CN1842952A - Efficient high-speed electric device using low-loss materials - Google Patents

Abstract

The invention relates generally to an electric device, such as an electric motor, a generator, or a regenerative motor, having a wound stator core made from advanced low-loss material. In preferred embodiments, the electric device is an axial airgap-type configuration. The invention provides an electric device having a high pole count that operates at high commutating frequencies, with high efficiency and high power density. Advanced low-loss materials exploited by the present invention include amorphous metals, nanocrystalline metals, and optimized Si-Fe alloys.

Description

Utilize the efficient high-speed electric device of low-loss material

The cross reference of related application

The application requires the provisional application No.60/444 respectively on January 31st, 2003 and submission on October 21st, 2003,271 and 60/513,892 priority.

Invention field

The present invention relates to be operated in the electric device of the high efficiency and the high power density of high commutating frequency.

Background of invention

Relate generally to electric device of the present invention, it includes, but are not limited to motor, generator, regenerative motor (collectively being called " electric device ", " calutron ", " motor " etc. herein).Term regenerative motor is used to refer to a kind of here or can be used as motor work, perhaps as the device of generator work.Described electric device can be one or more parts of composite set.An a kind of like this example of composite set is a compressor, and it comprises one or more motor, and wherein said one or more motor and ventilation blower constitute whole.The present invention preferentially relates to the efficient electric device with characteristic of having improved.The present invention more preferably relates to the efficient electric device that can be operated under the high-frequency.

The high frequency electrical device

Motor and generator industry are constantly sought provides efficient high and high motor and the generator of power density.The power of calutron is relevant with the frequency of described device, makes the power of described device increase and increase along with frequency.So, when the power that requires to increase, just wish to have the higher motor of some frequencies.The synchronizing frequency of synchronous machine usually can be expressed as f=S-P/2, and f is the frequency (Hz) of motor in the formula, S be speed (revolutions per second), and P is the number of poles of described motor.This shows that along with the speed raising of motor, frequency improves, power increases.Similarly, along with number of poles increases, the frequency of motor improves, and the power of motor increases.But point out following very important: along with number of poles increases, the variation of motor-field increases, and produces additional heat in motor, causes electric efficiency low thus.

The trial of making high-frequency electric machines (frequency is greater than the motor of 300Hz) in the past generally all relates at a high speed low number of poles down, because lower number of poles usually helps to reduce core loss, and the higher core loss that usually makes of number of poles increases.But the great core loss of seeing on the motor of traditional higher number of poles mainly is because the material of using in most old motors is siliceous 31/2% (by weight) or the Antaciron still less (Si-Fe) of being about traditionally.Specifically, traditional based on the Si-Fe material in, under the frequency greater than about 300Hz, the loss that cause in the magnetic field of variation heats the material to the degree that any acceptable device all can't cool off described device.Therefore, be difficult to realize commercial vital high-frequency electric machines always, therefore preferably can produce a kind of commercial vital high-frequency electric machines.The electric device that preferably also provide a kind of and can operate under the high frequency simultaneously, number of poles is high, the result draws the low cost/effective cost effective electric device high with power density of a kind of magnetic core magnetic loss.

Non-crystalline metal magnetic core

The appearance of amorphous metal and research are afterwards believed many people, and motor of making of non-crystalline metal magnetic core and generator have provides a kind of than the much higher efficient of traditional motor and generator and the potentiality of power density.Specifically, amorphous metal presents low loss characteristic likely, and the stator that many physiognomy credit non-crystalline metal magnetic cores are done can draw the higher motor of efficient.But the former trial that non-crystalline material is included traditional motor has all been failed, because these attempt just relating to simply in the lower motor of frequency with the ferrosilicon in the traditional magnetic core of non-crystalline material replacement.This improves electric efficiency, and loss reduces, but be accompanied by power output facet subsequently loss and with handle and form significantly improving of cost that non-crystalline material interrelates.

For example, U.S. Patent No. 4,578,610 disclose a kind of high-efficiency electric motor, and its stator is constructed by twining the amorphous metal band simply, wherein twines described amorphous metal tape, forms groove then, and the stator winding that matches is arranged in the described groove.

U.S. Patent No. 4,187,441 disclose the high motor of a kind of power density, and it has the stacked core of the spirality winding made from the amorphous metal band, has groove and is used for admitting stator winding.Described patent also openly utilizes laser beam to cut groove in the described amorphous magnetic core.

Although carry out great research in the use of motor around amorphous metal, but it is verified so far, the electric device that a kind of low loss material of utilization of easy manufacturing is provided with wanting cost/effective is very difficult, thereby many people have abandoned developing a kind of commercial vital trial with motor of non-crystalline metal magnetic core.Therefore, preferably provide a kind of efficient electric device, it has whole advantages of the particular characteristics that interrelates with low loss consumption material, thereby eliminates the shortcoming that interrelates with prior art.Best, described low-loss material be the brilliant metal of a kind of amorphous metal, millimicro, optimized Si-Fe alloys, crystal grain orienting based on the material of Fe or the material based on Fe of non-crystal grain orienting.

Brief summary of the invention

Calutron disclosed herein comprises such as the magnetic field component of rotor and stator module.Described stator module has the core material made from the low-loss high-frequency material.The best magnetic core of stator making with amorphous metal, millimicro crystalline substance metal, optimized Si-Fe alloys, crystal grain orienting based on the material of Fe or the material based on Fe of non-crystal grain orienting.The material based on Fe based on the material of Fe or non-crystal grain orienting of the brilliant metal of amorphous metal, millimicro, optimized Si-Fe alloys, crystal grain orienting is introduced electric device makes the frequency of described device can bring up to more than the 300Hz, only increase relatively in a small amount of core loss simultaneously (comparing) with enlarging markedly of being presented in the conventional motors, therefore, obtain a kind of income that the efficient electric device that increases power can be provided.The invention provides the efficient of the high power density that enhancing can be provided of a kind of number of poles, improvement and the efficient electric device of more foursquare torque-rate curve.

Disclose a kind of axial air-gap calutron, it comprises at least one stator module that comprises the whole magnetic core with some grooves.Stator winding twines described groove.Described whole magnetic core is made by the low-loss soft magnetic material, and described soft magnetic material is characterised in that: core loss is less than " L ", and L is provided by following formula in the formula: L=12fB ^1.5+ 30f ^2.3B ^2.3, L is to be the loss of unit with W/kg in the formula, f is to be the frequency of unit with KHz, and B is peak flux density (tesla).The example that is applicable to the low-loss soft magnetic material of magnetic core comprises amorphous metal, the brilliant metal of millimicro and optimized Si-Fe alloys.Described calutron also comprises at least one rotor assembly that comprises a plurality of rotor magnetic poles.Described rotor assembly is arranged to interact with described at least one stator magnet.In the running of described device, the frequency of described calutron is higher than 300Hz.

The accompanying drawing summary

Fig. 1: the illustration of stator structure;

Fig. 2: the illustration of stator winding;

Fig. 3: the illustration of rotor structure, the position and the polarity of expression magnet;

Fig. 4: the stator/rotor configurations illustration that is used for axialmode motor geometry;

Fig. 5: the relation curve of torque and speed, compare the performance of traditional motor and motor of the present invention;

Fig. 6: the chart of the relation of the core loss of different soft magnetic materials and magnetic flux density under the 0.4kHz;

Fig. 7: the chart of the relation of the core loss of different soft magnetic materials and magnetic flux density under the 1.0kHz;

Fig. 8: the chart of the relation of the core loss of different soft magnetic materials and magnetic flux density under the 2.0kHz;

Fig. 9: the chart of the relation of the core loss of different soft magnetic materials and frequency under 0.5 tesla;

Figure 10: the chart of the relation of the core loss of different soft magnetic materials and frequency under 1.0 teslas;

Figure 11: the chart of the relation of the core loss of different soft magnetic materials and frequency under 1.5 teslas;

Figure 12: utilize low-loss material to design the flow chart of the method for high speed axial airgap electric device efficiently;

Figure 13: the illustration of taking from the various sizes of the magnetic core that is used for Figure 12 method for designing; And

Figure 14: the surface curve of the demonstration of torque equation formula.

