For example, the rotor 204 can include a first pole enclosed by and represented by a third ellipse 552, and a second pole enclosed by and represented by a fourth ellipse 554. The third ellipse 552 and the fourth ellipse 554 comprise a variety of curved and dashed lines. In one example, each pole can include at least one first magnet 416a, one second magnet 416b, one third magnet 418, and one fourth magnet 420.

[0066] The poles and permanent magnets of the rotor 204 can transmit magnetic flux from electromagnetic forces of magnetic current, which is supplied by the end windings 304 and the stator windings 426. Fig. 4 flows, absorb. Impulses of magnetic current and magnetic flux between the windings 304, 426 and the poles of the rotor 204 can transmit magnetic forces from the windings 304, 426 to the rotor 204, such as torque, which can cause the rotor 204 to rotate. More specifically, torque for rotating the rotor 204 can include reluctance torque from the pulses and a changing polarity of the windings 304, 426, which drive the poles of the permanent magnets of the rotor 204, in order to align with the positively or negatively charged magnetic fields of the windings 304, 426 and drive the rotor 204 to rotate. Likewise, torque can include magnetic torque from the permanent magnets of the rotor 204 and flux fields from them, and the magnetic torque drives the rotor 204 to rotate. When driven to rotate, the rotor 204 can rotate around the axis 299.The flux paths for driving the rotor 204 can extend from the windings 304, 426 through the material of the stator core 302, across the airflow gap, represented by arrows 409, into the material of the rotor core 310 and into the magnets of the magnetic poles. Examples of flux paths are shown through modes I-III in the diagrams. Fig. 8A-8C are visible.

[0067] With reference to Fig. Figure 6 shows a view 600 of the rotor 204, in which the magnets 414 are made of Fig. 4 are integrated into the rotor 204. View 600 is a cross-sectional view of the rotor 204. View 600 is viewed from a plane perpendicular to axis 299 and the y-axis of reference axes 201.

[0068] A shaft 610 can be integrated into the rotor 204, with the shaft 610 being rigidly coupled to the rotor 204. The shaft 610 can be received via the second hole 408 in the rotor 204 and physically coupled to it, with the shaft 610 being located approximately concentric to the second hole 408. The shaft 610 can extend the shaft 208 from Fig. 2 be.

[0069] The rotor core 310 can include a plurality of first ribs 630, which are spoke-shaped. Each of the first ribs 630 can be enclosed between a set of first holes 440 and second holes 442. The first ribs 630 can include a plurality of channels 632, with each of the first ribs 630 including at least one channel 632. The channels 632 can be volumetrically connected to the third slots 466. The third slots 466 can be positioned radially above or on the first ribs 630. In other words, the third slots 466 can be directed radially outward from the first ribs 630. Each of the third slots 466 and the fourth slots 468 can be centered about a common axis with a first rib of the first ribs 630.

[0070] The rotor core 310 can include a plurality of second ribs 636 and a plurality of third ribs 638, each of the second ribs 636 and each of the third ribs 638 being located on opposite sides of a third hole of the third holes 444. In other words, each third hole of the third holes 444 can be enclosed between a second rib of the second ribs 636 and a third rib of the third ribs 638. Furthermore, each of the second ribs 636 can be enclosed between a first hole of the first holes 440 and a third hole of the third holes 444. Likewise, each of the third rib- pen 638 is enclosed between a second hole of the second holes 442 and a third hole of the third holes 444.

[0071] The first ribs 630 can prevent or reduce magnetic flux leakage from the first layer of magnets. In other words, the first ribs 630 can prevent or reduce magnetic flux leakage from the first magnets 416a and the second magnets 416b, such as when they are arranged in a V-shape and integrated into the rotor 204.

[0072] The third magnets 418 can have a first width, represented by a plurality of first arrows 652, and the fourth magnets 420 can have a second width, represented by a plurality of second arrows 654. The first width of the first arrows 652 can be spaced further apart than the second width of the second arrows 654, and the third magnets 418 can be wider than the fourth magnets 420 in this respect. Each of the third grooves 466 can have a first section that is approximately the same size as, or larger than, the first width represented by the first arrows 652. Furthermore, each of the third grooves 466 can have a second section that is approximately the same size as, or larger than, the second width represented by the second arrows 654, the second section having a smaller width than the first section of each of the third grooves 466.The third magnets 418 can be included in the first section. The fourth magnets 420 can be included in the second section.

[0073] With reference to Fig. 7 is a view 700 of a cut segment 702 of assembly 402 from the Fig. Figures 4-5 show that view 700 can be a section view (e.g., a cross-sectional view). View 700 is viewed from a plane perpendicular to axis 299 and the y-axis of reference axes 201.

[0074] The cut segment 702 is a disk of assembly 402 showing a pole surrounded by an ellipse 712. The ellipse 712 contains a variety of dashed and curved lines. The pole surrounded by the ellipse 712 can be the first pole surrounded by the third ellipse 552, or the second pole surrounded by the fourth ellipse 554. The cut segment 702 includes a first magnet of the first magnets 416a, a second magnet of the second magnets 416b, two different halves of the third magnets 418, and two different halves of the fourth magnets 420. The cut segment 702 also includes two different halves of the first ribs 630, one rib of the second ribs 636, and one rib of the third ribs 638.

