Method for determining a reactivation time in the event of a limit temperature-induced shutdown of a permanently excited synchronous machine

Abstract

The invention relates to a method for thermally optimizing the operation of a dynamoelectric machine (1), fed by a converter (50), of a rotor (9) equipped with permanent magnets (14), wherein: the rotor (9) has a magnetically conductive main body, in particular an axially layered laminated core (11), which provides permanent magnets (14) circumferentially and / or axially in substantially axially extending recesses (13) at least in some portions, wherein one or more permanent magnets (14) form a pole, which forms a north pole (N) or south pole (S) in the direction of the outer circumference (18) of the rotor (8); the conductive main body and the permanent magnets (14) each form part of a closed magnetic circuit (22); in the magnetic circuits (22), means are provided which are arranged magnetically in series in a magnetization direction of the permanent magnets (14) and protect the permanent magnets against excessively high temperatures and thus against irreversible demagnetization; each pole (19) of the rotor (9) or each permanent magnet (14) has a layer (20) in which the means influences the magnetic circuit (22) in a material-specific manner when a specifiable threshold temperature is exceeded; and - changes in the EMF, and / or - changes in the inductances (dL / dt) of the dynamoelectric machine (1), and / or - changes in the phase angle ϕ as a phase shift between the motor current and motor voltage or the output current and output voltage of the converter (50), and / or - deviations from a stored flux model, are detected in order, from these, to then initiate further temperature-reducing actions, such as at least current reduction, load reduction or emergency shutdown of the dynamoelectric machine (1) and / or activation of an external fan, in order to allow reactivation after a minimized period of time from a thermal aspect.

Description

[0001] Description

[0002] Method for determining a restart time in the event of a temperature-related shutdown of a permanent magnet synchronous machine

[0003] The invention relates to a method for detecting the limit temperature of permanent magnets in a permanent magnet synchronous machine and for determining the (re-)connection time of a permanent magnet synchronous machine due to a thermally induced shutdown at a limit temperature of the permanent magnets of a rotor equipped with permanent magnets. Furthermore, the invention relates to a rotor of a permanent magnet synchronous machine, a permanent magnet synchronous machine, and the application of a permanent magnet synchronous machine.

[0004] In rotors of dynamoelectric machines with permanent magnets, especially permanent magnet synchronous machines with buried permanent magnets, the permanent magnets are axially inserted into pockets in the rotor and, if necessary, positioned by webs.

[0005] When designing and operating permanent magnet synchronous motors, the permissible operating temperatures of the permanent magnets must be taken into account to protect them from irreversible demagnetization. Especially when using widely employed rare-earth materials with negative temperature coefficients Tk(HcJ) (e.g., NdFeB; neodymium-iron-boron), the decrease in opposing field resistance with increasing operating temperature necessitates reliable and precise knowledge of the operating condition and, above all, the temperature of the motor.

[0006] Direct and continuous measurement of the magnet temperature is only economically and technically feasible in exceptional cases due to the permanent magnets being located in the rotating part of the motor, i.e., the rotor.

[0007] Purely computational models require the motor model to be mapped to the inverter, which severely limits possible motor-inverter combinations, also known as drives, in practice. This is particularly true when, for example, different manufacturers of motors and inverters are to be connected by the customer.

[0008] Furthermore, such thermal models have a limited range of validity due to the modeling depth and the limitations of the sensors. The motor's design and operation must therefore be adjusted to account for the imprecise knowledge. For reasons of operational reliability, this leads, for example, to the selection of higher-grade permanent magnets, and / or the use of more material in the permanent magnets, and / or to a more robust cooling concept for the drive, or to accepting a comparatively lower motor utilization.

[0009] In addition to the resulting increase in costs, the motor still cannot be reliably protected from irreversible demagnetization in connection with high operating temperatures of the magnetic material.

[0010] From DE 10 2020 202 204 A1 a material is known which has a Curie temperature which corresponds to a threshold temperature of the permanent magnets and thus makes it possible to detect whether the threshold temperature is exceeded or not reached.

[0011] However, a disadvantage is always that the motor utilization remains comparatively low in order to avoid demagnetizing the permanent magnets.

[0012] Based on this, the invention aims to create a thermal operating optimization of a permanent magnet synchronous machine, which in particular enables the fastest possible reactivation of this permanent magnet synchronous machine after a thermally induced shutdown.

[0013] The problem can be solved by examining the characteristics of the independent claims. Advantageous variations can be found in the dependent claims.

[0014] Basically, the problem being solved is how the converter of a permanent magnet synchronous machine enables it to be switched back on as quickly as possible, either fully or with a predetermined load, after a thermally induced shutdown to protect the permanent magnets of the rotor, and by what method it accomplishes this.

[0015] The following considerations underlie the inventive method for determining a (re-)connection time of a limit temperature-induced shutdown of a permanent magnet rotor of a dynamoelectric machine, in particular a permanent excitation synchronous machine which is supplied by means of a converter.

[0016] In simplified terms, it can be assumed that the current flowing through the winding system of a dynamo-electric machine or motor has an active component and a reactive component. These components are known to the inverter or power converter, among other things, for controlling the magnetic field and the torque of the dynamo-electric machine. These values ​​form the basis for the drive control.

[0017] The electromotive force (EMF) of a dynamo-electric machine can be determined for a given operating condition. This can be calculated from measured values ​​such as rotational speed and values ​​known to the power converter, such as flux. If necessary, further values ​​from the datasheet, such as the number of windings or pole pairs of the dynamo-electric machine, can be used for the calculation.

[0018] Furthermore, inductance values ​​can be determined from current measurements or from values ​​such as space vectors derived from these measurements. When determining inductance from measurements, the derivative of the current can also be used in addition to the current itself.

