Systems, methods, and apparatus for electric machines with variable operating characteristics

Abstract

An example embodiment of the present invention includes an electric machine having a winding (W) divided into a plurality of sections (1-4) and a mechanical switch (12) having a plurality of switches (C1-Cn). Each switch (C1-Cn) includes first and second portions (120, 121) that are relatively movable between a first switch position and a second switch position, respectively, to connect a first winding section (1-4) of the winding WIN in series and / or parallel with the second winding section. An actuator is provided to relatively move the first and second portions (120, 121) of each switch between the first and second positions, such that movement of the portions can change the operating characteristics of the electric machine.

Description

[Technical Field]

[0001] The present invention relates to electric motors that can vary their output speed and torque characteristics to achieve one or more desired parameters, and to electric generators that have variable input and output characteristics. [Background technology]

[0002] The use of electric vehicles is becoming widespread, and due to environmental reasons and dwindling petroleum resources, it is expected that these vehicles will eventually completely replace those powered by internal combustion engines. Electric vehicles typically feature a conventional electric motor coupled to a fixed or variable-ratio mechanical gearbox for traction purposes. Therefore, to obtain the torque benefits from the mechanical gears, the electric motor must rotate at very high speeds. When an electric motor rotates at speeds of 12,000 to 20,000 revolutions per minute, a high voltage, typically between 400 and 800 volts, is required to achieve the desired speed-torque characteristics of the electric vehicle.

[0003] Using conventional mechanical gearboxes at such high speeds is challenging, requiring precise design and close tolerances for the system to function reliably. This makes the manufacturing process expensive. Furthermore, high-speed traction motors require significantly more expensive materials than low-speed traction motors, which operate at approximately 6,000 rpm to 10,000 rpm. Low-speed traction motors allow for simpler drivetrains for hybrid or fully electric vehicles, which are less expensive than those using conventional mechanical gearboxes.

[0004] U.S. Patent US7382103 discloses a "magnetic gear system" designed to alleviate the above problems. The system includes a permanent magnet brushless motor with three-phase windings, each divided into a plurality of individual winding sections, and field effect transistors (FETs) or other semiconductor devices for selectively connecting the winding sections of each phase winding in series or parallel with the other windings. The system further includes a controller that drives the FETs to connect the winding sections of each phase winding in different configurations while the motor is running.

[0005] In use, when the motor first starts, the FETs are controlled to connect the winding sections of each phase winding in parallel. The parallel / series combination or series connection is selected to meet torque requirements or a higher operating efficiency point. Thus, it can be seen that motor efficiency can be maximized without the need for a traditional mechanical gearbox.

[0006] The magnetic gear system of US7382103 is a unique system that offers a variety of advantages and cost savings. In the automotive industry, traction motors in hybrid and fully electric vehicles will benefit most because the system eliminates the need for a traditional gearbox and provides the functionality of several motors combined into one. Furthermore, the system offers the advantage of allowing the use of motors that operate at lower speeds, which are less expensive and more reliable than those used in conventional electric vehicles.

[0007] Despite the aforementioned advantages, electrical losses in the FETs and other semiconductor elements in the magnetic gear system of US Patent No. 7,382,103 have been found to be higher in series connections compared to parallel connections or other combinations. Furthermore, semiconductor elements may have limited voltage and current ratings, necessitating the addition of multiple expensive semiconductor switches in parallel to share the current load. Also, the waveform applied to the motor is alternating current (AC) (e.g., the waveform shape changes), requiring elements to be arranged back-to-back to allow conduction in both directions. This results in an increase in the number of switches. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] US Patent US7382103 Summary of the Invention [Problem to be solved by the invention]

[0009] With this in mind, the present invention provides an improved electric machine with variable operating characteristics. [Means for solving the problem]

[0010] According to an embodiment of the present invention, there is provided an electric machine having the following configuration: the electric machine includes a winding having a plurality of winding sections, each winding section having a first end and a second end; a mechanical switch assembly having a plurality of switches, each switch having a first and second portion that are relatively movable between first and second switch positions; each winding section is connected to at least one other winding section in series, parallel, or various combinations thereof; and an actuator for relatively moving the first and second portions of each switch, thereby allowing each switch to be selectively operated between its respective first and second positions.

[0011] The electric machine may be a motor or a generator, and the term "electric machine" as used herein includes, but is not limited to, motors, generators, permanent magnet machines, switched reluctance machines, axial machines, induction machines, coreless machines, yokeless machines, inductors, chokes, transformers, and the like.

[0012] These machines may be applied in market sectors such as aviation, marine, rail, and space applications. In the case of motors, the actuator is driven by connecting all winding sections in series, giving the motor high torque and low speed characteristics and operating similar to the low speed gear of a conventional gearbox. Alternatively, the actuator is driven by connecting some winding sections in parallel and others in series, giving the motor intermediate torque and speed characteristics.