[0075] The Fig. Figures 8A-8C show the cutaway segment 702 during a variety of modes for the flux control system. The magnetic flux is varied by applying a positive d-axis current pulse for remagnetization and a negative d-axis current pulse for demagnetization. The flux can be varied by changing the current in the stator windings 426. Varying the magnetic flux can switch the cutaway segment 702 between different modes of the variety of modes. The flux control mechanism of the present embodiment operates in three main modes: Mode I, Mode II, and Mode III. A control system, such as the control system 140 from Fig. 1 or the tax system 280 from Fig. 2, can include a controller, such as the controller 141 or the controller 282, which can be communicatively coupled to the rotor 204. The controller can selectively demagnetize or remagnetize one or more first magnets from the first set of magnets and / or one or more second magnets of the second set of magnets of the rotor 204. In other words, the controller can selectively demagnetize or remagnetize the first and second magnets 416a, 416b and / or the third magnets 418. The controller can also reverse the magnetization of the third magnets 418. Reversal magnetization changes the polarity of a magnet or magnets, such as the third magnets. The selective magnetization, demagnetization, and remagnetization of magnets by the controller can switch an electric machine comprising the rotor 204 and the stator 206 between Mode I, Mode II, and Mode III.

[0076] Fig. Figure 8A shows the cut segment 702 during a first mode 802. The first mode 802 is an example of mode I in which all magnets (e.g., the first magnets 416a, the second magnets 416b, the third magnets 418, and the fourth magnets 420) participate in the flux across the air gap, represented by arrows 409, between the stator 206 and the rotor 204. During the first mode 802, a plurality of first flux linkages can be represented by a plurality of first lines 812.

[0077] The first flux links can conduct magnetic current from the stator windings 426 through the stator core 302 and across the gap 308 to the rotor core 310. The current can flow via the flux links through the rotor core 310 to sets of the first and second magnets 416a, 416b, from the first and second magnets 416a, 416b across the rotor core 310 to the third magnets 418, from the third magnets 418 through the fourth magnets 420, and from the fourth magnets 420 through the rotor core 310. More specifically, the first flux links and the current can extend through the first ribs 630, the second ribs 636, the third ribs 638, and around the holes 440, 442, 444. The first river chains and the current that is located in them may also be curved around the second hole 408.

[0078] During the first mode 802, an electric machine that receives the cut segment 702 can be described as fully magnetized.

[0079] Fig. Figure 8B shows the cut segment 702 during a second mode 822. The second mode 822 is an example of mode II in which the first layer of magnets and the lower magnets of the second layer of magnets (e.g., the first magnets 416a, the second magnets 416b, and the fourth magnets 420) contribute to flowing across an air gap (e.g., the gap 308 of the distance shown by arrow 309) and between the stator 206 and the rotor 204. The first layer of magnets, which includes the first magnets 416a and the second magnets 416b, is fully magnetized. Likewise, the lower magnets of the second layer of magnets, which includes the fourth magnets 420, are fully magnetized. The uppermost magnets of the second layer of magnets, which includes the third magnets 418, are demagnetized.During the second mode 822, a multitude of second flow chains can be represented by a multitude of second lines 832.

[0080] The second flux links can conduct magnetic current from the stator windings 426 through the stator core 302 and across the gap 308 to the rotor core 310. The current can flow via the flux links through the rotor core 310 to sets of the first and second magnets 416a, 416b, from the first and second magnets 416a, 416b across the rotor core 310 to the fourth magnets 420, and from the fourth magnets 420 through the rotor core 310. More specifically, the second flux links and the current can extend through the first ribs 630, the second ribs 636, the third ribs 638, and around the holes 440, 442, 444. The second flux links and the current can also be curved around the second hole 408.

[0081] Fig. Figure 8C shows the cut segment 702 during a third mode 842. The third mode 842 is an example of mode III in which the main flux magnets of the first layer of magnets are demagnetized, while the upper magnets of the second layer of magnets and the sets of parallel magnets are remagnetized. In other words, the first and second magnets 416a, 416b are demagnetized, and the third magnets 418 are remagnetized. Additionally, the fourth magnets 420 remain magnetized. During the third mode 842, a variety of third flux chains can be represented by a variety of third lines 852.

[0082] During the third mode 842, the air gap flux can be reduced to zero or approximately zero, thus preventing current from flowing from the stator 206 to the rotor 204. During the third mode 842, there are no or negligible (e.g., within 5% of zero) amounts of flux linkages carrying current from the stator 206 to the rotor 204. For example, a flux linkage may exist, represented by line 852a, extending through the stator 206, across the stator core 302, to the air gap represented by arrows 409. However, the flux linkage represented by line 852a prevents crossing and linking with the rotor 204 and the rotor core 310 across the air gap represented by arrows 409.

[0083] With reference to Fig. Figure 9 shows a diagram 900. The diagram 900 consists of a variety of demagnetization curves (e.g., traces) of permanent magnet material that the magnets housed in and integrated into the rotor 204 may exhibit. Fig. Figure 9 shows a variety of tracks for a variety of magnetic materials, where the tracks show magnetic flux densities (B) at different magnetic field strengths (H). The magnetic materials can be used for the permanent magnets housed in and integrated into a rotor, such as the rotor 204 from the Fig. 2-8C.

[0084] Diagram 900 includes a first axis 904 and a second axis 906. The first axis 904 represents H in units of kiloamperes per meter (kA / m). The second axis 906 represents B in units of tesla (T). H on the first axis 904 can be the independent variable, and B on the second axis can be dependent on H.