Detailed description of the invention

Hereinafter with reference to accompanying drawing the embodiment that the present invention recommends is described in more detail.The present invention relates to design and/or manufacturing such as the electric device of the brushless motor of stator core with the winding of making by low-loss material.Stator core preferably includes several advanced persons' low-loss magnetic material, comprise the brilliant metal of amorphous metal, millimicro, optimized Si-Fe alloys, crystal grain orienting based on the material of Fe or the material based on Fe of non-crystal grain orienting.Following paragraph provides the example of these advanced low-loss magnetic materials, and carries out brief discussion with regard to each example.Being defined as follows jointly of such advanced person's low-loss material.

Advanced low-loss material

Amorphous, millimicro crystalline substance, optimized Si-Fe alloys, crystal grain orienting introduced electric device based on the material of Fe or the material based on Fe of non-crystal grain orienting, make the frequency of motor can bring up to more than the 300Hz, simultaneously with utilize traditional core material, compare such as tremendous growth that core loss presents in the conventional motors of Si-Fe alloy, core loss just increases relatively in a small amount.The use of low-loss material makes exploitation can provide the power density of enhancing, the efficient of improvement, the high frequency with more square torque-rate curve, high number of poles electric machine to become possibility in stator core.

Amorphous metal

Amorphous metal also is called metal glass, and exists in many modes of planting different compositions.Metal glass is under non crystallized situation, is formed by rapid quenching alloy.Amorphous metal is different from other metals, and described material is extremely thin, that is thickness is 2 mils (mil) (an inch 2/1000ths) or littler, and extremely crisp, thereby makes described material be difficult to handle.It is a kind of that can be applied to suitable non-crystalline material of the present invention be Metglas  2605SA1, by Hitachi MetalsAmerica, (information that will obtain relevant Metglas2605SA1 can be referring to http://www.metglas.com/products/paEe5 124.htm) sells in Metglas Solutions company that Ltd company has.

With respect to traditional Si-Fe alloy, amorphous metal has some significant disadvantages.With traditional Si-Fe alloy phase ratio, amorphous metal presents lower saturation flux density.The result of lower magnetic flux density is power of electric motor density lower (according to the conventional method).Other shortcomings of amorphous metal are that they have the coefficient of heat conduction lower than traditional Si-Fe alloy.Because the coefficient of heat conduction determines heat is transmitted to the difficulty or ease of cool position, when the conductive coefficient that numerical value is lower can be given cool motors used heat (because core loss) biography is walked to cause more problem.Traditional Si-Fe alloy presents the magnetostriction coefficient lower than amorphous metal.Under the influence in magnetic field, the material that magnetostriction coefficient is lower stands less size and changes, and this itself causes the less motor of noise.In addition, amorphous metal is difficult to process with a kind of more worthwhile mode of situation usefulness price than traditional Si-Fe, that is, be difficult to punching press, boring or welding.

Although non-crystalline material has these shortcomings, such amorphous metal can be used for successfully providing a kind of motor that operates in (that is frequency is greater than about 300Hz) under the high-frequency.This is that the favorable properties of utilizing amorphous metal to be better than traditional Si-Fe alloy realizes.Described amorphous metal presents much lower magnetic hysteresis loss under high frequency, this causes core loss much lower.The much lower conductance of amorphous metal causes lower eddy current amplitude, and this also causes lower core loss.In addition, the tape of amorphous metal or sheet thickness are generally much smaller than traditional Si-Fe alloy, and this also causes eddy current and core loss lower.The use of amorphous metal can successfully provide a kind of electric device, by the shortcoming of compensation amorphous metal, utilizes the favourable character of amorphous metal simultaneously, and such as lower core loss, described electric device can move under high frequency.

Antaciron

As what here use, traditional Si-Fe relates to silicone content about 3.5% or littler Antaciron by weight.The 3.5 percetages by weight restriction of silicon is that described industry is owing to the bad metal material processed characteristic of the higher Si-Fe alloy of silicone content forces to add.Traditional other core loss of Si-Fe alloy grade that causes greater than the operation under the magnetic field of about 300Hz in frequency roughly is 10 times of amorphous metal, and this makes traditional Si-Fe material be heated to traditional motor can't be by the degree of any acceptable device cooling.But some other Antaciron of level is called optimized Si-Fe here, can directly use and produce high-frequency electric machines.

Optimized Si-Fe alloys is defined as the Antaciron rank that comprises by weight greater than 3.5% silicon.The optimized Si-Fe alloys of recommending comprises the silicon of about 6.5%+/-1% by weight.The target of optimization processing is to obtain a kind of alloy of core loss being reduced to the silicone content of minimum.These other features of optimized Si-Fe alloys level are that core loss and magnetic saturation are similar to amorphous metal.A shortcoming of optimized Si-Fe alloys is that they are somewhat crisp, and most of traditional metalworking technology all proves infeasible at the described material of processing.But, be similar to amorphous metal a little around the fragility and the machinability problem of optimized Si-Fe, be in close proximity to the method for designing that optimized Si-Fe is used and be used for the method for designing that amorphous metal uses.

The traditional rolling technique that is used to make traditional Si-Fe usually is not used for making optimized Si-Fe.But, can utilize other technologies known in the sector to make optimized Si-Fe.For example, the optimized Si-Fe alloys that can utilize grinding technology manufacturing known in the prior art to mill.But it has proved cannot accept large-scale production.Optimized Si-Fe alloys is also made by the proprietary vacuum vapor deposition technology of Japanese JFE Steel Corporation (company).The composition of iron or ferrosilicon is covered by silicon vapor under vacuum state, thereby silicon can be moved in the described material.Control described vacuum vapor deposition technology, so that reach optimum content 6.5%Si by weight.Though more crisp than traditional SiFe in the optimized Si-Fe alloys that obtains from vapour deposition, fragility is lower than the optimized Si-Fe of milling.Optimized Si-Fe can be buied from JFE, and commodity are called " super E magnetic core ", and sells as high-performance 6.5% silicon magnetic links.

The brilliant metal of millimicro

The brilliant material of millimicro is a polycrystalline material, and crystallite dimension reaches 100 millimicrons approximately.The attribute of the brilliant metal of millimicro is compared with traditional coarse grained metal, comprises the specific heat of the modulus of density, the reduction of the ductility of diffusivity, improvement of enhanced strength and hardness, enhancing and toughness, reduction, higher resistance, raising, higher thermal coefficient of expansion, lower thermal conductivity and good soft magnetic characteristic.Preferably the brilliant metal of millimicro is based on the material of iron.But the brilliant metal of millimicro can also be based on other ferromagnetic materials, such as cobalt or nickel.A kind of brilliant metal of exemplary millimicro that has low loss characteristic is the Finemet FT-3M of Hitachi.Other brilliant metals of exemplary millimicro with low loss characteristic are can be from the Vacuumschmeize GMBH ﹠amp of Germany; Co. (company) Vitroperm500Z of buying.