[0013] Furthermore, the actuator is driven with all winding sections connected in parallel, and the motor has low-torque, high-speed characteristics, operating similarly to the high-speed gears of a conventional gearbox. If the vehicle's torque and speed characteristics allow efficient operation, any winding configuration can be selected and used, even at low speeds. Furthermore, the zero-cross arc suppression device can be energized during flight under load and used.

[0014] The electric machine of the present invention is significantly more efficient than an electric machine using semiconductor switches, and the electrical losses of mechanical switches are significantly less than those of semiconductor switches using suitable materials such as silver-tin oxide. Furthermore, mechanical switches are substantially less limited in voltage and current ratings than semiconductor switches. This eliminates the need to add multiple semiconductor switches in parallel to share the current load. Furthermore, the use of mechanical switches eliminates the need for back-to-back semiconductor configurations to provide bidirectional conduction paths for the AC supply. Therefore, the number of switches required is substantially reduced, dramatically reducing complexity. Mechanical switches are small and compact, making them cost-effective in price-sensitive markets. Furthermore, the use of mechanical switches alleviates the shortage of semiconductor supplies and eliminates the extensive cooling infrastructure required for semiconductor switches.

[0015] Additionally, mechanical switches have the advantage of providing a significantly greater number of winding configurations / gear styles in a compact unit, resulting in smoother vehicle "gear" shifts. This results in smaller transitions between different torque steps, mimicking the behavior of a continuously variable transmission. When using semiconductor switches, the size of the switch matrix increases with the increase in winding configuration. For example, a three-gear drive motor would require 54 semiconductor switches (excluding parallel switches), whereas the present invention uses only nine mechanical switches.

[0016] A mechanical switch can have a configuration in which at least one part moves relative to another part. A mechanical switch can be a mechanical assembly. For example, first and second parts can move relative to each other, or one part can move and the other part can be stationary.

[0017] In one embodiment, the first portion of each switch has a plurality of contact terminals, and the second portion has a plurality of conductive interconnects (e.g., electrical wiper contacts) that are selectively connected in first and second positions to provide different configurations. The electrical wiper contacts are typically made of a material such as carbon, graphite, or silver-tin oxide, and each contact is insulated from the others. In one embodiment, each contact may be fully insulated. The contact terminals are made of a material such as beryllium copper and are connected to where the stator winding terminates, or to the star point or live phase.

[0018] In one embodiment, the first portion of each switch has first and second contact terminals connected to the ends of the two winding sections and third and fourth contact terminals for connecting the two winding sections to a supply conductor. The first and second contact terminals are interconnected by a conductive interconnect in a first switch position, thereby connecting the two winding sections in series, and the first and third contact terminals are connected by a second conductive interconnect and the second and fourth contact terminals are connected by a third conductive interconnect, thereby connecting the two winding sections in parallel in a second switch position. The third conductive interconnect can connect the two winding sections in parallel between the supply conductors.

[0019] In one embodiment, each switch has a third switch position in which each winding section is disconnected.

[0020] In one embodiment, the actuator is movable between a plurality of positions, each of which has a different combination of positions for each of the mechanical switches. The actuator can be moved directly or indirectly from a first position to a second position via one or more intermediate positions, e.g., in a first actuator position, most of the winding sections are connected in series, and in a second actuator position, most of the winding sections are connected in parallel. In this case, the mechanical switches are arranged to selectively connect the winding sections in parallel as the actuator moves through one or more intermediate positions between the first and second positions.

[0021] In one embodiment, the mechanical switch can include an actuator that moves portions of the mechanical switch. In one embodiment, the actuator can include a single actuator. In one embodiment, the actuator can include multiple actuators.

[0022] In one embodiment, the actuator may include a single actuator for simultaneously or selectively moving portions of each switch relatively between their respective first and second positions.

[0023] In one embodiment, the actuator can be configured to actuate one or more switch portions, such as a disk, a ring, a cylinder, a linear member, or an arc-shaped member.

[0024] In one embodiment, the first portions of each switch are fixed to one another, and similarly, the second portions of each switch are fixed to one another.

[0025] For example, a first portion of each switch may be provided on a fixed member (e.g., a first switch portion) and a second portion of each switch may be provided on a movable member (e.g., a second switch portion), or vice versa. In this example, when the movable member moves, the second portion of each switch may move with it. In one embodiment, the second portion of each switch may move to contact the first portion of each switch.