[0019] It is also possible to determine the difference between the measured inductance and the inductance stored in the converter (for example, from datasheet values) of the dynamo-electric machine.

[0020] Instead of the inductance in the equivalent circuit, the phase angle (<|) can also be determined as the phase shift between motor current and motor voltage. However, this evaluation requires an operating point with a specific torque, since information about the motor inductance can only be obtained from the ratio if the angle is not equal to 90°.

[0021] These values ​​of the dynamo-electric machine change when the means surrounding the permanent magnet at least partially "respond" at a correspondingly increasing temperature, i.e., cause a change from ferromagnetism to paramagnetism.

[0022] The drive then reacts with temperature-reducing actions, such as reducing current in the motor's winding system, reducing load, or shutting down the dynamo-electric machine and / or switching on an external fan to continue operation.

[0023] To determine the current state, particularly the thermal state of the rotor of the dynamo-electric machine, after a temperature-reducing operation, test pulses from the inverter are applied to the machine or the winding system, especially when the dynamo-electric machine is idling. At least one of the aforementioned values ​​is determined based on these test pulses, and the control system then decides whether to reconnect the machine, further reduce the load, or switch off the dynamo-electric machine and / or activate an (additional) external fan.

[0024] Direct temperature limit determination involves calculating a limit temperature from measured variables, such as current, known control variables, such as the converter's output voltage, and model parameters, for example, for the thermal temperature model. The advantage is that motor monitoring can be performed based on temperature and corresponding limit values, regardless of the manufacturer. This data is available in the datasheets.

[0025] Indirect temperature determination avoids the need to determine an exact temperature value. Instead, a model parameter is used to monitor the motor. It has been found that the magnetization state, including the risk of temporary demagnetization of the rotor's permanent magnets, can be detected, particularly based on the motor's inductance. For known motors, the relationship between magnetization and inductance is sufficiently well understood, allowing for protection measures based on inductance measurement. The advantage lies in the ease with which these values ​​can be determined, eliminating the need for computational steps involving a more or less accurate temperature model.

[0026] For known motors, the relationship between magnetization and inductance is sufficiently well understood, and protection can be implemented based on inductance determination. However, the advantage of this method now lies in its particularly reliable detection of changes in magnetic behavior.

[0027] Protection via a temperature model requires a high degree of safety with regard to the limit values, so that the proposed method allows the dynamoelectric machine to be utilized much better in the limit range and protected from damage.

[0028] When the temperature of the dynamo-electric machine, particularly the rotor equipped with permanent magnets, increases towards the limiting temperature of the permanent magnets, the magnetic resistance (reluctance) of the material used increases. This leads to an increase in the material's magnetic resistance (reluctance) and a corresponding limitation of the magnetic flux in the magnetic circuits, which in turn limits the magnetic flux, among other things, through the permanent magnets. Investigations have shown that this affects the motor inductance in the manner described.

[0029] A magnetic circuit is a closed path of magnetic flux, formed by one or more permanent magnets and - in the operation of the dynamo-electric machine - by a current-carrying winding system.

[0030] The starting point is the use of a material (e.g., CeFeB) whose Curie temperature is within the range of the maximum operating temperature of the permanent magnet material used. When operating below this limit temperature, the material exhibits strong ferromagnetic magnetization behavior. This ensures the proper operation of the dynamo-electric machine and the drive system.

[0031] The following temperature designations will be used in the following.

[0032] The Curie temperature is the temperature at which a given material undergoes a transition from ferromagnetism to paramagnetism. According to the invention, this temperature is also referred to as the limiting temperature of the "mean" or simply as the limiting temperature.

[0033] The operating temperature is the temperature to which, among other things, the permanent magnets and the rotor are exposed.

[0034] The limiting temperature of the permanent magnet is the maximum permissible operating temperature of the permanent magnet at which irreversible demagnetization does not (yet) occur when the motor is subjected to the maximum opposing field specified in the development process. Depending on the motor's requirements, such an operating condition could be, for example, a high overload or a fault condition (e.g., a short circuit).

[0035] The overtemperature of the permanent magnet refers to a temperature (greater than the limiting temperature of the permanent magnet) above which irreversible demagnetization of the permanent magnet occurs when the dynamo-electric machine is subjected to the maximum intended opposing field in an operating condition. Depending on the requirements of the machine, such an operating condition, particularly in the case of a motor, can be, for example, a high overload or a fault condition (e.g., a short circuit).

[0036] The material thus has a Curie temperature lower than the limiting temperature of the permanent magnets (i.e., within the range of the maximum permissible operating temperature of the permanent magnet) and itself exhibits a reversible transition from ferromagnetism to paramagnetism under corresponding temperature changes. Above the material's limiting temperature (lower than the permanent magnet's limiting temperature), the material exhibits a change from ferromagnetic to paramagnetic behavior. This transition is advantageously a reversible process, so that the "normal" operation of the dynamo-electric machine or drive is not affected below this limiting temperature. After exceeding this limiting temperature and subsequently falling below it, the "normal" behavior is restored.

[0037] The arrangement of this material as a layer takes place in the magnetic circuit and is to be positioned as close as possible and electromagnetically in series with the permanent magnets of the rotor to be protected.

[0038] Preferably, this layer is positioned as close as possible to the permanent magnets. For example, this layer is applied directly to the respective permanent magnet, i.e., directly on the north pole side and / or the south pole side of the permanent magnet.

[0039] The layer is arranged in series with each permanent magnet in the respective magnetic circuits of the rotor. It thus surrounds the permanent magnet at least to the extent that the magnetic field lines of the circuit must pass through the layer. The layer thickness can optionally vary and tends to be thicker at the edges of the permanent magnet than in the center. By default, the layer has a constant thickness.