Crystal grain orienting and non-crystal grain orienting metal

With the known method of prior art to carry out the material that mechanical treatment can obtain crystal grain orienting based on the Fe material based on Fe.Crystal grain orienting is meant that the internal material characteristic is physically alignd in the operation of rolling, so that produce more and more thin metal, makes the crystal grain of material of gained volume have privileged direction of magnetization.The magnetization of crystal grain and magnetic domain is orientated on the direction of the operation of rolling.This magnetic domain orientation makes the upset of magnetic field orientating much easier, and the result has reduced the core loss on the recommended orientation.But, described core loss with the direction of the direction quadrature of described recommendation on increase, this may prove a shortcoming in electric device is used.

The material based on Fe of non-crystal grain orienting does not have the magnetic domain alignment direction of recommendation.The material based on Fe of described non-crystal grain orienting is not an amorphous, and it has a certain amount of degree of crystallinity.Current available traditional silicon steel has certain crystal structure, because it is slowly cooling, this causes crystallization to a certain degree, attenuation then.But with different such as the material based on Fe of traditional crystal grain orientings such as silicon steel, the material based on Fe of non-crystal grain orienting has more isotropic magnetization.

The material based on Fe that can be applicable to non-crystal grain orienting of the present invention preferably has the thickness less than 5 mils.

The low-loss material that definition is advanced

The core loss of soft magnetic material is usually expressed with the Steinmetz equation of following modification:

L＝a·f·B ^b+c·f ^d·B ^e

In the formula

L is loss, is unit with W/kg,

F is a frequency, is unit with KHz,

B is a peak flux density, is unit with the tesla, and a, b, c and d and e all are the loss coefficients to the uniqueness of described soft magnetic material.

Each top loss coefficient a, b, c, d and e usually can obtain from the manufacturer of given soft magnetic material.As what here use, term " advanced low-loss material " comprises and it is characterized in that core loss those materials less than " L " that L is provided by following formula in the formula: L=12fB ^1.5+ 30f ^2.3B ^2.3, in the formula

L is loss, is unit with W/kg,

F is a frequency, is unit with KHz, and

B is a peak flux density, is unit with the tesla.

Fig. 6-11 be provided under the different frequency of its scope from 0.4kHz to 2.0kHz with the different magnetic flux density of its scope from 0.5 tesla to 1.5 teslas under, the core loss of different soft magnetic materials is (by equation L=afB ^b+ cf ^dB ^eDefined) or with magnetic flux density or with the chart of the relation of frequency.The loss coefficient of each material shown in Fig. 6-11 is listed in the table below 1:

Table 1: loss coefficient

Loss coefficient	The isotropism powder, Hoeganes Somalloy 500 ,+0.05% Kenoube	The non-particulate orientation of Typical 26 gauge M19	Grain orientation, 0.014 " Othosil M6 29 gauge E1 1/2, Thomas ﹠ Skinner	The loss limit of " advanced material " definition
					a	40.27	11.39	38.13	12.00
B	2.15	1.62	2.37	1.50
					C	141.24	112.43	14.19	30.00
D	1.15	1.72	3.66	2.30
					e	1.46	2.01	2.14	2.30

Loss coefficient	Vapour deposition 6.5% Si, JFE Super E, 0.01mm	Amorphous Metglass 2605SA1, show and colour	The millimicro crystalline substance, VAC Vitroparm 500 Z	The millimicro crystalline substance, Hitachi Finemet FT-3M
					a	10.77	0	0	0.00
b	1.85	0	0	0
					c	7.83	6.5	0.84	1.05
d	1.93	1.51	1.5	1.15
					e	1.85	1.74	1	2.32

Each top material all is a soft magnetic material, at first comprises the alloy based on iron.Each coefficient of listing in the last table all is to draw from the manufacturer of described material or from the materials specification that the manufacturer of described material obtains, and described coefficient usually is included in the Technical Specification Sheet of described material.In order to reach this purpose, each manufacturer of soft magnetic material generally all participates in industry standard ASTM test program, and this produces the specification of described material, can calculate the coefficient that the Steinmetz equation is used thus.

As from Fig. 6-11 as can be seen, the threshold value of drawing line segment is so that show the loss equation formula of the loss threshold value that is used for definition " advanced low-loss material ".Its loss equation formula curve is higher than the material of this threshold value, is not " advanced low-loss material ".Its loss equation formula curve is defined as " advanced low-loss material " or " advanced material " here on this threshold value or the material below it.As from Fig. 6-11 as can be seen, advanced low-loss material includes, but not limited to amorphous metal, millimicro peritectic alloy and optimized Si-Fe.In disclosed following paragraph, with the high-efficiency electromagnetic motor of describing by such advanced person's low-loss material structure.Its scope of the graphical presentation that Fig. 6-11 provides is in frequency and the magnetic flux density of its scope from 0.5 tesla to 1.5 teslas of 0.4kHz to 2.0kHz, because these are typical ranges of motor operation described herein.But motor described herein is not limited in such scope operation.

General apparatus structure

The invention provides a kind of electric device, it comprises one or more stators and one or more magnetic field component, such as rotor.Described one or more stator is used forming based on the material of Fe or the advanced low-loss materials such as material based on Fe of non-crystal grain orienting such as the brilliant metal of amorphous metal, millimicro, optimized Si-Fe alloys, crystal grain orienting.In the embodiment that recommends, the stator of described electric device and magnetic field component are the axialmode configurations.

Figure 1A and 1B illustrate respectively according to the top view of the stator of one embodiment of the present of invention and end view.The tape of advanced low-loss material is wound in big annulus, so that form stator metal magnetic core 20.These tape general thickness are 0.10mm (0.004 ") or littler.When from described when axially watching, the annulus that is entwined by described tape has internal diameter and external diameter, and described internal diameter and external diameter have defined a known surface area that is called the gross area (TA).Then described metal magnetic core is processed and made it have groove 23, so that form the whole magnetic core of stator (following further go through).These grooves have reduced the surface area of metal magnetic core.

Figure 1A illustrates the internal diameter (d) and the external diameter (D) of described stator core 20, and the groove 23 with outer width (w) is shown in addition, and described groove has been processed in described metal magnetic core 20, so that form described stator.Remove the surface area that stays after the groove and be called the low-loss metal area.In the embodiment that recommends, described low-loss material is a kind of amorphous metal, and the low-loss metal area also is called amorphous metal area (AMA).Described metal magnetic core has inner periphery, and it defines internal diameter (d).Inner periphery is not continuous in the part that forms groove.But the inner periphery of these grooves is across the gap at groove place.These grooves are used for keeping stator winding.Each remainder of magnetic core inner periphery (that is, from each extension that back iron 24 stretches out) is called tooth 21.

Figure 1B illustrates the height (T) of tooth 21, and the total height (H) of it and stator 20 relatively.Total height comprises that the height of back iron 24 adds the height of tooth 21.The number of tooth 21 and groove 23 equates.In the embodiment that recommends, the narrowest part of tooth is not less than 0.100 inch.As known in the prior art, on stator processing during groove removed area can be packed and/or varnish compound or thin organic insulating material fill together with the stator winding of conduction.

As in the past pointed, stator core comprises advanced low-loss material, and in one embodiment, its structure is " integral body ".As used herein, structurally be that " whole " stator core is such stator core, it does not need the assembling of two or more subassemblies to finish described stator core.In addition, one-piece stator magnetic core disclosed herein still is " monomer " stator core.As used herein, term " monomer " is meant and is laminated from thin soft magnetic material tape, so that formation basic configuration, remove some materials from described basic configuration then, so that (for example form described stator core, make basic configuration form groove, so that on described stator core, form tooth).Unfortunately, advanced low-loss material is often extremely crisp, has proved that it is difficult forming the monomer stator core.Yet several companies comprise some manufacturer of advanced low-loss material, have utilized such as different technology such as wire edm, laser cutting, electrochemical milling or traditional processing by the such stator of advanced person's low-loss material manufacturing.