[0026] In one embodiment, the first and / or second portions of each switch are independently movable relative to at least one portion of the other switches. The portions of each switch can be interconnected such that movement of one portion causes movement of the other portions, e.g., via gears or an indexing mechanism. For example, the first portions of each switch can be provided with respective members that move in sequence. In one embodiment, a first movement can activate some of the first portions, a second movement can activate more or different first portions, and a third movement can activate all of the first portions of each switch.

[0027] In one embodiment, the first and second portions of each switch are movable relative to one another in a linear or arcuate fashion. The first and second portions are movable by an actuator. In one embodiment, the first and second portions of each switch are movable relative to one another in a single plane. In another embodiment, the first and second portions of each switch are movable relative to one another in multiple planes. For example, the first and second portions of each switch are movable relative to one another in an arcuate fashion in multiple planes that can be selected by moving the first or second portions of each switch linearly between the planes.

[0028] In one embodiment, the actuator is arranged to automatically, manually or semi-automatically move portions of each switch relative to one another to reconfigure the windings of the electric machine.

[0029] In one embodiment, in an automatic mode, the actuator moves the switch portions relative to one another based on a control program stored in a control unit of the switch device, for example, the control unit is configured to compare the actual rotational speed and torque of the machine with preset values ​​and operate the actuator to selectively move the switch portions when the actual values ​​are outside the preset ranges.

[0030] In one embodiment, the manual mode is implemented such that the portions of each switch are moved relative to one another based on the movement of an actuator by a user (eg, through a command, button, shifter).

[0031] In one embodiment, in semi-automatic mode, the control unit is provided with switches that a user can activate to operate actuators to selectively move portions of the switches to select a desired configuration of the machine windings.

[0032] In one embodiment, a switch may be provided to temporarily inhibit power supply to the winding while any switch of the switching device is moving between its first and second positions. A zero-cross arc suppression device may be used if power supply to the winding is not interrupted while any switch of the switching device is moving between its first and second positions. Portions of each switch may be immersed in a liquid within a sealed unit. The liquid prevents arcing at high currents during load switching. [Effects of the Invention]

[0033] The present invention provides an arrangement that is compact, electrically efficient, cost effective, easy to manufacture, can accommodate a large number of winding combinations / configurations, and offers improved switching efficiency over current switching devices. [Brief explanation of the drawings]

[0034] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Figure 1] 1 is a schematic diagram of an embodiment of an electric motor. [Figure 2] 2 is a circuit diagram of the phase connections of the motor of FIG. 1. [Figure 3] 2 is a circuit diagram of the phase windings and switching assembly of the motor of FIG. 1. [Figure 4] 4 is a plan view of a portion of the mechanical switch device of the phase winding and switching assembly of FIG. 3. [Figure 4A] 4 is a plan view of a portion of the mechanical switch device of the phase winding and switching assembly of FIG. 3. [Figure 4B] 4 is a plan view of a portion of the mechanical switch device of the phase winding and switching assembly of FIG. 3. [Figure 4C] 4 is a plan view of a portion of the mechanical switch device of the phase winding and switching assembly of FIG. 3. [Figure 5] FIG. 5 is a cross-sectional view taken along line vv in FIG. [Figure 6] FIG. 10 is a circuit diagram of a phase connection of an electric motor according to a second embodiment. [Figure 7] FIG. 10 is a plan view of a first portion of a mechanical switch device for an electric motor according to a second embodiment. [Figure 8] FIG. 10 is a plan view of a second portion of the mechanical switch device for the electric motor according to the second embodiment. [Figure 9] FIG. 10 is a schematic side view of a mechanical switch device and a motor unit of an electric motor according to a third embodiment. [Figure 10] 10 is an exploded view of a first portion and a second portion of a mechanical switch device for an electric motor according to a third embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0035] Referring to FIG. 1, a three-phase permanent magnet brushless motor apparatus 10 is shown having a rotating output shaft 11. The motor apparatus 10 can be electrically connected to a mechanical switch apparatus 12 having a plurality of switches C1-Cn. The mechanical switch apparatus 12 is connected to a supply S via a control unit 13. The control unit 13 can be connected to one or more sensors (e.g., 14) for detecting operating parameters of the motor apparatus 10, such as operating speed, torque, temperature, or inductance. The control unit 13 can include an isolator switch 15 for isolating the mechanical switch apparatus 12 from the supply S. An actuator 16 is provided for changing the conductive state of each switch (e.g., C1) of the mechanical switch apparatus 12. The actuator 16 can be a mechanical actuator that can be moved or operated by a user, or an electronic device such as a solenoid, stepper motor, or servo motor. In one embodiment, a user can physically operate the mechanical actuator using a lever or the like. In the case of an electronic actuator, the control unit 13 can include a selector switch 17 for causing movement of the actuator 16.