[0085] Diagram 900 includes a first track 912, a second track 914, and a third track 916. The first track 912 originates from B with different values ​​of H for the permanent magnet material or permanent magnets containing FeN, such as the first and second magnets 416a and 416b from the Fig. 4-8C. The second track 914 comes from B with different values ​​of H for the permanent magnet material or permanent magnets containing AlNiCo5, such as the third magnets 418 from the Fig. 4-8C. The second track 914 comes from B with different values ​​of H for the permanent magnet material or permanent magnets containing AINiCo9, such as the fourth magnets 420 from the Fig. 4-8C.

[0086] With reference to Fig. Figure 10 shows a diagram 1000 which includes a trace 1012 of magnetic flux in relation to the demagnetizing current through the electric machine. In other words, the trace 1012 represents the magnetic flux of magnetic flux links for the electric machine versus the magnetizing current for the electric machine. The electric machine is a VFM of the present disclosure, such as an electric machine comprising the assembly 402 from the Fig. Includes 4-5.

[0087] Diagram 1000 includes a first axis 1004 and a second axis 1006, where the values ​​of the first axis 1004 are independent and the values ​​of the second axis 1006 are dependent on the first axis 1004. The first axis 1004 is an axis that shows the demagnetizing current for the electric machine in units of amperes (A). The second axis 1006 is an axis that shows the magnetic flux in units of webers or volt-seconds (V*s) for flux links of the electric machine. The flux links of the second axis 1006 can be flux links derived from the first lines 812, the second lines 832, and the third lines 852. Fig. 8A-8B are shown.

[0088] Figure 1012 shows that when the strength of the demagnetizing current decreases, the magnetic flux for the flux links of the electric machine increases. Figure 1012 also shows an electric machine of the present disclosure which has the ability to withstand demagnetization under high stress. The electric machine can enable full utilization of reluctance torque from the electromagnets of the electric machine (e.g., the end windings 304 and the stator windings 426), while irreversible demagnetization of permanent magnets of a rotor of the electric machine, such as the magnets 414 of the rotor 204, which are shown in Fig. As shown in 4, this is prevented.

[0089] With reference to Fig. Figure 11 shows diagram 1100. Diagram 1100 shows the demagnetization ratios of the permanent magnets for the electric machine during demagnetization over a multitude of tracks. In other words, diagram 1100 shows a multitude of tracks of demagnetization curves for the magnetic materials, where the tracks show demagnetization ratios at different demagnetization currents.

[0090] Diagram 1100 includes a first axis 1104 and a second axis 1106, where the values ​​of the first axis 1104 are independent and the values ​​of the second axis 1106 depend on the first axis 1104. The first axis 1104 shows the demagnetizing current for the electrical machine in units of amperes (A). The second axis 1106 shows the demagnetization ratios (DRs) of the magnets as percentages (%).

[0091] The permanent magnets include magnets that comprise or contain Niron Gen 1, AlNiCo5, or AlNiCo9 as magnetic materials. Diagram 1100 includes a first track 1112, a second track 1114, and a third track 1116, which show demagnetization ratios at various demagnetization currents. The first track 1112 shows the demagnetization ratio at various demagnetization currents for magnets or magnetic material that comprises or contains Niron Gen 1. The second track 1114 shows the demagnetization ratio at various demagnetization currents for magnets or magnetic material that comprises AlNiCo5. The third track 1116 shows the demagnetization ratio at various demagnetization currents for magnets or magnetic material that comprises AlNiCo9.The demagnetization ratio of AlNiCo9 increases approximately less than the demagnetization ratios of Niron Gen 1 and AlNiCo5 with more negative demagnetization currents. Conversely, the demagnetization ratio of AlNiCo5 increases approximately more than that of Niron Gen 1 with more negative demagnetization currents.

[0092] Diagram 1100 includes a first threshold value 1132, shown as a dashed line. The first threshold value 1132 represents a demagnetization ratio of 100%. The first track 1112 and the second track 1114 show the main magnets comprising Niron Gen 1 and AlNiCo5, respectively, which may be completely demagnetized. When magnets comprising Niron Gen 1 and AlNiCo5 are completely demagnetized, the first track 1112 and the second track 1114 may each increase to the first threshold value 1132. Remagnetization occurs at demagnetization ratios above the first threshold value 1132 of 100%. The third track 1116 shows that the AlNiCo9 magnet can remain magnetized in the case of a reverse demagnetization process, in which the third track 1116 does not increase to a demagnetization ratio above the first threshold 1132.

[0093] With reference to Fig. Figure 12 shows a diagram 1200. Diagram 1200 is a network diagram with a multitude of radii (e.g., spokes) arranged around a center point 1234, including a first radius 1212, representing [insert variable], a second radius 1214, representing [insert variable], a third radius 1216, representing [insert variable], a fourth radius 1218, representing [insert variable], a fifth radius 1220, representing [insert variable], a sixth radius 1222, representing [insert variable], a seventh radius 1224, representing [insert variable], an eighth radius 1226, representing [insert variable], and a ninth radius 1228, representing [insert variable]. A multitude of lines 1232 connect the data values ​​of the radii, where the lines 1232 represent different values ​​of the magnetic flux (B) in units of T.

[0094] The scale of B for lines 1232 can range from a first threshold to a second threshold of B values, where the first threshold is a maximum and the second threshold is a minimum.

