Abstract:
An apparatus or assembly for forming injection molded magnets in permanent magnet rotors or laminations for such rotors. The assembly includes a plurality of platens defining an axial boundary of a die cavity and a plurality of support shoes that are radially moveable between a closed position defining a radial boundary of the die cavity, and an open position creating a gap between the rotor core and the plurality of support shoes. The assembly has an injection system for filling at least one of the plurality of voids of the rotor core with a magnetic slurry, and a plurality of alignment magnets configured to magnetically align the magnetic slurry.
Abstract:
An interior permanent magnet electric machine is described, and includes a stator including a plurality of electrical windings and a rotor disposed in a cylindrically-shaped void formed within the stator. The rotor includes a plurality of steel laminations assembled onto a shaft, wherein the shaft defines a longitudinal axis. Each of the steel laminations includes a plurality of poles and each of the poles includes a plurality of slots disposed near an outer periphery. The slots of the steel laminations are longitudinally aligned. A plurality of permanent magnets are disposed in a first subset of the slots, and plurality of packets assembled from anisotropic material are disposed in a second subset of the slots.
Abstract:
An interior permanent magnet electric machine is described, and includes a stator including a plurality of electrical windings and a rotor disposed in a cylindrically-shaped void formed within the stator. The rotor includes a plurality of steel laminations assembled onto a shaft, wherein the shaft defines a longitudinal axis. Each of the steel laminations includes a plurality of poles and each of the poles includes a plurality of slots disposed near an outer periphery. The slots of the steel laminations are longitudinally aligned. A plurality of permanent magnets are disposed in a first subset of the slots, and plurality of packets assembled from anisotropic material are disposed in a second subset of the slots.
Abstract:
A synchronous reluctance electric machine is described, and includes a stator including a plurality of electrical windings and a rotor disposed in a cylindrically-shaped void formed within the stator. The rotor includes a plurality of steel laminations assembled onto a shaft, wherein the shaft defines a longitudinal axis. Each of the steel laminations includes a plurality of poles and each of the poles includes a plurality of slots disposed near an outer periphery. The slots of the steel laminations are longitudinally aligned. A plurality of packets assembled from anisotropic material are disposed in the slots.
Abstract:
A method and assembly for forming a rotor include forming a rotor core having a plurality of voids and placing the formed rotor core into a die cavity. The method includes moving a plurality of support shoes to define an outer diameter of the die cavity, and injecting at least one of the plurality of voids with a magnetic slurry. At least one permanent magnet is formed from the magnetic slurry by applying pressure to the rotor core and the magnetic slurry within the die cavity and by applying a magnetic field to align the magnetic slurry. After forming the at least one permanent magnet within the rotor core, the plurality of support shoes are retracted and the rotor core removed with the at least one permanent magnet formed therein.
Abstract:
An improved rotor assembly configured for magnets with differing lengths, and methods and systems for manufacturing the same. The rotor assembly may be created by selectively creating first and second tabs extending into apertures of lamination sheets. The first and second tabs may be selectively removed, depending on the different magnet lengths and the specific lamination sheet, according to one of a first finishing schedule and a second finishing schedule. The lamination sheets are stacked with any remaining first and second tabs, and other features, aligned.
Abstract:
An interior permanent magnet machine includes a stator including a plurality of electrical conductors. The interior permanent magnet machine further includes a rotor concentrically disposed in relation to the stator. The rotor is configured to rotate relative to the stator about a rotational axis and includes a plurality of polar pieces arranged annularly about the rotational axis. At least one of the polar pieces includes a magnetic layer configured to magnetically interact with the electrical conductors. The magnetic layer has a substantially conic section shape.
Abstract:
Controlling a synchronous electric machine includes determining a rotor field current of a wound rotor of the synchronous electric machine and determining a time-rate change in field flux linkage. A rotor field voltage is determined based upon the time-rate change in the field flux linkage, and a rotor field resistance is determined based upon the rotor field voltage and the rotor field current. A rotor temperature is determined based upon the rotor field resistance. Operation of the synchronous electric machine is controlled responsive to a torque command and the rotor temperature.