[0036] The switches (C1...Cn) are phase-shifting switches (not semiconductors) whose state can be changed from conducting to non-conducting by applying light, pressure, or voltage, like an OLED switch.

[0037] 2 and 3, the electric motor of the illustrated embodiment, motor arrangement 10, has three different winding configurations, which can be compared to having three gears. Motor arrangement 10 includes three stator winding assemblies "WIN" connected in a star configuration between a common point P and each of the phase wires U, V, and W of a three-phase supply. Each winding assembly "WIN" includes four conductors, or so-called winding sections 1-4, which may be wound in parallel through the stator slots of motor arrangement 10. A motor having more than two different winding configurations would have a motor arrangement 10 with a greater number of winding sections.

[0038] 3, a first end of the first winding section 1 of each phase (e.g., phase U) may be connected to the first ends of the first winding sections of the other two phases V and W at a common point P. A second end of the fourth winding section 4 of each phase (e.g., phase U) is connected to the corresponding phase supply line (e.g., P, U).

[0039] The mechanical switch 12 of the illustrated motor has three gears, including three switches C1, C2, and C3 for each phase, for a total of nine switches. Each switch for each phase can have a configuration similar to C1 shown in Figure 3. Specifically, it has the following terminals:

[0040] The first terminal B is connected to the second end of the corresponding winding section of that phase (e.g., winding section 1). The second terminal C is connected to the first end of the corresponding adjacent winding section of that phase (e.g., winding section 2). The third terminal A is connected to the corresponding phase supply line (e.g., supply line U) of that phase. The fourth terminal D is connected to the common point P.

[0041] As can be seen from FIG. 3, winding sections 1-4 can be considered as adjacent winding sections.

[0042] 4 and 5, the mechanical switch device 12 includes inner and outer annular fixed rings 20 and 21 fixed to the body of the mechanical switch 12. Each ring 20 and 21 can be divided into three quadrants corresponding to each phase. For example, the inner annular ring 20 can include the first terminal D, second terminal C, third terminal B, and fourth terminal A of the switch C2 of each phase in each quadrant. As another example, the outer annular ring 21 can include the first terminal D, second terminal C, third terminal B, and fourth terminal A of the switches C1 and C3 of each phase in each quadrant.

[0043] The mechanical switch device 12 further comprises inner and outer annular rotating rings 22, 23 which are mounted face-to-face with the aforementioned fixed rings 20, 21.

[0044] The rotatable rings 22, 23 are independently rotatable within a common plane, which is parallel to the plane in which the fixed rings 20, 21 are disposed. Each rotatable ring 22, 23 can be divided into three quadrants, one for each phase. The inner rotatable ring 22 can include first, second, and third conductive connections 24, 25, and 26 of the switch C2 of each phase in its respective quadrant. The outer rotatable ring 23 can include first, second, and third conductive connections 24, 25, and 26 of the switches C1 and C3 of each phase in its respective quadrant. The first conductive connection 24 of each phase of the switches C1 through C3 is circumferentially separated from the second and third conductive connections 25 and 26 on the rotatable ring.

[0045] The rings 20, 21, 22, 23 may be immersed in a liquid such as oil in a sealed space within the mechanical switch device 12. In one embodiment, all contacts may be immersed in the liquid.

[0046] In use, rings 20, 21, 22, and 23 are initially aligned as shown in FIG. 4, and isolator switch 15 is operated to disconnect three-phase supply S from mechanical switch 12. Next, actuator 16 is activated to rotate inner and outer annular rotatable rings 22 and 23 by an angle. For example, clockwise rotation of approximately 15° relative to fixed rings 20 and 21 connects first conductive connection 24 of each switch C1, C2, and C3 to the corresponding switch's second and third terminals B and C, respectively, thereby connecting winding sections 1, 2, 3, and 4 of each phase in series between common point P and the corresponding phase supply wire (e.g., supply wire U) for that phase. Isolator switch 15 is then operated again to pass supply current through each winding section 1-4 in the same direction, avoiding flux collisions due to the polarity of each section. For example, if section 4 were oriented in the opposite direction, the flux generated by section 4 would be opposite the flux generated by sections 1, 2, and 3, which could have adverse effects. In exceptional cases, the direction of certain sections may be reversed.

[0047] Motor torque is directly proportional to current, and if the starting torque is high enough for the load attached to the motor, the rotor and shaft 11 will begin to rotate and accelerate until the torque equals the load. For example, the motor can continue to rotate at a constant speed. If the load changes, the motor will automatically adjust its torque (and therefore its speed) to balance the load.