Although stator core described herein is integrally-built monomer stator core, the non-integral of different types and stator core non-monomer are also intended the usefulness for motor described herein.For example, the section of being divided into subsequently, making the gained stator core is not that " whole " " monomer " stator core also is possible.Similarly, the form that can be molded as stator core by the material with the advanced person forms " integral body " stator core (comprising any tooth), but, because described stator core is not to form basic configuration by thin tape winding, remove some materials from described basic configuration subsequently, so the stator core of gained can not be " monomer " as a result.

Fig. 2 illustrates the stator core 20 of the monomer of an integral body of having twined stator winding 22.The stator 20 that has twined stator winding 22 sets in the annular outer cover, and encapsulates with suitable organic dielectric.Can connect into common magnetic section to a plurality of grooves with wire, make it to be about 0.5 corresponding to the value of every extremely every phase place slot number (SPP), the SPP ratio is the number of phases and the DC number of poles (SPP=slot number/number of phases/number of poles) of stator core groove number divided by stator winding in the formula.The area of the formation groove that is taken by winding not, that is encapsulation, varnish and insulating material area are useless areas (WA).Difference between the gross area and the useless area is called useful area.In the embodiment of a recommendation, SPP=0.5 in the formula distributes the useful space of twining or to approach described percentage for 35%+/-10%, and it optimizes the power density (watt output)/(cubic centimetre) of motor.This percent value is in constant fundamental frequency and is applied under the supposition of the constant number of ampere turns on each stator tooth and provides.By same calculating, under same supposition, obtain different percentage 50%+/-10%.So that optimize the torque of the effective material of every kg.

Any suitable material that can support suitably that described stator is arranged may be used to described annular outer cover.Although annular outer cover is preferably nonmagnetic, without limits to the conductance of annular outer cover material.Other factors also can influence the selection of annular outer cover material, such as requirement of mechanical strength etc.In a specific embodiment, described annular outer cover is formed by aluminium.

Magnetic field component is arranged near the stator body, and described magnetic field component disposes and is arranged in and stator magnet interacts, and is total as prior art.Fig. 3 A and 3B illustrate a kind of top view and end view of magnetic field component of form of axial type rotor 30 respectively.Rotor 30 is the center with described stator with common axle 31.Fig. 3 A illustrates a plurality of magnets 32 and has alter polarity, is positioned at peritrochanteric.In different embodiment, the location of magnet 32 and polarity can change according to the needs of motor designs.In the embodiment of a recommendation, described rotor comprises a plurality of permanent magnets.Fig. 3 B illustrates the end view along the straight line A of Fig. 3 A intercepting of described rotor.In the embodiment of the illustrational rotor of Fig. 3 B, magnet 32 extends to the thickness of rotor 30.In other embodiments, magnet 32 does not extend to the thickness of rotor 30.The arrangement of described rotor is a dish type preferably, and perhaps the axialmode rotor comprises the super permanent magnet (for example, such as rare-earth magnets such as cobalt rare-earth magnet or NdFeB) that radially separates each other, and each all has the opposite end of definition north and south poles.Support magnet 32 like this, make it around the rotation of the axis (along common axis 31 or any other suitable configuration) of axle (not shown), so as each magnet extremely can be along predetermined path near stator structure.The magnet area of rotor 30 has external diameter and internal diameter, and described internal diameter forms inner cavity 34.In the embodiment of recommendation that relates to the configuration of a kind of rotor and stator shaft orientation type, the external diameter of rotor 30 and internal diameter be identical with stator 20 basically.If the external diameter of described rotor 30 is greater than the external diameter of stator 20, then the outside of described rotor is inoperative to performance, and only gains in weight and inertia.If the external diameter of described rotor is less than the external diameter of stator, then consequently performance reduces.

When calculating the SPP value, magnetic pole is meant and the synergistic DC magnetic field, magnetic field that is changing.Therefore, in described preferred embodiment, permanent magnet is contained in DC magnetic field is provided on the rotor, draws the DC number of poles thus.In other embodiments, the DC electromagnet provides DC magnetic field.The electromagnet of described stator winding provides the magnetic field that is changing, that is, along with time and position and the magnetic field that changes.

In different embodiment, magnet is installed on the described rotor or its inside.Described magnet can separate each other like this, makes between the magnet that replaces on the circumference very close to each other.Interval between the magnet preferably remains on optimum value, it make torque cogging reduce to minimum.The torque cogging is after input current reduces widely, and is in zero point or rpm low-down the time at described axle, and torque changes along with the position, and this causes undesirable performance and acoustic problems.A kind of reckoning of optimal spacing is, at first the low-loss metal area of stator 20 divided by stator groove number, so that obtain the area of each single metal tooth.So the described optimal spacing between the magnet is such value, it makes the gross area of each magnet equal the 175%+ of magnetic core toothed area/-20%.

Although described magnet is described as permanent magnet, this is not a requirement.Described magnet can be the magnetic material of other types, perhaps, and in other embodiments, can be electromagnet, induction machine etc., in addition, although under the environment of dish type or axialmode embodiment described device has been discussed usually, electric device of the present invention is not limited to the axialmode device.But it can such as barrel-shaped or radius type motor, have the rotor magnet on the excircle that is positioned at the radius rotor in very wide various configurations.In addition, the magnet numbers that separates each other of crossing rotor structure can change, and still falls within the scope of the invention simultaneously.

Fig. 4 illustrates the end view of an embodiment of electric device, it comprises two stator cores 20 that are positioned in the axialmode configuration, two stator cores 20 respectively the either side of single rotor 30 and with single rotor 30 along common central axis 31, described single rotor 30 is 20 services of two stators.Winding 22 is wrapped on the stator 20.In a particular embodiment, have been found that and comprise and comprise Metglas@, present high power density at the electric device of the stator core of single rotor both sides.Fig. 6 to 29 illustrates the detailed design specification according to electric device specific embodiment of the present invention.The change of Fig. 6 to 29 detailed design specification comprises the change of each size of components, not even with giving locking assembly, will be conspicuous to those skilled in the art perhaps, and still fall within the scope of the invention simultaneously.

In above-mentioned preferred embodiment of the present invention, described stator arrangement comprises two stator cores, and they are positioned near the two opposite sides of rotor structure.But, be noted that in order to satisfy the requirement of the application want need what additional alternately stator and rotor arrangements, electric device of the present invention just allow overlapping what.Therefore described stator casing, only needs to describe a stator core in detail and gets final product generally each other in mirror image.

The performance characteristics of electric device is preferably optimized jointly according to the performance that described motor requires.The example of performance characteristics is included in commutation under the high frequency, keeps low inductance and keeps low speed control.In order to obtain maximum performance from so a kind of axialmode electric device, power electronic circuit is a key component.Bad power electronic circuit can cause power electronic circuit (PE) ripple, undesirable cogging in a kind of electric device running, and it has passive influence to performance.

