US20120007453A1 - Dual-rotor motor - Google Patents

Dual-rotor motor Download PDF

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Publication number
US20120007453A1
US20120007453A1 US13/255,030 US201013255030A US2012007453A1 US 20120007453 A1 US20120007453 A1 US 20120007453A1 US 201013255030 A US201013255030 A US 201013255030A US 2012007453 A1 US2012007453 A1 US 2012007453A1
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US
United States
Prior art keywords
electric motor
housing
motor according
supports
stator
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US13/255,030
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English (en)
Inventor
Heinz Leiber
Thomas Leiber
Valentin Unterfrauner
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
SONTER SA
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Assigned to CPM COMPACT POWER MOTORS GMBH reassignment CPM COMPACT POWER MOTORS GMBH ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: LEIBER, HEINZ, LEIBER, THOMAS, UNTERFRAUNER, VALENTIN
Publication of US20120007453A1 publication Critical patent/US20120007453A1/en
Assigned to SONTER SA reassignment SONTER SA ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CPM COMPACT POWER MOTORS GMBH
Abandoned legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K16/00—Machines with more than one rotor or stator
    • H02K16/02—Machines with one stator and two or more rotors
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12—Stationary parts of the magnetic circuit
    • H02K1/18—Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12—Stationary parts of the magnetic circuit
    • H02K1/20—Stationary parts of the magnetic circuit with channels or ducts for flow of cooling medium
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/28—Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/24—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors with channels or ducts for cooling medium between the conductors
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K5/00—Casings; Enclosures; Supports
    • H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
    • H02K5/08—Insulating casings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K5/00—Casings; Enclosures; Supports
    • H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
    • H02K5/20—Casings or enclosures characterised by the shape, form or construction thereof with channels or ducts for flow of cooling medium
    • H02K5/203—Casings or enclosures characterised by the shape, form or construction thereof with channels or ducts for flow of cooling medium specially adapted for liquids, e.g. cooling jackets
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K9/00—Arrangements for cooling or ventilating
    • H02K9/02—Arrangements for cooling or ventilating by ambient air flowing through the machine
    • H02K9/04—Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium
    • H02K9/06—Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium with fans or impellers driven by the machine shaft
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K9/00—Arrangements for cooling or ventilating
    • H02K9/19—Arrangements for cooling or ventilating for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K9/00—Arrangements for cooling or ventilating
    • H02K9/22—Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
    • H02K9/223—Heat bridges
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/12—Impregnating, heating or drying of windings, stators, rotors or machines
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K5/00—Casings; Enclosures; Supports
    • H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
    • H02K5/20—Casings or enclosures characterised by the shape, form or construction thereof with channels or ducts for flow of cooling medium
    • H02K5/207—Casings or enclosures characterised by the shape, form or construction thereof with channels or ducts for flow of cooling medium with openings in the casing specially adapted for ambient air
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K9/00—Arrangements for cooling or ventilating
    • H02K9/22—Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
    • H02K9/227—Heat sinks