[0095] Diagram 1200 contains a variety of tracks for different types of permanent magnets and / or permanent magnet materials, including a first track 1242, a second track 1244, and a third track 1246. The first track 1242 shows the change in B at different radii of Diagram 1200 for magnets or magnetic material that includes or contains Niron Gen 1. The second track 1244 shows the change in B at different radii of Diagram 1200 for magnets or magnetic material that includes or contains AlNiCo5. The third track 1246 shows the change in B at different radii of Diagram 1200 for magnets or magnetic material that includes or contains AlNiCo9.

[0096] The first trace 1242 shows that B of magnets or magnetic material comprising or containing Niron Gen 1 can remain above the third threshold at radii 1212, 1214, 1216, 1218, 1220, 1222, 1224, 1226 and 1228, but decreases as it approaches the shaded Be- The area of ​​radii 1236 can decrease at radii 1222, 1224, 1226, and 1228. At radii 1228, the first track 1242 can be located approximately within the shaded area 1236 and be equal to the third threshold value.

[0097] The second track 1244 shows that B of magnets or magnetic material comprising or containing AlNiCo5 can remain above the third threshold at radii 1212, 1214, 1216, 1218, 1220, 1222, and 1224, and can decrease as it approaches the shaded area 1236 at radii 1222, 1224, 1226, and 1228. At radii 1226, B of the second track 1244 can be approximately within the shaded area 1236 and / or equal to the third threshold. At radii 1228, B of the second track 1244 can be approximately within the shaded area 1236 and less than the third threshold.

[0098] The third trace 1246 shows that B of magnets or magnetic material comprising or containing AINiCo9 can remain above the third threshold at radii 1212, 1214, 1216, 1218, 1220, 1222, 1224, 1226 and 1228, and B of the third trace 1246 can remain approximately constant.

[0099] With reference to Fig. Figure 13 shows the remagnetization property for an electrical machine of the present disclosure in forward and reverse directions via a diagram 1300. Specifically, it shows Fig. 13 the forward and reverse remagnetization property for a topmost magnet of a circuit of parallel magnets of the present disclosure. The magnet or magnets that are forward and reverse magnetized, as shown via diagram 1300, may be one or more of the third magnets from the Fig. 4-8D. The electric machine can be an electric machine of the present disclosure comprising a rotor, a stator, and a plurality of magnets of the present disclosure. The rotor, the stator, and the plurality of magnets can be the rotor 204 from the Fig. 2-8C, the stator 206 from the Fig. 2-8C or the magnets 414 from Fig. 4.

[0100] Diagram 1300 includes three axes: a first axis 1304, a second axis 1306, and a third axis 1308. The values ​​of the first axis 1304 are independent, while the values ​​of the second axis 1306 and the third axis 1308 are dependent on the first axis 1304. The first axis 1304 shows the magnetizing current for the electric machine in units of A. The second axis 1306 is an axis that shows the magnetic flux in units of Weber or V*s for flux links of the electric machine. The flux links of the second axis 1306 can be flux links derived from the first lines 812, the second lines 832, and the third lines 852. Fig. 8A-8C are shown. The third axis 1308 shows the percentage difference (%) between two traces of at least one set of traces in diagram 1300. A region of moderate remagnetization states may be shown by a triangle with dashed lines 1310. The moderate remagnetization region may lie between a first threshold and a second threshold for current. For example, the moderate remagnetization states with dashed lines 1310 may lie between approximately 25 A and 100 A on the first axis 1304 and between approximately 0 and 0.4 V*s on the second axis 1306. Furthermore, the moderate remagnetization states may be narrower with respect to the magnetizing current, so that the moderate remagnetization states with dashed lines 1310 in this or another example may lie between approximately 25 A and 75 A.

[0101] Diagram 1300 includes a first track 1322, which shows the magnetic flux relative to various magnetizing currents during a process of forward remagnetization of a magnet. Diagram 1300 includes a second track 1324, which shows the magnetic flux relative to various magnetizing currents during a process of backward remagnetization of a magnet. For example, the forward remagnetization of one or more of the magnets shown via the first track 1322 can be carried out by a process of transitioning from the second track 822. Fig. 8B in first mode 802 off Fig. 8A take place. In another example, the reverse remagnetization of one or more of the magnets, represented via the second track 1324, can be achieved by another method of transitioning from the second mode 822. Fig. 8B into third mode 842 off Fig. 8C takes place. The first track 1322 and the second track 1324 show that the magnetic flux increases when the magnetic current increases.

[0102] Diagram 1300 includes a third track 1326. The third track 1326 shows the percentage difference between the first track 1322 and the second track 1324 with respect to the magnetic current. Each value of the percentage difference for the third track 1326 is the difference between a first magnetic flux of the first track 1322 and a second magnetic flux of the second track 1324 at the same magnetic current, divided by the larger of the fluxes and multiplied by 100%. The third track 1326 may be negligible at approximately 0% (less than 5%) outside of moderate remagnetization states, as represented by the dashed-line triangle 1310. In moderate remagnetization states, the difference may be approximately greater than 0. For example, the percentage difference of the third track 1326 can increase to a maximum value between 20% and 25% during states of moderate remagnetization, as shown within the dashed lines 1310.In other words, a nearly similar (e.g., approximately the same) remagnetization power is achieved for forward and reverse remagnetization, apart from the duration during states of moderate remagnetization.