Utilize number of poles, the high frequency design of low-loss material

In the embodiment of a recommendation, the invention provides a kind of motor, have high number of poles, operate under the high frequency, that is, greater than about 300Hz.Have high number of poles and also operate in electric device under the high frequency for a kind of, it is not that prior art is known.Utilize the known devices of traditional Si-Fe under the magnet rate that is higher than 300Hz significantly, to switch, because core loss is caused in the magnetic field that is changing, wherein core loss cause described material to be heated to described device can't be by the degree of any acceptable device cooling.Under some state, in any case the heating of traditional Si-Fe material even may will destroy voluntarily seriously to being enough to that described motor all can't be cooled off.But, determine, advanced low-loss material, comprise the low loss characteristic based on the material of Fe or non-crystal grain orienting of the brilliant metal of amorphous metal, millimicro, optimized Si-Fe alloys, crystal grain orienting, make the switching frequency more much higher become possibility than traditional Si-Fe material based on the material of Fe.Although in one embodiment, the system constraint that heating brought when described stator core used Metglas to eliminate the high frequency operation, described rotor design can also improve, so that utilize these characteristics of low-loss material.

For given device, high number of poles is a relative term.The number of poles of device of the present invention is a variable based on motor size (constraint of physics) and estimated performance scope.Number of poles can increase to flux leakage always and be increased to undesirable value, and perhaps less number of poles draws the performance of improvement.Stator also presents mechanically restriction to the rotor magnetic pole number, because the stator groove must be consistent with rotor magnet.Aspect the groove number that may form at described stator, also exist mechanically with electromagnetism on restriction, this becomes with the frame size of motor again itself.Under the suitable balance of copper and Metglas, for given rotor frame, certain border can be set, determining the upper limit of slot number, during the good axial gap motor of manufacturing property, this can be used as a parameter and uses.The invention provides the big 4 or 5 times motor of the industry value of some numbers of poles motor pole number more traditional than major part.

As example, industrial typical motor has 6 to 8 utmost points, is about 800 to 3600rpm motor for speed, and commutating frequency is about 100 to 400Hz.Described commutating frequency (CF) is that rotary speed multiply by extremely right number, in the formula extremely right number be number of poles divided by 2, and rotary speed unit is revolutions per second (CF=rpm/60x number of poles/2).In addition, industrial available be high number of poles greater than about 16 utmost points, but speed less than 1000rpm, this is still corresponding to the frequency less than 300Hz.As another program, also have the motor of number of poles low relatively (less than about 6 utmost points), speed is up to 3000rpm, and this still has the commutating frequency less than about 400Hz.In different embodiment, the invention provides some motors, for example, and 96 utmost points, 1250rpm is under 1000Hz; 54 utmost points, 3600rpmrpm is under 1080Hz; 4 utmost points, 30000rpm is under 1000Hz; And 2 utmost points, 60000rpm is at 1000Hz.Therefore, motor of the present invention is compared with " standard " motor, provides to exceed 4 or 5 times upper frequency.When being operated in same velocity interval, motor of the present invention is more effective than described industrial typical motor, and the result is, more speed selection is provided.

The method for designing of recommending

The design characteristics that the different preferred embodiment of a kind of definite the present invention is used determines that method is shown in Figure 12.The method for designing that Figure 12 proposed is according to such understanding, that is, and and by using less relatively variable-definition in conjunction with equational manipulation, axial air gap electric machine.By with the least possible variable-definition motor, some variable may maximize, and motor may be optimized under a given speed.The design of the method representation of Figure 12 a kind of under given speed the method for the axial air gap electric machine of torque optimization thereby power optimization.In order to design such motor, described motor must at first be reduced to single equation, and it represents the torque of motor with the least possible variable.In present method, determine that the torque of axial air gap electric machine can be expressed according to following equation:

$\mathrm{\τ}=\frac{1}{24}\·j\·2^{\frac{1}{2}}\·(-\mathrm{\λ}\·D\·\mathrm{\π}+h\·t+x\·t)\·L\·\mathrm{pf}\·D\·(-D\·\mathrm{\π}-D\·\mathrm{\π}\·{\mathrm{\λ}}^2+2\·\mathrm{\λ}\·D\·\mathrm{\π}-2\·h\·t+2\·h\·t\·\mathrm{\λ})\·B$

In the formula,

The output torque of τ=motor, Nm;

The j=current density, A/mm ²

The external diameter of D=stator, mm;

H=inner radius magnetic core point facewidth degree, mm;

Total slot number of the every stator of t=;

Total groove width of discarding owing to insulation in the described stator of x=, mm;

The pf=packing factor is as the percentage of groove filling;

The axial length of L=winding, mm;

The B=peak flux density, tesla;

Above-mentioned several variable is used in the figure of Figure 13.

As finding out, 9 variablees are arranged from aforesaid equation.But when when any design example, many in these variablees will be fixed values, be constant.For example, in aforesaid equation, suppose according to designed motor type, j, x, pf, L and B are really immovable.This remaining X, D, h and t only have several variablees as what will handle.As discussed below, the designer selects D and t value according to the flexibility of design then.So equation of the relation of remaining torque and h and λ.To draw surface chart from so equational curve chart, as shown in figure 14.Then, if the designer described torque equation formula to the λ differential, he or she can be provided with the gained equation and equal 0, and obtains λ.Separating of being drawn between 0 and 1 provides a torque to given input optimization, (because, by defining only can exist between 0 and 1).

As shown in figure 12, summarized above-mentioned method for designing among the figure.As shown in figure 12, the designer of motor supposes that a kind of its stator comprises the axial air gap electric machine of advanced low-loss material.The designer selects the high-end speed that requires then.Then, the synchronizing frequency of selecting about 1000Hz to require as described motor, f=SP/2 calculates number of poles according to equation, and S is the high-end speed of service of described requirement in the formula, and P is a number of poles.Then, utilizing the number of poles of calculating is 0.5 with the every extremely every slot number mutually of the described motor of supposition, as discussed below, as a preferred embodiment, can calculate the slot number of stator.The external diameter of described motor is selected in purposes as requested and restriction.This remaining h and k will be according to the torque equation formula decisions that provides above.Described then torque equation formula is carried out differential to λ, and the setting of gained equation is equaled 0.Solve λ from described equation then.Separating of drawing between 0 and 1 provides a torque to all given input optimization.

As above-described, above-mentioned method for designing provide a kind of effectively and utilize efficient, high power, preferred embodiment of high-speed electric device of advanced low-loss material.Certainly, can outside the embodiment of described recommendation, under the situation that does not break away from the spirit and scope of the present invention, imagine other embodiment and design.

Every extremely every phase slot number ratio

In the embodiment of a recommendation, the invention provides the motor that a kind of SPP ratio optimum equals 0.5.In the embodiment of a recommendation, the invention provides threephase motor.For threephase motor, the rotor magnetic pole number is 2/3 of a stator slot number, and slot number is the multiple of the number of phases.Although three-phase (star connection) is an industrial practice, the present invention does not get rid of the employing delta connection.

On the one hand, the SPP ratio with very high number for example, about 6 beginnings reduce to 0.5, electric device shows sizable torque cogging, power electronic circuit (" PE ") ripple and high noisy level.As previously mentioned, cogging and PE ripple all produce the change of torque, and the latter has undesirable influence to the performance of described electric device.

Traditionally, focus is to make a kind of magnetic core slot number to increase and the device of rotor magnetic pole number minimizing always, and it reaches SPP ratio 1.0 to 3.0, the electric device of provide with better function, noise is less.But though because winding distributes better, the motor that moves under greater than 1.0 SPP ratio provides smoother output, the influence of the terminal number of turn that they are increased.The terminal number of turn is in the wire part in the stator torque and the power of described motor to be exported inoperative part.In this sense, they are undesirable, and they have increased cost and have caused the ohmic loss of motor, and do not bring benefit simultaneously.Thereby described motor designs person's a target is that the terminal number of turn is reduced to minimum, and the motor that provides a kind of noise and cogging to be easy to control.