[0040] This layer according to the invention can also be used with permanent magnets that are arranged as surface magnets on the outer circumference of the rotor.

[0041] As an example of the material of this layer, the magnetizing behavior of an exemplary CeFeB alloy can be mentioned, which exhibits the transition to the paramagnetic state at a Curie temperature of approximately 150°C and has a coercive field strength Hcj of 50kA / m at 20°C and 20kA / m at 120°C.

[0042] The permanent magnet is designed to be resistant to demagnetization under normal operating conditions and has a Curie temperature significantly higher than the operating temperature, typically >300°C, and is made from the neodymium-iron-boron (NdFeB) class of magnets.

[0043] By actively influencing the magnetic circuit based on the use of materials with special material properties, in particular by utilizing the Curie temperature, a reversible self-protection of the magnetic circuit is created according to the invention, as well as a simple detection of the limit temperature is enabled.

[0044] This is achieved by first weakening the magnetic field when the limit temperature is reached or a temperature above the limit temperature, thus changing the motor parameters described above. From this, a rapid restart time can now be easily determined by sending test pulses from the inverter to the dynamo-electric machine at predefined time intervals.

[0045] Specifically, the opposing field stress on the permanent magnets is reduced under a given current condition by increasing the magnetic resistance of the magnetic circuit. Thus, a dynamo-electric machine can, with regard to demagnetization resistance, either handle higher maximum currents or, at a given maximum current, tolerate higher temperatures of the permanent magnets.

[0046] Therefore, a protective function is created as a first step. The associated change in motor parameters (e.g., inductance or no-load voltage (EMF)) also enables the detection of overtemperature (e.g., in the inverter).

[0047] Based on the datasheet values, the inverter can reliably determine the current, separating it into an active current component that generates the torque of the electric machine and a reactive current component for generating the magnetic field. The motor or inverter detects any change in the equivalent circuit inductance caused by temperature rise. In other words, the measured current does not correspond to the voltage generated by the inverter and the current operating point. The operating point can be determined, for example, from model-generated quantities such as flux or from measured quantities such as rotational speed.

[0048] Suitable detection is necessary to prevent a further temperature increase through appropriate countermeasures or to actively initiate measures to reduce the temperature.

[0049] Possible detection methods would include, for example, determining the electromotive force (EMF) or the current of the dynamo-electric machine during operation, determining the motor inductance, determining the phase angle (<|) by the converter, or deviations from a stored flux model.

[0050] In the simplest case, a change in the magnetic behavior of the machine can be detected via the electromotive force (EMF), since the flux is a factor in determining the EMF level. A reduced EMF can be detected, for example, by the active current, as the dynamoelectric machine requires a higher active current to maintain a specified torque.

[0051] Alternatively or additionally, the altered behavior of the machine can be detected by observing the changes in the reactive current used to generate the magnetic field. Since both active and reactive current affect the phase angle (<|), evaluating the phase angle provides a particularly robust parameter for detecting changes in magnetic behavior.

[0052] Furthermore, the converter's control system can make implausible operating conditions more plausible by adjusting the inductance to the operating conditions. This makes it possible to achieve high control dynamics even in the event of a fault. Additionally, it allows the temporal progression of thermal overload to be monitored. This makes it possible to determine whether the magnetic conditions are improving or becoming more critical and requiring further protective measures.

[0053] The drive control system intervenes when it detects altered magnetic conditions at the motor, either by reducing the power input to the dynamo-electric machine or by initiating an emergency shutdown due to motor overheating. It is essential to ensure that the rotor temperature decreases. This can be achieved, for example, by limiting the power, limiting the torque, or by changing, particularly increasing, the switching frequency of the power converter. Temperature reduction can also be achieved, if necessary, by forced cooling of the motor using an external fan. A combination of these measures also offers advantages.

[0054] This creates a protective function. The associated change in motor parameters (e.g., inductance or no-load voltage (EMF)) enables the inverter to detect over-temperature, primarily in the rotor. Based on the datasheet values, the inverter can reliably determine the current into an active current component, which generates the torque of the electric machine, and a reactive current component for generating the magnetic field. The motor or inverter detects temperature increases, particularly in the rotor, caused by the coating "responding" and the resulting change in motor parameters, such as the equivalent circuit inductance.The resulting power limitation or even shutdown of the drive should, however, be lifted as quickly as possible in order to continue the work process as quickly as possible. According to the invention, this is achieved by sending test pulses from the inverter to the dynamoelectric machine at predefined time intervals and recording its parameters. The control system then derives from this whether the drive can switch to normal operation, or whether the aforementioned temperature reduction measures must be continued or even intensified.

[0055] A temperature reduction, especially of the rotor and its permanent magnets, and thus a reduction below the critical temperature, can also be achieved, if necessary, by forced cooling of the motor using an external fan.

[0056] The described process directly protects the magnetic material in the rotor by reducing the opposing field, and on the other hand allows for the detection of temperature exceedance by a corresponding detection algorithm in the supplying frequency converter through the detectable influence on operating parameters of the motor (e.g. current).

[0057] Overall, the protective layer in the rotor's magnetic circuits allows for a higher and safer utilization of the materials used, and thus also of the motor.

[0058] In addition to this layer, further measures to improve counter-field stability can be particularly effective on the side of the recesses facing the outer circumference of the rotor. A demagnetizing field, which may be generated by a short-circuit current in a winding system of the motor's stator, typically has a particularly negative effect there. This demagnetizing field can be significantly reduced by means such as retaining elements or bridges. These retaining elements and / or bridges also perform the positioning function of the permanent magnets within the recesses.