[0048] When winding sections 1, 2, 3, and 4 of each phase are all connected in series, the motor has high torque characteristics but low speed, similar to Gear 1 in a conventional automobile. From the position of Gear 1 shown in Figure 4a, the configuration of winding sections 1, 2, 3, and 4 can be changed by rotating the inner and outer annular rotatable rings 22 and 23 relative to the inner and outer fixed rings 20 and 21, respectively, to select Gear 2 or Gear 3. For example, if the inner annular rotatable ring 22 is rotated 30° counterclockwise by the actuator 16, the second and third conductive connections 25 and 26 of switch C2 are connected to the first and second terminals A and B and the third and fourth terminals C and D of switch C2, respectively, thereby connecting winding sections 1 and 2 in parallel and winding sections 3 and 4 in parallel, thereby forming Gear 2 (see Figure 4b). This can be considered a motor characteristic similar to a middle or high gear in a conventional engine.

[0049] The outer rotating ring 23 is rotated 30° counterclockwise by the actuator 16, and the second and third conductive connections 25, 26 of the switches C1 and C3 are connected to the first and second terminals A, B and the third and fourth terminals C, D of the switches C1 and C3, respectively, thereby connecting the winding sections 1, 2, 3, and 4 in series and parallel between the common point P and the corresponding phase supply line (e.g., supply line U), thereby forming gear 3 (see FIG. 4c). In this way, 25% of the supply current passes through each winding section 1, 2, 3, and 4. Therefore, the motor speed further increases, and the torque further decreases compared to when the winding sections 1, 2, 3, and 4 are all connected in series. This state can be considered a motor characteristic similar to the high or top gear of a conventional engine.

[0050] It will be appreciated that the efficiency of the motor can be increased without the need for conventional gears (e.g., transmitting power through a gearbox to increase or decrease speed or torque based on the selected mechanical gear).

[0051] For example, the winding configuration can be changed from a high torque configuration to a high speed configuration, bypassing intermediate configurations. As another example, the windings can be reconfigured from any configuration to any other, so that the windings can be changed from a series connected configuration directly to a parallel connected configuration without going through any intermediate configurations.

[0052] In some embodiments, operating isolator switch 15 each time a configuration is changed allows for smooth gear changes without the risk of electrical arcing. In some embodiments, actuator 16 may be a manual actuator operated by a user (e.g., via a shifter, button, lever, etc.) to select the desired effective gear ratio. Alternatively, actuator 16 may be an electric actuator controlled by control unit 13 based on feedback from sensor 14. Alternatively, actuator 16 may be an electric actuator controlled by control unit 13 based on a signal from selector switch 17.

[0053] The present invention allows for the desired speed and torque to be achieved within a single electric motor or generator without the need for expensive mechanical gears or gearboxes, so that a moderately sized direct drive motor and fixed gear ratio can easily achieve the desired speed and torque range within the current configuration.

[0054] Winding sections 1, 2, 3, and 4 within each phase do not have to be wound with the same wire diameter or the same number of turns. In some embodiments, each phase can be wound with a different wire diameter or number of turns. Also, in some embodiments, each phase can be wound in the same manner. For example, winding section 1 of each phase can be wound with the same wire and number of turns. Also, winding section 2 can be wound with a different number of turns and a different wire diameter than winding section 1. However, it may be advantageous to wind each coil segment in the same manner. For example, coil segment 2 of each phase can be wound with the same wire and number of turns.

[0055] While the embodiment described herein uses a three-phase configuration, it is understood that a motor according to the present invention may have any number of phases. Furthermore, the present invention is applicable to electric machines having similar speed-torque characteristics as the motor described herein. It is also understood that the present invention is applicable to electric generators. Furthermore, the winding configurations described above are only examples of possible configurations, and other combinations are also contemplated. For example, winding sections 1 and 2 could be connected in parallel with each other, and winding sections 3 and 4 could be connected in parallel with each other, and then connected in series with the parallel group of winding sections 1 and 2. This configuration would provide an effective additional gear ratio that is essentially between the intermediate gear and the low gear. Yet another possible configuration would be to rotate the outer rotatable ring 23 counterclockwise and the inner rotatable ring 22 clockwise, thereby connecting winding sections 2 and 3 in series between common point P and the supply line for that phase (e.g., supply line II), and connecting both winding sections 1 and 4 in parallel thereto. This would provide a gear characteristic between the low gear and intermediate gear characteristics described above. To further expand the configuration, a configuration may be used in which an independently rotatable ring is provided for each of the switches C1, C2, and C3.

[0056] In another embodiment, the rotatable and fixed rings (20, 21, 22, 23) may be replaced by corresponding members that are linearly movable relative to one another, thereby achieving the same functionality with linear rather than rotational movement.