Preferably wish in the about 0.5 time operation of SPP ratio, because consequently obtain the minimum electric device of a kind of terminal number of turn.Generally, terminal each circle is shorter, causes more effectively utilizing copper product, and torque may improve, though torque perturbation (cogging) increases.The embodiment of axial arrangement of the present invention is from can not get benefit greater than the 1.0SPP ratio, and obtains better performance under the condition of 0.5 SPP.In addition, provide the higher relatively number of poles of described motor and 0.5 or lower SPP ratio here, it is lower with cost that the magnet of described rotor (with rotor structure usually) may be done thinly.

Might utilize wire that a plurality of grooves are connected into common magnetic section, this is to be defined by the SPP greater than 0.5.This is the result of stator slot number more than the rotor magnetic pole number, produces a kind of distributed winding.The value of SPP is less than or equal to 0.5 and shows there is not distributed winding.Convention on the industry is the distributed winding that comprises in the stator.But distributed winding rises the value of SPP, and frequency reduces.The result is in traditional SPP=0.5 and low-frequency motor, still to have low number of poles.SPP=0.5 adds low number of poles, and the result is the extremely difficult control of cogging.

The motor that makes up a kind of mark SPP is favourable, because such motor may use preformed winding, on single stator tooth.In different embodiment, the SPP ratio is 0.25,0.5,0.75,1.0 or greater than 1.0.In the embodiment of a recommendation, the SPP ratio is 0.5.

Flexibility on wiring/design of Windings

Another advantage of device of the present invention is that it allows manufacturer to utilize different wiring configurations.Traditional stator design restriction design of Windings is selected, and is 1.0 to 3.0 focus because utilize the SPP ratio, and this requirement distributes winding on a plurality of grooves.This becomes and is difficult to have winding option greater than 2 or 3 distributed windings.The invention provides the ability of utilizing the SPP=0.5 design, general each stator tooth has only a discrete winding in the formula.But the present invention does not get rid of other SPP=0.5 devices.Single tooth winding can easily be revised, and reconnects, so that any voltage request of given purposes is provided.So,, can provide scope broad solution simply with single group of motor hardware as long as change winding.Usually, winding is the assembly of easy change in the electromagnet loop.

So, given one near 0.5 SPP ratio, as in device of the present invention, in the stator winding configuration, huge flexibility is arranged.For example, manufacturer can be independently of one another each stator, and perhaps manufacturer can provide the stator winding of separation in same stator.This ability is the advantage that SPP equals 0.5 system.Although there is industrial system to use SPP=0.5 once in a while, they are not extensively to adopt, and only successfully obtain satisfactory result in suitable application places yet.The system that the present invention successfully provides a SPP to equal 0.5, it is got ready for the flexibility on this winding.

Hot property

Utilize traditional Si-Fe alloy but also comprise that one of characteristic of restraint device output is a used heat in the whole electric devices based on the material of Fe based on the material of Fe or non-crystal grain orienting that utilize amorphous metal, the brilliant metal of millimicro, optimized Si-Fe alloys, crystal grain orienting not only comprising.Used heat has some kinds of sources, comprises (but being not limited to): the rotor loss that eddy current causes in ohmic loss, become skin and closing effect loss, magnet and other rotor assembly and the core loss of stator core.Because produce a large amount of used heat, traditional motor reaches the capacity limit of their discharging used heat soon." the continuous power limit " of traditional motor often can be operated continuously by motor, and the maximal rate of whole used heat of the generation that still can dissipate is simultaneously determined.The described continuous power limit also becomes with electric current.

But, the used heat that produces in device of the present invention is less, because the brilliant metal of amorphous metal, millimicro, optimized Si-Fe alloys, crystal grain orienting has the loss lower than traditional Si-Fe based on the material of Fe or the material based on Fe of non-crystal grain orienting, thereby the designer can be by improving frequency, speed and power, utilize these low loss characteristic, then the ohmic loss that increases of core loss that correctly balance is lower and possibility and between them, carry out " transaction ".

Generally, for the power same with traditional motor, motor of the present invention presents lower loss, thereby higher torque and speed, as what illustrate at Fig. 5 and discuss in more detail below.

Therefore, device of the present invention can reach the continuous velocity limit higher than traditional motor.

Raise the efficiency

An advantage of the invention is it to make the maximizing efficiency of device and keep the ability of cost/effectiveness simultaneously.Definitions of efficiency is that the power output of device is imported divided by power.The result who operates in the ability under higher commutating frequency and the high number of poles simultaneously of the present invention has low core loss and high power density.The high frequency limit of 400Hz is a kind of industry standard, and practical application is even arranged, also seldom.

The efficient of performance of the present invention and raising is not to use a kind of simple intrinsic feature when replacing traditional Si-Fe such as low-loss materials such as amorphous metals.From the viewpoint of history, there is the people once to attempt before about 15 years, but fails to meet performance requirement (comprising overheated lower) with power.This failure be with a kind of only at traditional material (for example, by weight Si-Fe have 3.5% or littler Si) design or mode that it is suitable for is adopted the result of new material (amorphous).This early stage performance failure, the sensorial cost that is processed as motor with amorphous metal combines, and makes that the whole companies of almost described industry all abandon this research.The present invention also utilizes the electric rotating machine based on the properties of materials of Fe based on the material of Fe or non-crystal grain orienting of the brilliant metal of amorphous metal, millimicro, optimized Si-Fe alloys, crystal grain orienting by design, overcome described performance failure.Consequently, a kind ofly under commutating frequency, move, have high number of poles, the motor of whole advantageous feature of high efficiency and high power density greater than 400Hz.And simultaneously other traditional methods have only allowed to the invention provides the motor that presents whole four characteristics simultaneously in conjunction with two in described four characteristics.

Other advantages of the present invention are to reduce loss in efficiency significantly, comprise magnetic hysteresis loss.Magnetic hysteresis loss is caused by the impedance magnetic domain wall movement in crystal grain orienting Si-Fe alloy magnetization process, and it can cause the overheated of magnetic core.The result who raises the efficiency is that motor of the present invention can reach bigger continuous velocity scope.Described velocity interval problem description is the area below the torque rate curve.Traditional motor is subjected to them or provides low torque (small-power) in high-speed range, and perhaps lower speed range provides the restriction of high torque (HT).The present invention successfully provides the motor of high-speed range high torque (HT).

Table 2: the comparison of design parameter and performance

	Cylindrical no iron core band magnetic core 1Dish-type 2	Motor example 70-32 of the present invention 3Motor 4
			Power, kW	10 10	10 12.4
Speed, rpm	750 750	750 750
			Torque, Nm	133 131	131 158
Efficient	91.4％ 92.5％	92.3％ 92.1％
			Current density, (Jnns) A/mm2	4.2 4.2	9 10
The permanent magnet quality, kg	1.57 12.4	2 1.9
			Effective quality of materials, kg	41 22.5	23 13.8
The effective material of W/kg	244 444	435 899
			Cost, all material is disregarded the labourer	$588 $1,232	$440 $224
Frequency	100	225 400
			Winding, external diameter (OD), mm	360	300 360
Equate thermal rating power	Natural cooling	1W/in2

¹Traditional iron core motor (providing data) by people such as Gieras

²People's such as Gieras no iron core collar plate shape design

³Under the situation not according to the present invention's redesign, 70-32 is reduced to 750rpm

⁴As example electric motor disclosed herein, press people's such as Gieras same external diameter redesign

Table 2 provides people's (on July 2nd, 2002) such as motor of the present invention and Gieras at the disclosed 10kW of IEEE, the no magnetic core collar plate shape permanent magnet brushless motor of 750rpm, with a kind of 10kW of equivalence, the comparison of the stator that 750rpm is traditional and the design parameter of rotor magnetic core and performance.Just as shown in table 2, example electric motor according to disclosed principle design here, provide and equate or bigger power, same speed, equate or big torque, roughly the same efficient and bigger current density (result is lower core loss).Compare with people's such as Gieras motor or traditional motor generally, motor of the present invention also uses less permanent magnet material and in fact, less effective material.Table 2 also represents, compares with people's such as Gieras system, and the effective material of per kilogram of the present invention provides and equates or torque preferably, and with similar thermal rating power, cost is lower and operate on the much higher frequency and (be twice).This is to finish by the favourable characteristic of utilizing the amorphous metal that this embodiment uses.