[0059] Such an opposing field can result, for example, from a surge short-circuit current, other load conditions of the permanent magnet synchronous machine, high overload torques, current faults of the converter and various short-circuit faults in the winding system.

[0060] Particularly vulnerable are exposed areas of the permanent magnets, such as the corners, as they are subjected to especially high opposing magnetic fields in the event of a fault. Irreversible demagnetization of the permanent magnets would therefore occur first in these areas. This is prevented by the retaining elements or webs on the side of the recesses facing the outer circumference of the rotor. Advantageously, these webs, retaining elements, functional components, etc., are part of the rotor's dynamo sheet and are integrally formed with it. This is ensured, for example, by one or more stamping processes.

[0061] The machine's shock short-circuit resistance can also be achieved additionally or instead by the comparatively elaborate and therefore expensive use of magnet grades with high HcJ and / or by the use of thicker permanent magnets.

[0062] The arrangement of the recesses or permanent magnets in the rotor poles depends on the duty cycle of the permanent magnet synchronous machine. Higher magnetic field air gap densities can be achieved through flux concentration, as is possible, for example, with a V-shaped, double-V-shaped, or U-shaped arrangement.

[0063] A skew and / or staggering of the rotor or its poles along the axial length of the rotor can still be applied. This reduces, among other things, the cogging torque of the permanent magnet synchronous motor.

[0064] Applications of such rotors in permanent magnet synchronous machines are primarily intended in industrial environments such as pumps, fans, compressors, roller conveyors, and conveyor systems that have a very long continuous operating time.

[0065] Their use in traction drives such as mining vehicles, e-buses, trams or trains is also conceivable.

[0066] After a shutdown or a reduction in drive power - as described above

[0067] - However, the drive system aims to deliver the expected or required performance again as quickly as possible.

[0068] According to the invention, the converter sends short pulses to the winding system of the stator of the dynamo-electric machine to detect the rotor's response. In other words, the detected values ​​are used to test whether the operating temperature is below the limit temperature of the permanent magnets.

[0069] In this process, a magnetic field can be built up within an electric machine running at no load for a defined period. This field generates no torque and therefore no active current. The dynamo-electric machine remains at no load, but with an increased magnetic field. The motor inductance can be reliably determined from the measured electromotive force (EMF) and reactive current. Furthermore, operating at no load, i.e., without torque-generating current, is thermally uncritical for the electric machine, even after prior thermal overload, and, most importantly, does not lead to significant further heating of the machine.

[0070] In an electric machine that is in operation and therefore generating torque, it is also possible to briefly increase the magnetic field within the motor. From the motor's response, for example, from the back EMF or a change in speed, the magnetic conditions and, in particular, the motor's inductance can then be easily determined. Once the electric machine is operated using this method, the reactive current can be briefly increased.

[0071] In other words, the additional signal is used, for example, to test whether the magnetic conditions have returned to their intended behavior with operating parameters within the permissible range of the permanent magnets after cooling. This permissible range prevents damage to the motor, ensures a long service life for the electric machine, and contributes to optimized utilization of the dynamo-electric machine.

[0072] This desired (re-)switching process can also be supported by a flanking temperature model of the dynamo-electric machine.

[0073] Such methods are used with rotors of permanent magnet synchronous machines, which are primarily operated in industrial environments. They are intended as drives for pumps, fans, compressors, roller conveyors, and conveyor systems, with continuous operating times that place high thermal demands on the drive (especially the motor and inverter), and which are monitored according to the invention.

[0074] Such synchronous machines can also be used in traction drives such as mining vehicles, e-buses, trams or trains.

[0075] The idea underlying the invention can also be transferred to permanent magnet synchronous machines with external rotors, such as those used in directly driven generators of wind turbines.

[0076] The underlying idea of ​​the invention can also be transferred to other dynamoelectric machines that have permanent magnets in their rotors, such as synchronous machines with a starting cage or synchronous reluctance machines with permanent magnets. In a further advantageous embodiment of the invention, exceeding the limit temperature is determined by evaluating the motor currents. It has been shown that exceeding the limit temperature can be detected in various ways by observing the motor currents, which are identical to the output currents of the inverter. It has been found that exceeding the limit temperature manifests itself so rapidly and with such a significant change in physical behavior that the rate of change of the motor currents significantly exceeds the values ​​of the rate of change of the motor currents encountered in operation.Thus, for example, it is possible to monitor the rate of change of the motor currents to detect when the limit temperature has been exceeded. In other words, an exceedance of the limit temperature can be detected by the rate of change exceeding a predefined limit.

[0077] Furthermore, it has been shown that under particularly critical operating conditions, the current waveform can change and then differ from a sinusoidal waveform. This means that exceeding the limit temperature can be detected, for example, if the total harmonic distortion (THD) of the motor currents exceeds a predefined limit.

[0078] In a further advantageous embodiment of the invention, the motor currents are related to the motor voltages to detect when the limit temperature is exceeded. By relating them, changes due to a change in the operating point can be reliably distinguished from changes due to a change in the physical behavior of the electric machine. It is not necessary to calculate the quotient of the motor current and the output voltages of the inverter. Since these quantities are complex, the ratio can also be calculated particularly simply by using the phase difference between these two quantities. In other words, the phase difference between the motor currents and the output voltages of the inverter is calculated. This phase difference can then be monitored to determine whether it exceeds a permissible limit.Once the limit temperature is exceeded, it can then be monitored in a simple and reliable way.

[0079] Alternatively or additionally, it is possible to determine the quotient of the magnitude of the complex motor current and the complex output voltage of the inverter. It has been shown that changes in the magnetic field have such a significant impact on the motor that they are not only detectable by the motor's inductive behavior, mathematically expressed by the imaginary components, but also by the magnitudes of the complex values, which include both the real and imaginary parts. Thus, real limit values ​​can be easily specified, allowing for the reliable detection of exceeding the limit temperature, the effects of which are reflected in complex quantities, with minimal computational effort.