[0103] With reference to Fig. Figure 14 shows a diagram 1400, which displays the demagnetization conditions at different magnetizing currents for a variety of permanent magnets of the present disclosure during magnetization. The diagram 1400 includes a first axis 1404 and a second axis 1406, wherein the values ​​of the first axis 1404 are independent and the values ​​of the second axis 1406 may depend on the first axis 1404. The first axis 1404 shows the magnetizing current for the electrical machine in units of A. The second axis 1406 shows the demagnetizing currents (DRs) of the magnets as percentages (%). The first axis 1404 from Fig. 11 and the first axis 1404 can be part of the same axis on opposite sides of 0. Likewise, the second axis 1106 can be formed from Fig. 11 and the second axis 1406 are the same axis.

[0104] The permanent magnets include magnets that comprise or contain Niron Gen 1, AlNiCo5, or AlNiCo9 as magnetic materials. Diagram 1400 includes a first track 1422, a second track 1424, and a third track 1426, which show demagnetization ratios at various magnetizing currents for specific magnets comprising or containing different materials. The first track 1422 shows the demagnetization ratio at various magnetizing currents for magnets or magnetic material comprising or containing Niron Gen 1. The second track 1424 shows the demagnetization ratio at various magnetizing currents for magnets or magnetic material comprising or containing AlNiCo5. The third track 1426 shows the demagnetization ratio at various magnetizing currents for magnets or magnetic material comprising or containing AlNiCo9.The demagnetization ratio of AlNiCo9 increases less than that of Niron Gen 1 and AlNiCo5 with more negative magnetizing currents. Conversely, the demagnetization ratio of AlNiCo5 increases more than that of Niron Gen 1 with more negative magnetizing currents. The demagnetization ratios of Niron Gen 1, AlNiCo5, and AlNiCo9 decrease towards 0% as the magnetizing current becomes more positive and larger.

[0105] Diagram 1400 includes the first threshold 1132, shown by a dashed line. In summary, the first threshold 1132 represents a demagnetization ratio of 100%. Magnetization occurs at demagnetization ratios below the first threshold 1132 of 100%. The third track 1426 shows that the AlNiCo9 magnet can remain magnetized in the case of a reverse demagnetization process, where the third track 1426 does not increase to a demagnetization ratio above the first threshold 1132. The first track 1422 shows that the main magnets, which include Niron Gen 1, can be completely demagnetized at a current equal to or below a second threshold magnetization current.The first track 1422 shows that Niron Gen 1 cannot remagnetize and can remain approximately at the demagnetization ratio of the first threshold for magnetizing currents, approaching 0 A and below the second threshold for magnetizing currents. The second track 1424 shows that the magnets comprising AlNiCo5 can be demagnetized at a magnetizing current equal to a third threshold for magnetizing currents. Furthermore, the second track shows the magnets comprising AlNiCo5 at magnetizing currents below the third threshold for magnetizing currents. When magnets comprising Niron Gen 1 and AlNiCo5 are fully magnetized, the first track 1422 and the second track 1424, respectively, can be reduced below the first threshold 1132.

[0106] With reference to Fig. Figure 15 shows diagram 1500. Diagram 1500 shows the electromagnetic forces (back-EMFs) at a maximum magnetization state (MS) and a minimum MS. The electric machine can, during a Mode I, such as the first Mode 802, which is described in Fig. 8A shows the maximum MS operating. Similarly, the electric machine can operate during a Mode II, such as the third Mode 842. Fig. 8C, operating at the minimum MS.

[0107] Diagram 1500 includes a first axis 1504 and a second axis 1506. The first axis 1504 is a time axis, with time represented in units of seconds (s). The second axis 1506 is a back EMF axis, with back EMF represented in units of volts (V). The minimum back EMF value is zero, as shown, to allow the flux to be reduced to zero. However, even with zero back EMF, the rotor can still carry the magnetic flux from one or more magnets with the lowest coercivity of the magnetic circuits and the second magnetic layer. For example, with zero back EMF, the rotor can carry the magnetic flux from a magnet that includes AINiCo9.

[0108] Diagram 1500 includes a first track 1522 and a second track 1524. The first track 1522 represents the back EMF over time during maximum MS. The second track 1524 represents the back EMF over time during minimum MS. The minimum back EMF is zero or approximately zero, as shown, to allow the flux to be reduced to approximately zero. However, in this case, the rotor still carries the flux of the AlNiCo9 magnet (e.g., an AlNiCo9 magnetic flux).

[0109] With reference to Fig. Figure 16 represents the energy of the torque generated by a VFM of the present disclosure, after remagnetization for various currents, as shown in diagram 1600. The VFM includes a rotor, a stator, and a plurality of magnets of the present disclosure, such as rotor 204 from the Fig. 2-8C, the stator 206 from the Fig. 2-8C or the magnets 414 from Fig. 4. More specifically, diagram 1600 shows the torque generated at different currents when current is applied at a first current angle of 30° and a second current angle of 50°.

[0110] Diagram 1600 includes a first axis 1604 and a second axis 1606. The first axis 1604 shows the current transferred to the magnet, in units of amperes (A). The second axis 1606 shows the energy of the torque generated by the current through the electric machine, in units of newton-meters (Nm).