Table 3: the comparison of design parameter and performance

	IM a IPM c AFTPM d RTFTPM e (NdFeB) (Ferrite) (Ferrite)	Electric motor I fElectric motor I I g
			Power (HP)	3 4.96 1.18 2.98
Kw	2.2 3.7 0.9 2.2	2.6 6.8
			Torque (Nm)	12.18 20.2 3 11.78	14 36
Speed	1755 1750 2800 1800	1800 1800
			Volume (cm3)	8092b 10391 1272 2730	6919 8042
Weight (kg)	35.4 48 5.5 11.76	5.2 12.8
			Torque/quality (Nm/kg)	0.34 0.42 0.55 1.00	2.69 2.81
Torque/volume (Nm/cm3)	0.0015 0.0019 0.0024 0.0043	0.0020 0.0045
			Efficient	82.5％ 88.0％ 83.0％ 87.1％	87.9％ 92.1％

A GE motor, model are #5K182BC218A, the data that people such as Qu provide

The space that b deduction fan and radiator are used

C Yasakawa Electric Co. (company) motor, the data that people such as Qu provide

D is by Federico Caricchi design, the data that people such as Qu provide

E radius-magnetic flux, annular is twined, and the permanent magnet motor is designed by people such as Qu

The torque of f per unit mass

The torque of g per unit volume

Table 3 provides motor of the present invention and birotor, radius-magnetic flux, annular to twine permanent magnet motor (RFTPM), and people such as Qu (on July 2nd, 2002) are in disclosed motor of IEEE and commercial induction motor (IM) and interior permanent magnet motor (IPM) and the design parameter of axial magnetic flux annular winding permanent magnet motor (AFTPM) and the comparison of performance.Two kinds of electric motor I and electric motor I I operate under frequency 1000Hz, have about 13cm external diameter and similar thermal rating power (1.0-1.45W/in ²).Table 3 expression motor of the present invention provides bigger torque for given speed and with greater efficiency.

Utopian square torque-rate curve

The invention provides a kind of electric device, it is with more foursquare torque-rate curve operation.Fig. 5 a represents situation 1: the torque-rate curve of motor and traditional motor designed according to this invention, and its medium velocity is drawn on the horizontal axis, and torque is on vertical axis.Selected number of poles is 8, although any number of poles can be elected to be the device of comparison.Be preferably in the motor and can reach any torque for any speed, this is depicted as the rectangle or the area of described motor operation.

Because the thermal loss that torque (vertical axis) is caused by ohmic loss limits, traditional motor can only form square torque rate curve for percentage of given free space.In addition, speed (trunnion axis) is subjected to increasing progressively frequency limitation, and as previously discussed, this also makes the core loss in the material increase progressively.In other words, if traditional torque-rate curve of the motor of analysis conventional, people can obtain one and be similar to the curve shown in Fig. 5 a.Under the contrast, although there is similar torque in motor of the present invention, compare with traditional motor, because the loss relevant with frequency is much lower, velocity interval has been widened widely.

Fig. 5 b represents situation 2: having redesigned according to motor of the present invention is 36 utmost points, so that utilize the benefit of high frequency operation, advises as the present invention.Allow described core loss to have such value, make the new speed limit that can reach be similar to the speed limit of traditional motor.But as the result of high frequency generation electromotive force (EMF), in motor of the present invention, therefore the corresponding ohmic loss of given torque, is being no more than under the situation of thermoae limit than much lower in traditional motor, allows the torque of increasing motor of the present invention.Therefore, utilize the result of the characteristic of described low-loss material to be, performance of the present invention surpasses traditional motor.

Electric device of the present invention provides a kind of torque-rate curve, compares with traditional device, and the area below the described curve increases greatly.The area that increases under described curve shows, can reach more and bigger purposes now for given design.Known power increases along with speed is linear.As provided by the present invention, increase of device speed and torque are constant, and described device has bigger power density, that is, more powerful for fixing size.Under the situation 1 that presents in the above and the 2 two kind of situation, motor performance of the present invention all is better than traditional motor.

Total harmonic distortion

Another advantage of the present invention is that device of the present invention produces the low clean and tidy sine curve of total harmonic distortion (THD) when the magnetic pole of rotor arrangement is crossed over the magnetic pole of stator.THD is undesirable, because it causes additional flowing with unproductive electric current, the latter itself causes additional heating again.Low THD is relative, " good " design always less than 5%, and can require to be lower than 1%.In addition, some the regulation THD of regulatory authority threshold value if do not obtain the approval of regulations, can not surpass described THD threshold value.For example, in order to obtain the ce mark in Europe, must satisfy certain THD value.

0.5 SSP ratio help to produce more sine-shaped output, can improve described output by means of one step of electronic circuit machine.Since the present invention use the brilliant metal of amorphous metal, millimicro, optimized Si-Fe alloys, crystal grain orienting based on the material of Fe or non-crystal grain orienting based on the material of Fe so that advantageously use the optimum value of SSP=0.5, therefore by considering suitably to use described material, can obtain the 3rd benefit of low THD.

Example

According to a kind of motor of above-mentioned motor conceptual design.The magnetic core of described motor is made by Metglass  alloy 2605SA1, and forms groove, has 54 teeth that equidistantly separate each other.Stator winding is single layer coil 26+/-1 circle, and resistance is about 0.011 Ω under the room temperature.Rotor assembly is made of 36 rotor magnets, is arranged on the rotor flat board alternating polarity.Rotor magnet is rare earth/iron/boron magnets, and the ceiling capacity product is greater than 36MGOe, and inner coercive force is greater than 21kOe.This motor properties characteristic is listed in following table 4:

Table 4: exemplary performance

Inverter 320 Vrms circuits

80852 watts of effective outputs

Shaft torque 214 Nm

Speed 3600 rpm

Efficient 94%

The motor cooling liquid

Number of pole-pairs 18

Every stator slot number 54

The motor overall dimension

External diameter 308 mm

Length 117 mm

Electric, phase characteristic

Ke 66 Vrms/krpm circuits

Ke 0.363 V-s

The THD 2.9% of Ke

Resistance 11.8 m-ohm

Inductance 85.8 μ H

Effective quality of materials

NdFeB magnet 2.0 kg

Copper 3.7 kg

Amorphous metal 19.1 kg

Those skilled in the art is not difficult to recognize that the present invention is very suitable for reaching target, and obtains above-mentioned purpose and advantage and its intrinsic advantage.Electric device described herein as the embodiment of the current recommendation that presents, is exemplary and do not plan to limit the present invention.The professional and technical personnel can expect change and other purposes wherein, and these all are included in the spirit of the present invention, by the scope definition of claims.