[0080] In a further advantageous embodiment of the invention, exceeding the limit temperature is detected by varying the amplitude of the inverter's output voltage. This amplitude variation directly affects the electric field of the motor generated by the stator. Therefore, even small changes in amplitude can reveal altered behavior of the electric machine with respect to its flux characteristics.

[0081] In a further advantageous embodiment of the invention, the rotor angle of the electric machine is kept constant when the limit temperature is exceeded. To ensure that the motor is not subjected to further high thermal stress by compensating for the reduced field with increased active current, it has proven advantageous to keep the rotor angle constant. This not only provides reliable protection against thermal overload due to high active current, i.e., a high real current component in the motor current, but also ensures stable motor operation, as exceeding the breakaway limit due to an excessively high rotor angle is reliably prevented.

[0082] In a further advantageous embodiment of the invention, the layer thickness is at least 0.5 mm. With this layer thickness, it is also possible to produce layers that exhibit sufficient stability against the prevailing forces for high-speed applications. It has been shown that, particularly when using a layer made of a CeFeB alloy, the strength can be increased to such an extent that the permanent magnets can be reliably and permanently arranged in the rotor with the layer. Even high rotational speeds then have no negative effects on the service life and the arrangement of the layer on the permanent magnet material.

[0083] Furthermore, the thickness of the layer can also vary such that it increases towards its edges. An advantageous embodiment, for example, involves making the layer thin in its center, for instance, but not necessarily thinner than 0.5 mm, while having a thickness greater than 0.5 mm at the edges.

[0084] The invention and further advantageous embodiments of the invention are explained in more detail with reference to exemplary embodiments shown in principle, in which: FIG 1 shows a longitudinal section of a dynamoelectric machine with a converter, FIG 2 shows a detailed cross-sectional view of a rotor.

[0085] It should be noted that terms such as "axial," "radial," "tangential," etc., refer to the axis 6 used in the respective figure or in the described example. In other words, the directions axial, radial, and tangential always refer to an axis 6 of the rotor 9 and thus to the corresponding axis of symmetry of the stator 8. "Axial" describes a direction parallel to the axis 6, "radial" describes a direction orthogonal to the axis 6, either towards or away from it, and "tangential" is a direction that is circular around the axis 6 at a constant radial distance and with a constant axial position. The expression "circumferential" is synonymous with "tangential."

[0086] With regard to a surface, e.g. a cross-sectional area, the terms "axial", "radial", "tangential", etc. describe the orientation of the normal vector of the surface, i.e. the vector that is perpendicular to the surface in question.

[0087] The term "coaxial components," e.g., coaxial components such as rotor 9 and stator 8, refers here to components that have the same normal vectors, meaning that the planes defined by the coaxial components are parallel to each other. Furthermore, the term implies that the centers of coaxial components lie on the same axis of rotation or symmetry. However, these centers may be located at different axial positions on this axis, and the planes in question may therefore have a distance greater than zero from each other. The term does not necessarily require that coaxial components have the same radius.

[0088] The term "complementary," in the context of two components that are complementary to each other, means that their external forms are designed such that one component can preferably be completely enclosed within its complementary component, so that the inner surface of one component and the outer surface of the other ideally touch without gaps or across their entire surface. Consequently, in the case of two complementary objects, the external form of one object is determined by the external form of the other. The term "complementary" could be replaced by the term "inverse."

[0089] For the sake of clarity, in some cases where components are present multiple times, not all depicted components are labeled with reference numerals in the figures. The described embodiments can be combined as desired. Likewise, individual features of the respective embodiments can also be combined without departing from the essence of the invention.

[0090] FIG. 1 shows a schematic representation of a permanent magnet synchronous machine 1 powered by a converter 50. This arrangement, "permanent magnet synchronous machine 1 with converter 50," is also referred to as a drive. The converter 50, with its control unit 35, is either integrated into the permanent magnet synchronous machine 1, mounted directly on or remotely from it. This depends, among other things, on the power class of the drive. In any case, data exchange 37—preferably bidirectional—takes place between the permanent magnet synchronous machine 1 and the converter 50 or the control unit 35.

[0091] Separated from a stator 8 by an air gap 25, a rotor 9 with its permanent magnets 14 is arranged. In this embodiment, these permanent magnets 14 are arranged in a V-shape within the rotor 9. Two permanent magnets (at least one permanent magnet 14 per recess 13) form one pole of the rotor 9. The V-shaped arrangement of the permanent magnets 14 has the advantage that, among other things, the magnetic field density in the air gap 25 is increased. This is also referred to as flux concentration.

[0092] In this embodiment, the permanent magnets 14 are each cuboid in shape and are located in a recess 13. The recess 13 is only partially occupied by the permanent magnet 14, which is flanked by flux barriers 34.

[0093] These flux barriers 34 consist of either air or non-magnetic material. These flux barriers 34 in the poles of the rotor 9 are necessary to prevent magnetic short circuits of the permanent magnets 14, among others, in the region of the respective poles.

[0094] Between the flux barriers 34 and the permanent magnets 14, webs 21 of different shapes are provided, which are arranged on the side facing the air gap 25, i.e., towards the outer circumference 18 of the rotor 9 of the recess 13. This arrangement of the webs 21 also largely prevents demagnetization of the permanent magnets 14, especially in the edge regions of the permanent magnets 14, for example, by an impulse short circuit in the winding system 7 of the stator 8.

[0095] The stator 8 is arranged in a housing 2, which is supported on a shaft 5 via bearing shields 3 and their bearings 4. The winding system 7 is housed in slots 16 of the stator 8.