[0111] Diagram 1600 includes a first track 1622 of torque generated at various currents for the first current angle of 30° and a second track 1624 of torque generated at various currents for the second angle of 50°. The first and second angles are current angles. At a current of 0 A, a greater torque is generated via the first track 1622 compared to the second track 1624, and higher torques can be achieved at an angle of 30° compared to 50°. As the current increases, the torque of the second track 1624 increases at a faster rate than the torque of the first track 1622. When the current exceeds a current threshold, the torques of the first track 1622 and the second track 1624 may be approximately equal.

[0112] With reference to Fig. Figure 17 shows a diagram 1700 for energy of torque at various angles when the electric machine, which includes a rotor, a stator, and a plurality of magnets of the present disclosure, operates at a maximum MS. The rotor, the stator, and the plurality of magnets of the present disclosure can be the rotor 204 from the Fig. 2-8C, the stator 206 from the Fig. 2-8C or the magnets 414 from Fig. 4. Diagram 1700 shows a change in torque energy relative to the angle of the torque. Diagram 1700 shows a change in torque energy relative to the angle of the current. Diagram 1700 shows a variety of tracks, including a first track 1722, a second track 1724, and a third track 1726.

[0113] The first axis 1704 of diagram 1700 represents current angles in degrees (°). The second axis 1706 of diagram 1700 represents energy of torque in units of Nm. The angles of the first axis 1704 can be the independent variable, and the energy of the second axis 1706 can depend on the angles.

[0114] The first track 1722 represents the energy of a first torque at various and increasing angles, where the first torque is a permanent magnet torque (Tpm torque), and the permanent magnets can be magnets 414. The second track 1724 represents the energy of a second torque at various and increasing angles, where the second torque is a reluctance torque (Trel torque). The third track 1726 represents the energy of a third torque at various and increasing angles, where the third torque is a total torque (Ttotal) that is the sum of the first torque and the second torque.

[0115] The peak energy of the total torque of the third track 1726 lies within a circular shaded area 1732. The peak energy of the torque occurs at a current angle of the first axis 1704, which can be called the peak current angle. At the peak current angle, the torque can reach its maximum. For example, the peak energy of the total torque can occur at a current angle of approximately 30°. A current angle of 30° can maximize torque while the electric machine operates at maximum MS.

[0116] With reference to Fig. Figure 18 shows a diagram 1800 for energy of torque at various angles when the electric machine, which includes a rotor, a stator, and a plurality of magnets of the present disclosure, operates at a minimum MS. The rotor, the stator, and the plurality of magnets of the present disclosure can be the rotor 204 from the Fig. 2-8C, the stator 206 from the Fig. 2-8C or the magnets 414 from Fig. 4. Diagram 1800 shows a change in torque energy relative to the angle of the current. The diagram shows a variety of traces, including a first trace in 1822, a second trace in 1824, and a third trace in 1826.

[0117] The first axis (1804) of diagram 1800 represents current angles in degrees. The second axis (1806) of diagram 1800 represents torque energy in units of Nm. The angles of the first axis (1804) can be the independent variable, and the energy of the second axis (1806) can be dependent on the angles.

[0118] The first track, 1822, shows the energy of a first torque at various and increasing angles, where the first torque is a permanent magnet torque (Tpm torque), and the permanent magnets can be magnets 414. The second track, 1824, shows the energy of a second torque at various and increasing angles, where the second torque is a reluctance torque (Trel torque). The third track, 1826, shows the energy of a third torque at various and increasing angles, where the third torque is a total torque (Ttotal), which is the sum of the first and second torques.

[0119] The peak energy of the total torque of the third track 1826 lies within a circular shaded area 1832. The peak energy of the torque occurs at a current angle of the first axis 1804, which can be called the peak current angle. At the peak current angle, the torque can be at its maximum. For example, the peak energy of the total torque can occur at a current angle of approximately 50° (e.g., 50° is the peak current angle). A current angle of 50° can maximize torque while the electric machine operates at minimum MS.

[0120] With reference to Fig. Figure 19 shows a diagram 1900 for the energy of torque over time when an electric machine of the present disclosure operates at a maximum MS and a minimum MS. The diagram 1900 includes a first axis 1904 of time in milliseconds (ms) and a second axis 1906 of torque energy in newton-meters (Nm). The electric machine is a VFM of the present disclosure, wherein the VFM includes a rotor, a stator, and a plurality of magnets of the present disclosure. The rotor, the stator, and the plurality of magnets of the present disclosure can be the rotor 204 from the Fig. 2-8C, the stator 206 from the Fig. 2-8C or the magnets 414 from Fig. 4.

[0121] A first trace (1922) is shown by a solid set of curves, and a second trace (1924) is shown by a dashed set of curves. The first trace (1922) is a trace of energy generated via torque over time when the electric machine is operating at maximum MS (mass flow). The second trace (1924) is a trace of energy generated via torque over time when the electric machine is operating at minimum MS. The first trace (1922) generates continuously higher energy via torque input compared to the second trace (1924). Both the first and second traces (1922, 1924) exhibit a sinusoidal shape and pattern.