Definitions

  • the present invention relates to a double rotor motor according to the preamble of claim 1 .
  • Double rotor motors which have an individual tooth technology and a high efficiency but a low strength and poor heat dissipation are known from WO 06/083097, U.S. Pat. No. 6,002,192, WO04/004098 and U.S. Pat. No. 5,982,070. These motors are characterised by a high efficiency of the magnetic circuit, since with the impression of a current in the stator tooth, a torque is generated by two rotors. Individual teeth in the exciting circuit are particularly advantageous, as stated in the above-mentioned applications.
  • Double rotors can be configured for high outputs and torques.
  • the excitation teeth, coils and attachments must have a high degree of rigidity.
  • the excitation teeth with coils have to be constructed close together.
  • the stator is self-supporting in the case of a double rotor motor with individual teeth, the teeth and coils have to be supported on the housing with a high degree of rigidity.
  • the variation in the magnetic flux in double rotor motors is very high so that electrically conductive materials are undesired in the magnetic circuit, because very high eddy currents are generated therein. For this reason, electrically conducive materials with a large cross section are to be avoided particularly in the region of the greatest changes in flux, as occur in the poles and in the air gaps.
  • WO2006/083097 discloses a double rotor motor of this type.
  • the self-supporting coils are injection moulded with the coil bodies and yoke to produce a stator.
  • the application does not show a cross section through the coils to detect the distance to the adjacent yoke. It can therefore be assumed that the illustrated wall thickness also applies in the circumferential direction and thus there is a large distance to the adjacent coil.
  • the torque is substantially supported by the insert moulded bodies and the ribbing on the side of the housing. Since very high moments are primarily effective in the outer region, the stator can only support torques to a limited extent.
  • WO 2004/004098 also discloses a double rotor motor, in which the yokes are insert moulded with the coil bodies.
  • the coil bodies are centred with the wound coils in a housing by positioning webs of a plastics material body ( FIG. 13A ) and then encapsulated with the plastics material body and the housing with cast resin. Since the positioning webs only have a small width, their geometrical moment of inertia Ia is very low so that the positioning webs can only transmit low forces.
  • cast resin has a low modulus of elasticity so that high moments cannot be transmitted by the encapsulation either.
  • the tooth is primarily supported on the coil body which, in turn, is connected to the housing and the support by the encapsulating compound. Thus, the construction can only be loaded to a limited extent and can only be used for motors with a low torque load.
  • Double rotor motors which have a high degree of rigidity and efficiency are already known from EP 1879283 (Matsushita), EP 1191673 (Denso) and U.S. Pat. No. 5,260,642 (Huss).
  • EP 1879283 and EP 1191673 a stator construction is in each case already known, in which two rotors provided with permanent magnets are joined to one another via a shaft. In this respect, the rotors are driven by a stator wound with excitation coils.
  • the stator is configured as a single part and consists of inner and outer teeth with pole shoes and a tangential connecting web between the yoke arms.
  • An excitation coil is in each case wound in the circumferential direction on each connecting web, as illustrated in FIG. 8 of EP 1879283 and in FIG. 38 of EP 1191673. Due to this coil arrangement, the magnetic flux is generated tangentially in the connecting web.
  • the magnetic flux is at the same time divided into two magnetic partial fluxes in the yoke teeth. One of the partial fluxes goes radially outwardly to the outer rotor and is closed via the outer rotor, and goes radially inwardly via the adjacent stator tooth to the connecting web.
  • the second partial flux leads radially inwardly and is closed via the inner rotor, and is led radially outwardly via the adjacent stator tooth and is closed via the connecting web.
  • EP 1191673 in contrast to the stator structure of EP 1879283, the rotors are not joined to one another via a shaft. Instead, the relative rotor position of the outer and inner rotors is regulated by a control algorithm.
  • a further double rotor is known from U.S. Pat. No. 5,260,642.
  • a plurality of rotors equipped with permanent magnets are arranged axially with respect to one another and are driven via an external excitation stator.
  • the winding technique known from EP 1191673 and EP 1879283 is disadvantageous.
  • the tangential winding technique is on the one hand very complicated, and on the other hand a good copper space factor cannot be achieved with automated winding, since the space covered by the pole shoes is very difficult to fill during winding.
  • the magnetic flux is generated in the tangential direction from the connecting web and is then deflected by 90° in the radial direction. This is unfavourable for the efficiency of the magnetic circuits and prevents the use of soft magnetic material with grain orientation.
  • the object of the invention is to provide a double rotor motor for high torques and output.
  • the invention is based on the concept that the coil supports which also form the poles and the yoke are insert moulded with a plastics material, the plastics material forming a support structure which is also formed between the individual coil supports and coils. During the insert moulding procedure, the plastics material joins with the housing or with a part connected to the housing, thereby producing a stable unit.
  • the plastics material is preferably a high-strength plastics material.
  • the plastics material composition injected between the coil supports forms supports in each case, the cross section of which is advantageously U-shaped, T-shaped or double-T-shaped.