[0096] An integrated fan 15 and / or an external fan can cool both the stator 8 and the rotor 9 via their cooling channels 12 and 17, respectively. The stator 8 and rotor 9 each have laminated cores 10 and 11, respectively.

[0097] Due to electromagnetic interaction of the winding system 7 of the stator 8, which is energized via the converter 50, with the rotor 9 via the air gap 25, the latter rotates around the axis 6.

[0098] To protect the permanent magnet 14, a layer 20 is arranged in series with the permanent magnet 14 in the respective magnetic circuits 22 of the rotor 9, as shown in FIG. 2. This layer 20 surrounds the permanent magnet 14 at least to such an extent that the field lines of the magnetic circuit 22 must pass through the layer 20.

[0099] In other words, layer 20 lies in the main flux direction of the dynamoelectric machine 1 or the rotor 9 (d-axis) and in series with the permanent magnet 14.

[0100] The layer thickness can vary and tends to be thicker at the edges of the permanent magnet 14 than in the center of the permanent magnet 14. As an example of a material for this layer 20, the magnetizing behavior of CeFeB can be mentioned, which exhibits the transition to the paramagnetic state at a Curie temperature of approximately 150°C and has a maximum opposing field strength (coercive field strength Hcj) of 50 kA / m at 20°C and 20 kA / m at 120°C.

[0101] The permanent magnet 14 is designed to be resistant to demagnetization under normal operating conditions and typically has a Curie temperature >300°C, which is significantly higher than its operating temperature (e.g., maximum operating temperatures (under load) are usually ~150°C). The permanent magnet 14 is made of neodymium-iron-boron (NdFeB) material. According to the invention, by actively influencing the magnetic circuit 22 based on the use of materials with these specific material properties, in particular by utilizing the Curie temperature, both a reversible intrinsic protection of the magnetic circuit 22 and a simple detection of a limit temperature of the permanent magnets 14 are achieved.

[0102] This layer 20 is either positioned directly on the permanent magnet 14 and simultaneously inserted axially into the recess 13 during the assembly of the permanent magnet 14, or it is inserted separately as a separate component. This material can also be added to an adhesive used to fix the permanent magnet 14 in its recess 13. In this case, too, the layer 20 would be located in the recess 13 and thus on the permanent magnet 14 in the main flux direction. If this layer 20 is provided in its own axially extending slot in the lamination stack 11, spaced apart from the recess 13, it can be designed as a malleable, plate-shaped element or as a potting compound with appropriate additives.

[0103] In addition to the advantage that these bridges 21 or holders counteract any demagnetization phenomena in the event of a short circuit of the winding system 7, these bridges 21 or holders are also suitable for positioning and fixing the permanent magnets 14 in the recess 13.

[0104] The permanent magnet arrangement of a recess 13 and / or a pole of the rotor 9 can therefore comprise one integrally formed permanent magnet 14 or several permanent magnets 14. The permanent magnets 14, with or without a layer 20, are in complementary contact with the air gap side 23 and / or the shaft side 24 of the recess 13. In other words, there is continuous contact, possibly with an adhesive layer / encapsulating compound, between the laminations and the permanent magnets 14.

[0105] The poles of the rotor 9 are arranged alternately with respect to their magnetization direction when viewed in the circumferential direction.

[0106] Openings 17 serve to reduce the inertia of the rotor 9, as well as to cool the rotor 9 and its permanent magnets 14.

[0107] The underlying idea of ​​the invention can also be applied to permanent magnet synchronous machines that have rotors 9 with permanent magnets 14 on their outer surface 18. These layers 20 are arranged radially below or above the permanent magnets 14, in other words, between the axis 6 of the rotor 9 and the respective permanent magnets 14 or between the permanent magnets 14 and the air gap 25. Specifically, the opposing field load on the permanent magnets 14 is reduced at a certain current state by increasing the magnetic resistance of the magnetic circuit. Thus, for example, a motor 1 can, with regard to demagnetization resistance, either carry higher maximum currents or, at a given maximum current, tolerate higher magnet temperatures.

[0108] This layer 20 initially provides a protective function, particularly for the permanent magnets 14. The activation of layer 20, with the associated changes in motor parameters (e.g., inductance or no-load voltage (EMF)), also enables the detection of overtemperature, for example, in the rotor 9 (e.g., via the inverter 50). Suitable detection is necessary to prevent further temperature increases through appropriate countermeasures or to actively initiate measures for temperature reduction.

[0109] The detection methods include, for example, determining the electromotive force (EMF) voltage amplitude during operation of the dynamo-electric machine 1 or determining the d-inductance of the rotor 9. These values ​​can be determined from the operating currents. The inverter 50 has 35 current transformers for control purposes, which reliably monitor the current of the motor 1. Furthermore, the voltage at the motor terminals is also known from the modulation level.

[0110] Both the voltage and the current of the dynamo-electric machine 1 can be transformed into complex space vectors for control engineering purposes. From the phase relationship and the amplitudes, the electromotive force (EMF), inductance, and phase angle (θ) can be determined. These values, forming an equivalent circuit of the dynamo-electric machine 1, particularly the synchronous machine, are sufficiently accurate to describe its operating state. Specifically, a complex impedance can be determined from the quotient of the voltage space vector and the current space vector. The real part of this impedance is a measure of the EMF, and the imaginary part is a measure of the inductance of the equivalent motor circuit.