[0122] The disclosure further provides a support for a rotor of an electric machine, comprising: a first set of magnets with a higher coercivity, integrated into at least one slot of the rotor, the magnets arranged in a V-shape in the slot; and a second set of magnets with a lower coercivity compared to the first set of magnets, the second set of magnets comprising at least one pair of magnets of different degrees arranged parallel in a radial slot of the rotor, the first set of magnets forming a first magnetic layer of the rotor and the second set of magnets forming a second magnetic layer of the rotor. In a first example of the system, the first set of magnets is integrated into a set of slots comprising a first slot and a second slot.In a second example of the system, which may include the first example, the first magnet of the pair of magnets has a lower coercive force than the second magnet of the pair, and the first magnet is arranged in a radially outward direction from the second magnet. In a third example of the system, which may include one or both of the first and second examples, the first and second magnets are magnetically coupled in a parallel configuration to form a magnetic current. In a fourth example of the system, which may include one or more or each of the first through third examples, the first magnet is wider than the second magnet.In a fifth example of the system, which may optionally include one or more or each of the first four examples, neither the first nor the second set of magnets are rare-earth permanent magnets. In a sixth example of the system, which may optionally include one or more or each of the first five examples, the rotor is free of rare-earth materials. In a seventh example of the system, which may optionally include one or more or each of the first six examples, the first set of magnets is formed from a material comprising iron nitride (FeN). In an eighth example of the system, which may optionally include one or more or each of the first seven examples, the second set of magnets comprises a first-grade AlNiCo material and a second-grade AlNiCo material, the second grade being different from the first grade.In a ninth example of the system, which may include one or more or each of the first through eighth examples, the first AlNiCo material is AlNiCo5 and the second AlNiCo material is AlNiCo9. In a tenth example of the system, which may include one or more or each of the first through ninth examples, the electric machine includes a controller communicatively coupled to the rotor and configured to selectively demagnetize or remagnetize one or more first magnets of the first set of magnets and one or more second magnets of the second set of magnets. In an eleventh example of the system, which may include one or more or each of the first through tenth examples, the second set of magnets includes a third magnet that remains magnetized when the first or second magnets are demagnetized.

[0123] The disclosure also provides a support for an electric machine, comprising a rotor with a first layer of magnets responsible for generating the torque of the electric machine and a second layer of magnets responsible for flux control of the electric machine, wherein the first layer of magnets has a higher coercive force than the second layer of magnets and neither the first nor the second layer of magnets includes rare-earth permanent magnets. In a first example of the system, the second layer of magnets includes pairs of magnets arranged in parallel in a radial groove of the rotor and magnetically coupled in a parallel configuration to form a magnetic current.In a second example of the system, which may optionally include the first example, the first layer of magnets is formed from a material comprising iron nitride (FeN), a first magnet of each pair of magnets is formed from a first-grade AlNiCo material, and a second magnet of the pair of magnets is formed from a second-grade AlNiCo material of a different grade, the first magnet having a lower coercive force than the second magnet. In a third example of the system, which may optionally include one or both of the first and second examples, the first magnet is arranged in a radially outward direction from the second magnet.In a fourth example of the system, which may include one or more or each of the first to third examples, the system further comprises: a controller communicatively coupled to the rotor and configured to selectively demagnetize or remagnetize one or more magnets of the first layer of magnets and one or more magnets of the second layer of magnets.In a fifth example of the system, which may include one or more or each of the first to fourth examples, the flux control of the electric machine has three modes: In a first mode of control, all magnets of the first layer of magnets and the second layer of magnets are magnetized; in a second mode of control, the first layer of magnets and the second magnet of the second layer of magnets are magnetized, and the first magnet of the second layer of magnets is demagnetized; and in a third mode of control, the first layer of magnets is demagnetized, the first magnet undergoes remagnetization, and the second magnet is magnetized.

[0124] The disclosure also provides a carrier for a method for controlling the flux of an electric machine, the method comprising: in a first mode of the electric machine, magnetizing a first layer of magnets arranged in a V-shape in slots of a rotor of the electric machine, and magnetizing a second layer of magnets of the rotor, the second layer of magnets comprising pairs of magnets of different degrees arranged parallel in radial slots of the rotor; in a second mode of the electric machine, magnetizing the first layer of magnets and magnetizing a second magnet of each pair of magnets of the second layer of magnets and demagnetizing a first magnet of each pair of magnets of the second layer of magnets; and in a third mode of control, demagnetizing the first layer of magnets.Magnetizing the second magnet of each pair of magnets in the second layer of magnets and generating a remagnetization in the first magnet of each pair of magnets in the second layer of magnets, wherein the first layer of magnets is formed of a material comprising iron nitride (FeN), each first magnet of the second layer of magnets contains a first-grade AlNiCo material, and each second magnet of the second layer of magnets contains a second-grade AlNiCo material, the second grade being different from the first grade, and neither the first layer of magnets nor the second layer of magnets contains rare-earth permanent magnets. In a first example of the method, the first magnet, for each pair of magnets in the second layer of magnets, has a lower coercive force than the second magnet.The first magnet is arranged in a radially outward direction from the second magnet, and the first and second magnets are magnetically coupled in a parallel configuration to form a magnetic current.

[0125] Fig. 1 and Fig. Figure 3 shows schematic representations of exemplary system configurations with relative positioning of the various components. Fig. 2 and Fig. Figures 4-8C show exemplary configurations with approximate positions. Fig. 2 and Fig. Figures 4-8C are shown approximately to scale; however, other relative dimensions may also be used. In this context, the term "approximately" is to be understood as including plus or minus five percent of the range, unless otherwise stated.