  • the configuration of the double rotor motor for high torques, output and a compact construction requires specific solutions in terms of rigidity and heat dissipation, since the insert moulding/encapsulating alone of coil supports and yoke is not sufficient for this.
  • a high rigidity a high geometrical moment of inertia Ia for a low bending of the stator and a high modulus of elasticity is required.
  • the coil body was used as the support and is connected to the housing by the encapsulating compound, or an insert moulding of the stator teeth which produces the rigidity.
  • the invention provides using the production-related space or spacing between the coils which is filled by the injected plastics material and forms a support structure or a support.
  • This produces a geometrical moment of inertia Ia which is greater than the coil body by a factor of four.
  • the entire yoke or the external pole can also be insert moulded with a relatively thin wall of plastics material.
  • the reinforcement is supported by a high-grade plastics material.
  • a filler with a high modulus of elasticity it is also possible for a filler with a high modulus of elasticity to be additionally injected.
  • a thermosetting plastics material is preferably used in which an effective heat-conducting filler, for example boron-nitride is embedded.
  • the insert moulding is connected to the housing with suitable profiled parts and anchors. The use of plastics material advantageously minimises the eddy current losses to achieve a good efficiency.
  • parts which are of a particularly thin-walled configuration, with a high modulus of elasticity can be embedded or incorporated in the injection moulding.
  • stator tooth with a body-less coil or with insulation parts only on the tooth neck wall and front with a corresponding spacing to the external and internal poles. The material is then injected into this space formed by the spacing.
  • All the individual yokes with their coils are connected to the housing and centred accordingly by the previously described insert moulding procedure.
  • the free space or spacing between the coils and yokes, like the front of the coil, is then sheathed or filled with plastics material, it being possible for a corresponding structure and contour of the plastics material with respect to the outer reinforcement to be formed.
  • the free space or spacing between the individual yokes and the coils forms a double-T-support-shaped space which is filled by the plastics material.
  • the plastics material forms in cross section a double-T-support-shaped support which is anchored in the housing or in the part joined to the housing.
  • a particularly good rigidity is thus achieved by this cross-sectional contour.
  • the cross-sectional contour of the supports can advantageously extend into the correspondingly formed recesses in the housing or in the part joined thereto, thereby producing a particularly good rigidity of the supports.
  • the cross-sectional area of the recesses can be larger than the support cross-sectional area in the region of the rotor, so that a type of widened base is produced on the support which extends into the recesses in the housing or housing part.
  • reinforcing elements can be provided, one end of which extends in each case up into a recess and the other end extends as far as the stator tooth or up into the gap between the adjacent stator teeth.
  • the reinforcing elements can be embedded in the region of the external pole shoe and/or the internal pole shoe.
  • stator teeth which in cross section can advantageously have a double-T shape, i.e. they have radially outer and inner pole shoes, are initially wound axially and then positioned in the injection moulding die.
  • the stator does not have any tangential connecting webs.
  • the magnetic flux is generated radially and is closed via the outer rotor, the adjacent stator teeth and the inner rotor.
  • the individual teeth are firmly anchored to the housing and are held in position by the supports and support elements injected from plastics material.
  • the injected support elements are preferably T-shaped of more preferably double-T-support-shaped so that the stator is provided with a very high rigidity for radial and tangential loads.
  • the plastics material is preferably formed from materials which have a high thermal conductivity but a low electrical conductivity.
  • FIG. 1 shows the motor construction according to the invention with an optional outer and inner back-circuit element
  • FIG. 1 a is a plan view of the reinforcing element
  • FIG. 2 is a partial cross-sectional view through stator, outer rotor and inner rotor with a support structure injected from plastics material;
  • FIG. 2 a shows a support structure with a reinforcing element
  • FIG. 2 b is a sectional view of the housing part and of two supports
  • FIG. 2 c shows the motor with externally and internally insert moulded pole shoes.
  • FIG. 1 is a cross-sectional view through a first possible embodiment of the motor according to the invention along line x-x in FIG. 2 .
  • the support structure 35 , 35 a , 35 b , 35 c consists of a high-grade, bending-resistant and, at the same time, electrically insulating material with a high modulus of elasticity, preferably a thermosetting plastics material with filler.
  • the cross-sectional contour of the individual supports 35 formed by the injected composition, is shown in more detail in the following figures.
  • Positioned in the injected composition of the support material is the coil 4 with yoke 1 and is held by said injected composition on the housing 12 .
  • the insert moulded structure 35 which forms the individual supports has on the housing side a respective thickening 35 a in the form of a base which extends up to the axial side 1 a of the yoke 1 and is anchored in the housing 12 in a corresponding recess 12 b .