[0111] Alternatively, or to increase the accuracy of these parameters, test pulses can be superimposed on the operating voltage. The test pulses of the inverter 50 are also suitable when the motor 1 is operating at no load. The resulting time profiles, e.g., the rate of change of the current at the time of the test pulse, can be used to determine the inductance and / or EMF and to decide whether the drive can be switched to its "normal state" or whether additional measures for temperature reduction need to be taken. In the simplest case, a change in the magnetic behavior of machine 1 can be detected via the EMF, since the flux is a factor in the magnitude of the EMF. A reduced EMF can be detected, for example, by the active current, indicating that the electric machine 1 requires a higher active current to maintain a required torque.

[0112] Alternatively or additionally, the changed behavior of machine 1 can be detected based on the altered reactive current used to generate the magnetic field. Since both active and reactive current affect the phase angle (<|), evaluating the phase angle provides a particularly robust parameter for detecting altered magnetic behavior.

[0113] Furthermore, the control unit 35 of the inverter 50 can validate implausible operating states by adjusting the inductance to the operating conditions. This makes it possible to achieve high control dynamics even in the event of a fault. In addition, it allows the temporal progression of thermal overload to be recorded. This makes it possible to determine whether the magnetic conditions are improving or becoming more critical and requiring further protective measures.

[0114] Upon detecting altered magnetic conditions, the drive's control unit 35 intervenes via the inverter 50 at the motor by reducing the power input to the dynamo-electric machine 1 or initiating an emergency shutdown due to motor overheating. It is essential to ensure that the rotor temperature decreases. This can be achieved, for example, by limiting the power, limiting the torque, changing (especially increasing) the inverter's switching frequency, or by applying forced cooling.

[0115] Knowing the equivalent circuit parameters allows conclusions to be drawn about the thermal state of the electric machine 1, in particular the rotor 9 and its permanent magnets 14. Based on this, or only after a further calculation of the corresponding temperature, the control unit 35 of the drive can intervene by reducing the power input, the torque to the dynamo-electric machine 1, changing the switching frequency of the inverter 50, or initiating a shutdown and / or emergency shutdown due to motor overheating.

[0116] This can also be achieved, if necessary, by forced cooling of the dynamo-electric machine 1 using external fans, which can be controlled by the control unit 35 associated with the inverter 50. The described process directly protects the magnetic material, i.e., the permanent magnet 14 in the rotor 9, by reducing the opposing magnetic field. Furthermore, by detecting changes 37 to the operating parameters 37 of the machine 1 (e.g., the current), it allows for the detection of temperature overruns by a corresponding detection algorithm in the supplying inverter 50. This is accomplished, for example, through simple measures such as overcurrent detection in the inverter 50.

[0117] This arrangement enables a two-stage protection system that meets high safety requirements. The primary protection provided by the materials used in the dynamoelectric machine 1 ensures its safety and protects it from damage. Furthermore, the converter-side protection intervenes in the operating behavior to prevent defects or a reduction in the service life of the dynamoelectric machine 1, particularly the permanent magnets 14 of the rotor 9.

[0118] Such rotors 9 are primarily used in permanent magnet synchronous machines operated in industrial environments. They serve as drives for pumps, fans, compressors, roller conveyors, and conveyor systems, with continuous operating times that place high thermal demands on the drive (especially the motor 1 and inverter 50), which are monitored according to the invention. Such synchronous machines can also be used in traction drives for mining vehicles, electric buses, trams, or trains to ensure more reliable operation, also by increasing the retarding field stability.

[0119] The idea underlying the invention can also be transferred to permanent magnet synchronous machines with external rotors, such as those used in directly driven generators of wind turbines.

[0120] The idea underlying the invention can also be transferred to other dynamoelectric machines 1 which have permanent magnets 14 in their rotors 9, e.g. synchronous machines with a starting cage or synchronous reluctance machines with permanent magnets 14. List of reference numerals

[0121] 1 dynamoelectric machine

[0122] 2 cases

[0123] 3 Storage sign

[0124] 4 bearings

[0125] 5 wave

[0126] 6-axis

[0127] 7 winding system

[0128] 8 Stator

[0129] 9 Rotor

[0130] 10 stator lamination stack

[0131] 11 Laminated rotor

[0132] 12 Cooling channel stator

[0133] 13 Recess in rotor for permanent magnets

[0134] 14 permanent magnet

[0135] 15 built-in fans

[0136] 16 slots stator

[0137] 17 Cooling opening

[0138] 18 Outer circumference of the rotor

[0139] 20 shifts

[0140] 21 Bridge

[0141] 22 Magnetic circuit

[0142] 23 Air gap side of the permanent magnet

[0143] 24 Axis side of the permanent magnet

[0144] 25 air gap

[0145] 34 River dam

[0146] 35 Regulation

[0147] 37 Energy and / or data exchange

[0148] 50 converters N North Pole S South Pole

Claims

Patent claims 1. Method for the thermal optimization of the operation of a dynamoelectric machine (1) powered by a converter (50) and a rotor (9) equipped with permanent magnets (14), wherein the rotor (9) has a magnetically conductive base body, in particular an axially layered laminated core (11), which provides permanent magnets (14) at least partially circumferentially and / or axially in substantially axially extending recesses (13), wherein one or more permanent magnets (14) form a pole (19) which forms a north pole (N) or south pole (S) in the direction of the outer circumference (18) of the rotor (9), wherein the conductive base body and the respective permanent magnets (14) each form part of a closed magnetic circuit (22), wherein means are provided in the magnetic circuits (22) which are magnetically arranged in series in the magnetization direction of the permanent magnets (14) and which protect the permanent magnets (14) from overheating and thus from irreversible damage Protect from demagnetizationwherein each pole of the rotor (9) or each permanent magnet (14) has a layer (20) such that the agent, when a predefinable limit temperature is exceeded, causes a material-specific influence on the magnetic circuit (22), wherein, -Changes to the EMC and / or -Change in the inductances (dL / dt) of the dynamo-electric machine (1), and / or -change in the phase angle <j>as phase shift between motor current and motor voltage or output current and output voltage of the inverter (50), and / or deviations from a stored flux model, in order to then initiate further temperature-reducing actions, such as at least current reduction, load reduction or emergency shutdown of the dynamo-electric machine (1) and / or switching on an external fan, in order to be able to switch on again thermally after a minimized time.