[0057] The above sequence allows the winding configuration of the electric machine to be reconfigured by rotating the ring 23 clockwise or counterclockwise the appropriate number of degrees. The winding sections "WIN" are switched electromechanically using special low-resistance electrical contacts, which significantly reduces losses compared to semiconductor switching, improving electrical efficiency and reliability.

[0058] Such electromechanical switching schemes are cost-effective and reduce the number of switches required, making them easily applicable to any electric machine where reconfigurable windings would be beneficial to the system.

[0059] 6, 7, and 8, the mechanical switch of this embodiment is similar to that shown in FIGS. 1-5, and like parts are designated with the same reference numerals. In the embodiment shown in FIGS. 6, 7, and 8, the first end of the first winding section 1 of each phase (e.g., phase II) is connected to a common point P, as are the first ends of the first winding sections of the other two phases (phases V and W). Additionally, the second end of the fourth winding section 4 of each phase (e.g., phase II) is similarly connected to the respective phase supply line.

[0060] The switching device may include three switches C1, C2, and C3 for each phase, for a total of nine switches. Each switch in each phase may follow the configuration of C1 shown in Figure 6, which includes:

[0061] · First terminal B: Connected to the second end of winding section 1 of the corresponding phase. · Second terminal C: Connected to the first end of the adjacent winding section of the corresponding phase (e.g. winding section 2). · Third terminal A: Connected to the second end of the corresponding adjacent winding section (e.g. winding section 2). ·Fourth terminal D: Connected to the second end of winding section 1 of the corresponding phase.

[0062] As can be seen from FIG. 6, winding sections 1 to 4 can be considered as adjacent winding sections.

[0063] 7, the mechanical switch 12 may include a disk 120 fixed to the main body. The disk 120 is divided into three quadrants corresponding to phases II, V, and W. On the top surface of the disk 120, a first terminal D, a second terminal C, a third terminal B, and a fourth terminal A of switches C1, C2, and C3 for phases II, V, and W are arranged in the respective quadrants.

[0064] 8, the mechanical switch 12 may include a rotatable disk 121 disposed opposite the fixed disk 120. The rotating disk 121 is rotatable in a plane parallel to the plane in which the fixed disk 120 is located. The rotating disk 121 is also divided into three quadrants corresponding to phases II, V, and W.

[0065] For purposes of illustration, the rotating disk 121 is depicted as being made of a transparent substrate, with the conductive interconnects on its backside visible.

[0066] The conductive interconnects disposed on the underside of the rotating disk 121 may be arranged in a number of groups 110, 111, 112 that form part of the switches C1, C2, C3, each separated circumferentially and radially.

[0067] The interconnect group 110 of switch C1 includes a first conductive interconnect 124a located at circumferential position X and two sets of second and third conductive interconnects 125a, 126a located at circumferential positions Y and Z, respectively.

[0068] Circumferential positions X, Y, and Z are spaced apart from one another by, for example, 17.5°. Interconnect group 112 of switch C3 has the same interconnect pattern as interconnect group 110, but is spaced apart circumferentially by, for example, 70°. Interconnects 124c, 125c, and 126c of switch C3 can be located at similar radial positions as interconnects 124a, 125a, and 126a of switch C1.

[0069] The interconnect group 111 of switch C2 may include a first conductive interconnect 124b positioned at circumferential position X, a second conductive interconnect 124b positioned at circumferential position Y, and second and third conductive interconnects 125b, 126b positioned at circumferential position Z.

[0070] Interconnect group 111 is disposed between groups 110 and 112 and is circumferentially separated by an angle of, for example, 35°. Interconnects 124b, 125b, 126b of switch C2 may be disposed radially inward from the interconnects of the other groups 110, 112.

[0071] The disks 120 and 121 may be immersed in a liquid, such as oil, within a sealed cavity within the mechanical switch 12 .

[0072] In use, disks 120 and 121 are aligned in an initial position, with conductive interconnects 124, 125, 126 (a, b, c) and rotating disk 121 not in contact with any of terminals A, B, C, and D on fixed disk 120. In this state, isolator switch 15 can be operated to disconnect three-phase power source S from mechanical switching device 12. Actuator 16 is then activated to rotate rotating disk 121, moving first conductive interconnect 124a of switch C1 to a position where it connects across terminals D and C at position X. At the same time, first and second terminals D and C of switches C2 and C3 are connected by their respective first conductive interconnects 124b and 124c. This connects winding sections 1, 2, 3, and 4 of each phase (e.g., phase II) in series between common point P and the respective phase's supply line. Thereafter, by operating the isolator switch 15 again, it is possible to make the current flow through each of the series-connected winding sections 1 to 4 in the same direction relative to the polarity direction of each section.