  • the insert moulding can preferably be carried out in two steps so that a different filler with better heat conducting properties, for example boron nitride, is introduced in region 35 a and a filler with a high modulus of elasticity, for example glass fibre-reinforced plastics material is introduced in region 35 . This can further improve the heat dissipation between stator and housing.
  • the stator consists of individual stator teeth 1 with pole shoes 1 a in the outer region and pole shoes 1 b in the inner region, which are wound with excitation coils 4 .
  • the motor comprises an outer rotor 3 a provided with permanent magnets 2 a and an inner rotor 3 b provided with permanent magnets 2 b .
  • two back-circuit elements 24 a , 24 b are shown which are optional.
  • the back iron can also take place via the rotors 3 a , 3 b .
  • Air gaps 1 f are in each case between the pole shoes 1 a , 1 b and the rotors 3 a , 3 b as well as the optional back-circuit elements 24 a , 24 b.
  • a pressed screen 23 can also be provided which is also insert moulded for contacting purposes, so that the contacting of the coils 4 takes place before the insert moulding procedure and thus the tool configuration is simplified.
  • the injection moulding compositions interlock.
  • a corresponding interlocking region and separating region of the moulded compositions is shown at 35 d.
  • the housing 12 in region 12 a is to be configured such that the spacing between coil side 4 a and housing region 12 a is minimised. Therefore, the housing region 12 a widens towards the rotation axis to be adapted to the coil contour. This ensures that the wall 35 w , produced by insert moulding, is as thin as possible for a good heat transfer.
  • the wall region 35 w can also be produced by a plastics material with good heat conduction properties.
  • Injection moulded on the inside is a reinforcing insert 36 with a high modulus of elasticity and heat conduction which, during injection moulding, is pressed positively onto the stator teeth 1 by suitable tools.
  • a further outer insert part 37 is optionally provided which is also joined to the injection moulding in region 35 c by one or a plurality of recesses 40 also in the inner insert part.
  • a connecting web or connecting ring 38 can also be provided between the insert parts 36 and 37 for further reinforcement.
  • the insert part 36 , 37 can also project laterally out of the housing 12 and rest resiliently against the housing 12 to maintain a bias. This improves the bond, in particular when a metallic material is used as the insert parts 36 , 37 .
  • the insert part 36 , 37 is thin and is provided with stamped-out elongated slots 37 a , as shown in FIG. 1 a.
  • the coil 4 is also insert moulded, the injection composition forming reinforcing ribs 35 b . These enhance the rigidity and enlarge the surface for heat dissipation by air cooling.
  • the air cooling is furthered by a fan impeller 21 .
  • recesses 39 can be made in the rotor and in the housing 12 .
  • the magnetic back irons 24 a and 24 b are mounted such that they are fixed to the housing. There are two air gaps if in each case between stator, rotors 3 a and 3 b and back irons 24 a and 24 b .
  • the rotors 3 a and 3 b are configured with thin walls. This reduces the mass of inertia of the rotor and the cooling channels 18 can extend axially in the housing, thereby improving the rotor cooling.
  • the support structures 35 configured as double-T supports extend as far as the inside of the yoke to increase the geometrical moment of inertia Ia and thus to improve the tangential load.
  • the radial web height of the supports 35 is to be configured as high as possible, which results in a high degree of rigidity.
  • stator tooth For the structure, it is necessary for the stator tooth to be previously wound and positioned relative to the housing.
  • FIG. 1 a shows the double-T support 35 with a radially outer reinforcing element 37 .
  • the reinforcing element 37 can be arranged relative to the excitation coils 4 , but can also be arranged radially inside.
  • reinforcing elements 37 can also be arranged outside and inside and injection moulded.
  • the reinforcing element 37 is preferably made of a poorly conductive metallic material, for example stainless steel, with stamped-out areas 37 a to reduce the current conductivity and thus the eddy current losses.
  • FIG. 2 b shows the cut-off T-supports 35 with a thickening 35 a as well as the contour of the housing recess 12 b which is configured in terms of injection moulding so that a high degree of rigidity is obtained.
  • the contour of the housing recess 12 b should correspond to the cross-sectional contour of the supports 35 , so that a high degree of rigidity results and the supports extend up into or through the housing wall. In this respect, attention should also be paid to a minimum use of material, while bearing in mind the necessary rigidity.
  • FIG. 2 c shows a widening of the T-support structure 35 .
  • the supports 35 are connected to an outer ring 35 e as part of the injection moulding over the regions 35 s , which comprise the external poles 1 a including the outer reinforcing ring 35 e . Even in the case of a small wall thickness, this ring 35 e is also very effective for reinforcement with a tangential load.
  • region Z-Z a further alternative is shown, in which both the external and the internal yoke poles 1 a , 1 b are insert moulded through rings 35 e in a thin-walled manner and are connected to webs between the coils.
  • a thermosetting plastics material is preferably suitable for producing a thin wall thickness.
  • the region E between the poles can be configured to be slightly recessed if appropriate due to the formation of burrs.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)
  • Motor Or Generator Cooling System (AREA)
  • Motor Or Generator Frames (AREA)
  • Manufacture Of Motors, Generators (AREA)
US13/255,030 2009-03-05 2010-03-05 Dual-rotor motor Abandoned US20120007453A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE102009011383.5 2009-03-05
DE102009011383 2009-03-05
PCT/EP2010/001383 WO2010099975A2 (de) 2009-03-05 2010-03-05 Doppelrotormotor