2. Method according to claim 1, wherein the exceeding of the limit temperature is determined by evaluating the motor currents.

3. Method according to claim 2, wherein the motor currents are compared to the output voltages of the inverter (50) to detect when the limit temperature is exceeded.

4. Method according to one of claims 2 or 3, wherein the exceeding of the limit temperature is detected by varying the amplitude of the output voltage of the inverter (50).

5. Method according to any one of claims 1 to 4, wherein the rotor angle of the electric machine is kept constant when the limit temperature is exceeded.

6. Method according to one of claims 1 to 5, characterized in that, in the event of thermally induced shutdown of the dynamo-electric machine (1) at the limit temperature of the permanent magnets (14) of the rotor (9), an early (re-)switch-on time is determined such that the converter (50) feeds test pulses into the machine, in particular when the electric machine is idling, in order to obtain the resulting -Changes to the EMC and / or -Changes in the inductances (dL / dt) of the dynamo-electric machine (1), and / or -changes in the phase angle <|) as phase shifts between motor current and motor voltage or output current and output voltage of the inverter (50), and / or -deviations from a stored flux model, to check and determine whether it is possible to switch to the “normal state” of the drive or whether additional measures to reduce the temperature are necessary.

7. Rotor (9) of a dynamo-electric machine (1) with permanent magnets (14) for carrying out the method according to one of claims 1 to 6, comprising a magnetically conductive base body, in particular an axially stacked laminated core (11), which provides permanent magnets (14) at least partially circumferentially and / or axially in substantially axially extending recesses (13), wherein one or more permanent magnets (14) form a pole which forms a north pole (N) or south pole (S) in the direction of the outer circumference (18) of the rotor (9), wherein the conductive base body and the respective permanent magnets (14) each form part of a closed magnetic circuit (22), wherein means are provided in the magnetic circuits (22) which are magnetically arranged in series in the magnetization direction of the permanent magnets (14) and which protect the permanent magnets (14) from overheating and thus from irreversible demagnetization,wherein each pole (19) of the rotor (9) or each permanent magnet (14) has a layer (20) which causes a material-specific influence on the magnetic circuit (22) when a predefinable limit temperature is exceeded, in order to avoid irreversible demagnetization of the permanent magnets (14), 8. Rotor (9) of a dynamoelectric machine (1) with permanent magnets (14) according to claim 7, characterized in that the thickness of the layer (20) is at least 0.5 mm.

9. Rotor (9) of a dynamoelectric machine (1) with permanent magnets (14) according to claim 7 or 8, characterized in that the layer (20) at least partially surrounds the magnetic pole (19) or the permanent magnet (14).

10. Rotor (9) of a dynamoelectric machine (1) with permanent magnets (14) according to claim 3 or 4, characterized in that the layer (20) is directly adjacent to the permanent magnet (14) or is spaced apart from it.

11. Rotor (9) of a dynamoelectric machine (1) with permanent magnets (14) according to one or more of the preceding claims 7 to 10, characterized in that the thickness of the layer (20) and / or the distance to the permanent magnet (14) is of a different nature.

12. Rotor (9) of a dynamoelectric machine (1) with permanent magnets (14) according to one or more of the preceding claims 7 to 11, characterized in that the layer (20) is formed from CeFeB.

13. Rotor (9) of a dynamoelectric machine (1) with permanent magnets (14) according to one or more of the preceding claims 7 to 12, characterized in that the permanent magnets (14) contain NdFeB.

14. Rotor (9) of a dynamoelectric machine (1) with permanent magnets (14) according to one of the preceding claims 7 to 13, characterized in that the recesses (13) of a pole (19) of the rotor (9) are arranged in particular tangentially or in a V-shape or in a double-V-shape or in a U-shape.

15. Dynamo-electric machine with a rotor (9) with permanent magnets (14) for carrying out the method according to one of claims 1 to 6, with a magnetically conductive base body, in particular an axially stacked laminated core (11) which provides permanent magnets (14) at least partially circumferentially and / or axially in substantially axially extending recesses (13), wherein one or more permanent magnets (14) form a pole which forms a north pole (N) or south pole (S) towards the outer circumference (18) of the rotor (9), wherein the conductive base body and the respective permanent magnets (14) each form part of a closed magnetic circuit (22), wherein in the magnetic circuits (22) means are provided which are magnetically arranged in series in the magnetization direction of the permanent magnets (14) and protect the permanent magnets (14) from overtemperature and thus from irreversible demagnetization, wherein each pole (19) of the rotor (9) or each permanent magnet (14) has a layer (20) which causes a material-specific influence on the magnetic circuit (22) when a predefinable limit temperature is exceeded in order to avoid irreversible demagnetization of the permanent magnets (14), wherein the thickness of the layer (20) corresponds to < 25% of the thickness of the permanent magnet (14) in the magnetization direction, wherein the magnetic circuit (22) interacts electromagnetically at least with a winding system (7) of a stator (12) of the dynamoelectric machine (1) and the permanent magnets (14) of the rotor (9) which is energized by means of a converter (50).

16. Drive with a converter (50) and a dynamoelectric machine (1) according to claim 15, wherein the limit temperature of the permanent magnets (14) can be monitored via a control system (35) associated with the converter (50) by, among other things, monitoring the predefinable motor parameters.

17. Conveyor system, compressor, compactor or traction drive with at least one drive according to claim 16.< / j>

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