[0073] The configuration of winding sections 1, 2, 3, and 4 of each phase can be changed by rotating rotating disk 121 counterclockwise by 17.5 degrees. This causes second and third conductive interconnects 125a and 126a of the first set of interconnect group 110 to overlap at position Y, connecting across first and third terminals D and B of switch C1 and second and fourth terminals C and A of switch C1, respectively. At the same time, first conductive interconnects 125c and 126c of group 112 overlap at positions connecting across terminals D and B of switch C3 and C and A of switch C3, respectively. At the same time, another first conductive interconnect 124b of group 111 overlaps at positions connecting first and second terminals D and C of switch C2 and second and fourth terminals C and A of switch C2, respectively. In this manner, winding sections 1 and 2 are connected in series between common point P and the supply line of each phase (e.g., supply line II), and winding sections 3 and 4 are similarly connected in series between common point P and the supply line.

[0074] Next, to further change the configuration of winding sections 1, 2, 3, and 4 of each phase, rotating disk 121 is further rotated counterclockwise, for example, by 17.5°, so that second and third conductive interconnects 125a and 126a of the second set of group 110 overlap positions connecting first and third terminals D and B to second and fourth terminals C and A of switch C1 at position Z. At the same time, second set of conductive interconnects 125c and 126c of group 112 overlap positions connecting corresponding terminals of switch C3.

[0075] At the same time, the second and third conductive interconnects 125b, 126b of group 111 overlap the positions connecting the first and third terminals D, B of switch C2 to the second and fourth terminals C, A, respectively. In this way, all of winding sections 1 to 4 can be connected in parallel between common point P and the supply line of each phase (e.g., supply line II).

[0076] 7, fixed disk 120 may be provided with a number of conductors (e.g., 130, 131) for interconnecting terminals D, C, B, and A of switches C1, C2, and C3, thereby eliminating the need to hardwire the ends of winding sections 1, 2, 3, and 4 directly to their respective connection points.

[0077] 9 and 10, in another embodiment, outer and inner cylindrical members 220, 221 may be used in the mechanical switch 12 instead of the disks 120, 121 of FIGS. 7 and 8. The cylindrical members 220, 221 are arranged coaxially with the rotational axis of the motor unit 10. An end 222 of each stator winding "WIN" extends axially of the motor unit 10 and terminates in the outer cylindrical member 220, and may be arranged together with a phase supply conductor. The winding ends and the phase supply conductors are suitably connected to a group of contact terminals 223 (e.g., 223A, 223B) arranged on the radially inward cylindrical surface of the outer cylindrical member 220. The contact terminals 223 may be suitably connected to each other by conductors 224 as needed.

[0078] The radially outward cylindrical surface of the inner cylindrical member 221 may be provided with a plurality of electrically conductive interconnects 225. The inner cylindrical member 221 is rotatable about its own axis and axially displaceable. The rotational and axial positions of the inner cylindrical member 221 are set by a servo motor 226 controlled by the electronic control unit 13.

[0079] At the start of the sequence, the initial positions of the cylindrical members 220 and 221 may be set to a neutral position, in which neither conductive interconnect 225 has a contact terminal 223 connected.

[0080] In use, the inner cylindrical member 221 is rotated and / or axially displaced by the servo motor 226, causing the conductive interconnects 225 to contact and appropriately connect the contact terminals 223 on the outer cylindrical member 220, thereby appropriately configuring the windings in a manner similar to that described above.

[0081] Any of the mechanical switches 12 described above can be operated under fully automatic, manual, or semi-automatic control to appropriately reconfigure the windings "WIN" of the electric vehicle motor unit 10, thereby providing multiple virtual gears.

[0082] In fully automatic mode, the reconfiguration of the windings (gear changes) is performed based on mapping software stored in the control unit 13. Speed ​​and torque are constantly monitored by sensors 14 and compared with pre-set data stored in the software. Algorithms in the software determine when to shift gears.

[0083] In the manual mode, an appropriate gear can be selected based on user instructions or inputs according to the user's driving experience. For example, the user can press a button to activate the clutch 18 and temporarily activate the isolator switch 15, and then switch a lever to move the ring, disc, cylinder, or other part of the mechanical switch to the appropriate position and properly connect the corresponding terminals.

[0084] This temporary disconnection period is brief, on the order of 1 millisecond, and typically in the range of 1 to 10 milliseconds. Releasing the clutch 18 energizes the appropriately configured windings of the motor unit 10. In this example, the sequence of clutch depression, shifting, lever operation, and clutch release provides the electric vehicle user with a driving experience similar to that of a conventional manual transmission vehicle.

[0085] In semi-automatic mode, the electronic gear actuator 16 within the switching device 12 operates like a manual gear change pedal in a conventional vehicle. For example, when a user presses a selector switch 17, an electrical signal is sent to the switching device 12, which can electronically change the winding configuration.