Publications (1)

Publication Number Publication Date
US20120007453A1 true US20120007453A1 (en) 2012-01-12

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Family Applications (2)

Application Number Title Priority Date Filing Date
US13/255,005 Expired - Fee Related US8541923B2 (en) 2009-03-05 2010-03-05 Dual-rotor motor having heat dissipation
US13/255,030 Abandoned US20120007453A1 (en) 2009-03-05 2010-03-05 Dual-rotor motor

Family Applications Before (1)

Application Number Title Priority Date Filing Date
US13/255,005 Expired - Fee Related US8541923B2 (en) 2009-03-05 2010-03-05 Dual-rotor motor having heat dissipation

Country Status (6)

Country Link
US (2) US8541923B2 (ja)
EP (3) EP2404365B1 (ja)
JP (1) JP2012519463A (ja)
KR (1) KR20110128334A (ja)
CN (2) CN102422512A (ja)
WO (3) WO2010099974A2 (ja)

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US20180076148A1 (en) * 2016-09-15 2018-03-15 Skyworks Solutions, Inc. Through-mold features for shielding applications
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US11025137B2 (en) 2016-09-14 2021-06-01 Mts Systems Corporation Electric machine with stator cooling channels
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US11355987B2 (en) * 2017-04-19 2022-06-07 Vitesco Technologies GmbH Pole tooth module for an electric machine, active part comprising a pole tooth module, and electric machine
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CN102428629B (zh) 2014-12-03
WO2010099975A2 (de) 2010-09-10
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US8541923B2 (en) 2013-09-24
WO2010099974A2 (de) 2010-09-10
EP2404367A2 (de) 2012-01-11

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