[0126] The Fig. Figures 1-8C show exemplary configurations with the relative positioning of the various components. If such elements are shown in direct contact with each other or directly coupled, then in at least one example they can be described as being in direct contact with each other and directly coupled. Likewise, in at least one example, elements shown adjacent to or near each other can be described as being adjacent to and near each other. For example, components that are in surface contact with each other can be described as being in surface contact. As another example, elements that are separated from each other with only a gap between them and that have no other components can be described as such in at least one example.As a further example, elements shown above and below each other, on opposite sides, or to the left and right of each other can be described as such in relation to one another. Furthermore, as shown in the figures, in at least one example, a topmost element or the highest point of an element can be described as a "top" of the component, and a bottommost element or the lowest point of the element can be described as a "bottom" of the component. In the present context, the terms top / bottom, upper / lower, above / below can refer to a vertical axis of the figures and be used to describe the positioning of elements of the figures relative to each other. Thus, in one example, elements shown above other elements can be positioned vertically above the other elements.As a further example, the shapes of elements depicted within the figures may be described as having these shapes (e.g., as circular, straight, planar, curved, rounded, chamfered, angled, or the like). Furthermore, elements that intersect may, in at least one example, be described as intersecting elements or as intersecting each other. Additionally, an element shown within another element or shown outside another element may, in one example, be described as such. It is understood that one or more components described as "substantially similar and / or identical" may differ from each other according to manufacturing tolerances (e.g., within a deviation of 1-5%). Fig. 2-10D are shown approximately to scale.

[0127] The following claims highlight in particular certain combinations and subcombinations that are considered novel and not obvious. These claims may refer to "one" element or "a first" element, or the equivalent thereof. Such claims are to be understood as including one or more such elements, not as requiring or excluding two or more such elements. Other combinations and subcombinations of the disclosed features, functions, elements, and / or properties may be claimed by amending the present claims or by presenting new claims in this or a related application. Such claims, whether broader or narrower, identical or different with respect to the original claims, are also considered to be included in the subject matter of the present disclosure. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] US 63 / 689,127

[0001]

Claims

[1] Rotor (204) of an electric machine (106), comprising: a first set of magnets (416a) with a higher coercive force, which is integrated into at least one groove (462, 464, 466, 468) of the rotor (204), wherein the magnets are arranged in a V-shape in the groove (462, 464, 466, 468); and a second set of magnets (416b) with a lower coercive force compared to the first set of magnets (416a), wherein the second set of magnets (416b) comprises at least one pair of magnets of different degrees arranged in parallel in a radial groove (462, 464, 466, 468) of the rotor (204), wherein the first set of magnets (416a) forms a first magnetic layer of the rotor (204) and the second set of magnets (416b) forms a second magnetic layer of the rotor (204). [2] Rotor (204) according to claim 1, wherein the first set of magnets (416a) is integrated in a set of slots comprising a first slot (462) and a second slot (464). [3] Rotor (204) according to one of the preceding claims, wherein a first magnet of the pair of magnets has a lower coercive force than a second magnet of the pair of magnets and the first magnet is arranged in a radially outward direction from the second magnet. [4] Rotor (204) according to claim 3, wherein the first magnet and the second magnet are magnetically coupled in a parallel configuration to form a magnetic current. [5] Rotor (204) according to claim 3 or 4, wherein the first magnet is wider than the second magnet. [6] Rotor (204) according to one of the preceding claims, wherein neither the first set of magnets (416a) nor the second set of magnets (416b) are rare-earth permanent magnets. [7] Rotor (204) according to claim 5 or 6, wherein the rotor (204) is free of rare earth materials. [8] Rotor (204) according to any one of claims 5 to 7, wherein the first set of magnets (416a) is formed from a material comprising iron nitride (FeN). [9] Rotor (204) according to any one of claims 5 to 8, wherein the second set of magnets (416b) comprises a first grade AlNiCo material and a second grade AlNiCo material, the second grade being different from the first grade. [10] Rotor (204) according to claim 9, wherein the first AlNiCo material is AlNiCo5 and the second AlNiCo material is AlNiCo9. [11] Rotor (204) according to one of the preceding claims, wherein the electric machine (106) comprises a control (141) which is communicatively coupled to the rotor (204) and is configured to selectively demagnetize or remagnetize one or more first magnets of the first set of magnets (416a) and one or more second magnets of the second set of magnets (416b). [12] Rotor (204) according to claim 11, wherein the second set of magnets (416b) includes a third magnet which remains magnetized when the first magnets or the second magnets are demagnetized. [13] Electric machine (106) comprising a rotor (204) with a first layer of magnets responsible for generating the torque of the electric machine (106) and a second layer of magnets responsible for flux control of the electric machine (106), wherein the first layer of magnets has a higher coercive force than the second layer of magnets and neither the first layer of magnets nor the second layer of magnets includes rare-earth permanent magnets. [14] Electric machine (106) according to claim 13, wherein the second layer of magnets comprises pairs of magnets arranged in parallel in a radial groove (462, 464, 466, 468) of the rotor (204) and magnetically coupled in a parallel configuration to form a magnetic current. [15] Electric machine (106) according to claim 14, wherein the first layer of magnets contains a material comprising iron nitride (FeN), a first magnet of each pair of magnets is formed from a first AlNiCo material of a first grade and a second magnet of the pair of magnets is formed from a second AlNiCo material of a second, other grade, wherein the first magnet has a lower coercive force than the second magnet.

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