[0086] The electric machine according to the present invention overcomes the drawbacks of conventional semiconductor switches and is adaptable to a variety of applications, such as the automotive industry, wind power generation, marine and aerospace.

[0087] The electric machine of the present invention is also compact, electrically efficient, cost-effective, simple to manufacture, and adaptable to a wide variety of winding combinations and configurations.Furthermore, the electric machine of the present invention dramatically improves switching efficiency by achieving low contact / switch resistances of less than 1 milliohm compared to existing semiconductor switches and other known switch configurations.

Claims

1. a. a winding having a plurality of winding sections; b. a mechanical switch having a plurality of switches; c. an actuator for relative movement of the first and second portions of each switch between the first and second switch positions; An electric machine comprising: Each section has a first end and a second end; each switch includes a first portion and a second portion relatively movable between the first switch position and the second switch position, the first portion and the second portion connecting a first winding section and a second winding section, respectively, that are part of the winding section; the first winding section is configured to be selectively connectable in series or parallel with the second winding section.

1. An electric machine characterized by:

2. each switch having a third switch position in which a first winding section of the machine is disconnected; 2. An electric machine according to claim 1.

3. Each switch has a first portion having a plurality of contact terminals and a second portion having a plurality of conductive connections configured to interconnect selected contact terminals in different configurations in the first and second switch positions, respectively.

2. An electric machine according to claim 1.

4. the first part of each switch having first and second contact terminals respectively connected to ends of two winding sections of the machine; third and fourth contact terminals connect these two winding sections to the machine supply conductors; the first contact terminal and the second contact terminal are interconnected by a conductive connection in the first switch position to connect two winding sections in series; the first contact terminal and the third contact terminal are interconnected by a second conductive connecting portion; the second contact terminal and the fourth contact terminal are interconnected by a third conductive connection, thereby connecting the two winding sections in parallel between the supply conductors; 4. An electric machine according to claim 3.

5. The actuator is movable between a plurality of positions each having a different combination of positions of the mechanical switches.

2. An electric machine according to claim 1.

6. the actuator is configured to move from a first position to a second position directly or indirectly via one or more intermediate positions; most winding sections of the machine are connected in series at the first actuator position and in parallel at the second actuator position; a mechanical switch configured to selectively connect the winding sections in parallel when the actuator moves to one or more intermediate positions between the first position and the second position; 6. An electric machine according to claim 5.

7. the actuators include a single actuator for relatively moving the first and second portions of each switch between the first and second positions; 2. An electric machine according to claim 1.

8. the actuator is configured to actuate a switch portion including a disk, a sphere, a ring, a cylinder, or a linear or arcuate member; 2. An electric machine according to claim 1.

9. the first and / or second portions of each switch are fixed in position relative to the portions of the other switches; 2. An electric machine according to claim 1.

10. a first portion of each switch is provided on the fixed member and a second portion of each switch is provided on the movable member, or vice versa; 10. An electric machine according to claim 9.

11. the first and / or second portions of each switch are independently movable in position relative to at least the portions of the other switches; 10. An electric machine according to claim 9.

12. The parts of each switch are interconnected, and movement of one part causes movement of another part via a gear or index.

12. An electric machine according to claim 11.

13. a first portion of each switch is provided on each of the sequentially moving members; 13. An electric machine according to claim 12.

14. The first and second portions of each switch are movable relative to one another in a linear or arcuate manner.

2. An electric machine according to claim 1.

15. the first and second portions of each switch are relatively movable in a single plane; 15. An electric machine according to claim 14.

16. the first and second portions of each switch are relatively movable in a plurality of planes; 15. An electric machine according to claim 14.

17. the actuator is arranged to automatically, manually or semi-automatically move the switch portions relative to one another to reconfigure the windings of the electric machine; 2. An electric machine according to claim 1.

18. In the automatic mode, the switch sections move relative to one another based on a control program stored in the control unit of the switching device; The control unit is configured to compare the actual rotational speed and torque of the machine with preset values ​​and to activate the actuator to selectively move portions of each switch.

18. An electric machine according to claim 17.

19. In the manual mode, the switch portions are configured to move relative to one another based on movement of the actuator by a user.

18. An electric machine according to claim 17.

20. In a semi-automatic mode, the control unit is provided with user-operated switches configured to activate actuators to selectively move portions of the switches to select a desired configuration of machine windings.

18. An electric machine according to claim 17.

21. a switch is provided for inhibiting power supply to the winding while any switch of the switching device is moving between the first position and the second position; 2. An electric machine according to claim 1.

22. Each switch part is immersed in liquid within a sealed unit, 2. An electric machine according to claim 1.

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