Those skilled in the art be it is evident that, under situation about not departing from the scope of the present invention with spirit, can make change, substitute and revise the present invention disclosed herein.For example, although described axial gap motor here, can design the motor of other types according to principle disclosed herein, such as radius clearance motor or linear electric machine.

In addition, motor can comprise the motor beyond the plurality of permanent magnets motor, such as induction machine, synchronous machine, synchronous magnetic resistance motor, switched reluctance machines and direct current magnet motor.In addition, the rotor of other types and/or stator winding scheme are all within the scope of the present invention.So such additional embodiment is in the scope of the present invention and following claims.

This paper has described assembly or restriction, described assembly or restriction have various different possible number or the size that interrelates with described assembly or restriction, in additional embodiment, assembly or restriction are in the certain limit, stipulate described scope by get any two values from the special value that the end points as described scope provides.Described scope comprises end points, unless spell out opposite situation.

Claims (42)

1. calutron, it comprises:

(a) at least one stator module, it comprises the whole magnetic core of being made by the low-loss soft magnetic material, wherein said whole magnetic core comprises some grooves, and wherein twines described groove with stator winding; And

(b) at least one magnetic field component, it comprises a plurality of magnetic poles, described magnetic field component disposes and is arranged in and described at least one stator magnet interacts,

The feature of wherein said low-loss soft magnetic material is: core loss is less than " L ", and L is provided by following formula in the formula: L=12fB ^1.5+ 30f ^2.3B ^2.3

L is loss, is unit with W/kg,

F is a frequency, is unit with KHz, and

B is a peak flux density, is unit with the tesla; And the frequency of wherein said calutron is higher than 300Hz in the process of described device operation.

2. device as claimed in claim 1, wherein said device are the axial air-gap devices.

3. device as claimed in claim 1, the frequency of wherein said calutron in the process of described device operation greater than about 400Hz.

4. device as claimed in claim 1, the frequency of wherein said device is between 400Hz and the 1000Hz in the process of described device operation.

5. device as claimed in claim 1, the frequency of wherein said device is about 1000Hz in the process of described device operation.

6. device as claimed in claim 1, wherein said low-loss soft magnetic material is the amorphous metal.

7. device as claimed in claim 1, wherein said low-loss soft magnetic material are the brilliant metals of millimicro.

8. device as claimed in claim 1, wherein said low-loss soft magnetic material is an optimized Si-Fe alloys.

9. device as claimed in claim 1, wherein said whole magnetic core also are the monomer magnetic cores.

10. device as claimed in claim 1, every extremely every phase slot number of wherein said device is about 0.5.

11. device as claimed in claim 1, wherein magnetic field component is a rotor.

12. device as claimed in claim 1, wherein said a plurality of magnetic poles under greater than about 12,000 rev/mins speed more than 4 magnetic poles.

13. a method of making calutron, described method comprises:

(a) select the low-loss soft magnetic material, described low-loss soft magnetic material is characterised in that core loss less than " L ", and L is provided by following formula in the formula

L=12fB ^1.5+ 30f ^2.3B ^2.3, in the formula

L is loss, is unit with W/kg,

F is a frequency, is unit with KHz, and

B is a peak flux density, is unit with the tesla;

(b) provide at least one stator module, it comprises the whole magnetic core of being made by described low-loss soft magnetic material;

(c) in described groove, stator winding is set; And

(d) provide at least one magnetic field component, described at least one magnetic field component comprises and being used for and the synergistic a plurality of magnetic poles of described stator winding magnetic.

14. method as claimed in claim 13, wherein said calutron are the axial air-gap devices.

15. method as claimed in claim 13, wherein said a plurality of magnetic poles comprise 36 utmost points.

16. method as claimed in claim 13, wherein said a plurality of magnetic poles under greater than about 12,000 rev/mins speed more than 4 magnetic poles.

17. method as claimed in claim 13, the slot number of the every extremely every phase of wherein said device is about 0.5.

18. method as claimed in claim 13, wherein said low-loss soft magnetic material is the amorphous metal.

19. method as claimed in claim 13, wherein said low-loss soft magnetic material are millimicro crystalline substance metals.

20. method as claimed in claim 13, wherein said low-loss soft magnetic material is the Si-Fe alloy.

21. method as claimed in claim 13, wherein said whole magnetic core also are the monomer magnetic cores.

22. a calutron, it comprises:

(a) at least one stator module, it comprises the monomer magnetic core of being made by the low-loss soft magnetic material, wherein said monomer magnetic core comprises some grooves, and wherein twines described groove with stator winding; And

(b) at least one magnetic field component, it comprises a plurality of magnetic poles, described magnetic field component disposes and is arranged in and described at least one stator magnet interacts,

Wherein, the feature of described low-loss soft magnetic material be core loss less than " L ", wherein L provides L=12fB by following formula ^1.5+ 30f ^2.3B ^2.3, in the formula

L is loss, is unit with W/kg,

F is a frequency, is unit with KHz, and

B is a peak flux density, is unit with the tesla; And

The frequency of wherein said calutron is higher than 300Hz in the process of described device operation.

23. device as claimed in claim 22, wherein said device are the axial air-gap devices.

24. device as claimed in claim 22, the frequency of wherein said calutron in the process of described device operation greater than about 400Hz.

25. device as claimed in claim 22, the frequency of wherein said device is between 400Hz and the 1000Hz in the process of described device operation.

26. device as claimed in claim 22, the frequency of wherein said device is about 1000Hz in the process of described device operation.

27. device as claimed in claim 22, wherein said low-loss soft magnetic material is the amorphous metal.

28. device as claimed in claim 22, wherein said low-loss soft magnetic material are millimicro crystalline substance metals.

29. device as claimed in claim 22, wherein said low-loss soft magnetic material is an optimized Si-Fe alloys.

30. device as claimed in claim 22, the slot number of the every extremely every phase of wherein said device is about 0.5.

31. device as claimed in claim 25, wherein said a plurality of magnetic poles comprise 36 utmost points.

32. device as claimed in claim 22, wherein under greater than about 12,000 rev/mins speed described a plurality of magnetic poles more than 4 magnetic poles.

33. device as claimed in claim 25, wherein said magnetic field component is a rotor.

34. a method of making calutron, described method comprises:

(a) select the low-loss soft magnetic material, described low-loss soft magnetic material is characterised in that core loss less than " L ", and L is provided by following formula in the formula: L=12fB ^1.5+ 30f ^2.3B ^2.3, in the formula

L is loss, is unit with W/kg,

F is a frequency, is unit with KHz, and

B is a peak flux density, is unit with the tesla;

(b) provide at least one stator module, it comprises the monomer magnetic core of being made by described low-loss soft magnetic material;

(c) in described groove, stator winding is set; And

(d) provide at least one magnetic field component, described at least one magnetic field component comprise in order to the synergistic a plurality of magnetic poles of described stator winding magnetic.

35. method as claimed in claim 34, wherein said calutron are the axial air-gap devices.

36. method as claimed in claim 34, wherein said a plurality of utmost points comprise 36 utmost points.

37. method as claimed in claim 34, wherein under greater than about 12,000 rev/mins speed described a plurality of magnetic poles more than 4 magnetic poles.

38. method as claimed in claim 34, the slot number of the every extremely every phase of wherein said device is about 0.5.

39. method as claimed in claim 34, wherein said low-loss soft magnetic material is the amorphous metal.

40. method as claimed in claim 34, wherein said low-loss soft magnetic material are millimicro crystalline substance metals.

41. method as claimed in claim 34, wherein said low-loss soft magnetic material is the Si-Fe alloy.

42. method as claimed in claim 34, wherein said magnetic field component is a rotor.

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