PERMANENT MAGNET SYNCHRONOUS MOTOR AND DRIVE SYSTEM

• US 20100084935A1
• Filed: 10/02/2009
• Published: 04/08/2010
• Est. Priority Date: 10/03/2008
• Status: Active Grant

• Current Assignee: Johnson Controls Tyco IP Holdings LLP (Johnson Controls International plc)
• Original Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: WARNER, Justin Drew, ADIGA-MANOOR, Shreesha, BORISOV, Konstantin, JADRIC, Ivan, WU, Zhiqiao, TODD, Michael S., HANSEN, John C., SLOTHOWER, Scott V., DUBEY, Kanishk
• Granted Patent: US 8,258,664 B2
• Time in Patent Office: Days
• US Class Current: 310/112
• CPC Class Codes: F25B 2600/0253 with variable speed
• CPC Class Codes: F25B 49/025 Motor control arrangements
• CPC Class Codes: H02P 6/085 in a bridge configuration
• CPC Class Codes: Y02B 30/70 Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating

Abstract

A hybrid motor for powering a compressor of a chiller system includes a first rotor portion and a first stator portion configured as a permanent magnet motor and a second rotor portion and a second stator portion configured as a reluctance motor. The second rotor portion includes a reluctance-type rotor, and the second stator portion includes electromagnetic windings capable of inducing a rotary magnetic field. The first rotor portion and the second rotor portion are attached to a common drive shaft. The reluctance motor is arranged to generate start-up torque and initiate rotation of the drive shaft until the drive shaft achieves a predetermined rotational speed. The permanent magnet motor is arranged to power the drive shaft between the predetermined rotational speed and a maximum rotational speed.

Claims

1. A vapor compression system comprising:

a compressor, a condenser and an evaporator connected in a closed refrigerant loop;

a motor connected to the compressor to power the compressor, the motor comprising;

a first rotor portion and a first stator portion configured as a permanent magnet motor;

a second rotor portion and a second stator portion configured as a reluctance motor, the second rotor portion comprising a reluctance-type rotor, and the second stator portion comprising electromagnetic windings capable of inducing a rotary magnetic field;

the first rotor portion and the second rotor portion attached to a common drive shaft of the compressor; and

a controller configured to operate the reluctance motor to generate start-up torque and initiate rotation of the drive shaft until the drive shaft achieves a predetermined rotational speed and to operate the permanent magnet motor to rotate the drive shaft between the predetermined rotational speed and a maximum rotational speed.

2. The system of claim 1, further comprising:

the first stator portion configured substantially similar to a stator of a conventional induction motor, the first stator portion comprising;

a plurality of windings disposed in corresponding slots, each slot defined by a pair of adjacent teeth symmetrically distributed about an inside radius of the first stator portion, the first rotor portion disposed axially concentrically with and inside the first stator portion, and first rotor portion and first stator portion separated by a first air gap;

first rotor portion further comprising a plurality of permanent magnets arranged to produce a magnetic field in the first air gap.

3. The system of claim 1, wherein the second rotor portion and second stator portion are configured to be controllably switched out of a power circuit of the motor.

4. The system of claim 2, wherein first rotor portion further comprises a rotor cage, and the plurality of permanent magnets are arranged peripherally on the rotor cage.

5. The system of claim 2, wherein the plurality of permanent magnets are arranged in multiple pole arrangements.

6. The system of claim 4, wherein the plurality of permanent magnets being adhesively affixed to the rotor cage, the plurality of the permanent magnets enveloped by a sleeve to maintain the plurality of permanent magnets on the rotor cage when centrifugal forces act on the rotor portion during rotation of the motor.

7. The system of claim 4, wherein the rotor cage is a cylindrical steel rotor cage.

8. The system of claim 6, wherein the sleeve portion comprises a flexible, high strength, magnetically non-permeable material.

9. The system of claim 8, wherein the material is carbon fiber tubular sheet material or stainless steel.

10. The system of claim 2, wherein a height of the first air gap is less than a height of an effective air gap, the effective air gap comprising a height of one of the plurality of permanent magnets and a thickness of the sleeve portion.

11. The system of claim 2, wherein at least a portion of the plurality of permanent magnets are implanted within an interior of first rotor portion.

12. The system of claim 1, wherein the controller is configured to control motor speed at any rotational speed in a speed range defined by the predetermined minimum speed and a maximum speed.

13. The system of claim 12, wherein the predetermined minimum speed is a speed at which the controller is capable of determining a magnetic flux along a q-axis and a d-axis without the need for an internal sensor mounted on one of the first or second rotor portions.

14. A hybrid motor for powering a compressor of a chiller system, the hybrid motor comprising:

a first rotor portion and a first stator portion configured as a permanent magnet motor;

a second rotor portion and a second stator portion configured as a reluctance motor, the second rotor portion comprising a reluctance-type rotor, and the second stator portion comprising electromagnetic windings capable of inducing a rotary magnetic field;

the first rotor portion and the second rotor portion attached to a common drive shaft; and

the reluctance motor being operated to generate start-up torque and initiate rotation of the drive shaft until the drive shaft achieves a predetermined rotational speed and the permanent magnet motor being operated to power the drive shaft between the predetermined rotational speed and a maximum rotational speed.

15. The hybrid motor of claim 14, further comprising:

the first stator portion configured substantially similar to a stator of a conventional induction motor, the first stator portion comprising;

a plurality of windings disposed in corresponding slots, each slot defined by a pair of adjacent teeth symmetrically distributed about an inside radius of the first stator portion, the first rotor portion disposed axially concentrically with and inside the first stator portion, and first rotor portion and first stator portion separated by a first air gap;

first rotor portion further comprising a plurality of permanent magnets arranged to produce a magnetic field in the first air gap.

16. The hybrid motor of claim 14, wherein the second rotor portion and second stator portion are configured to be controllably switched out of a power circuit of the hybrid motor.

17. The hybrid motor of claim 15, wherein first rotor portion further comprises a rotor cage, and the plurality of permanent magnets are arranged peripherally on the rotor cage;

and the plurality of permanent magnets arranged in multiple pole arrangements on first rotor portion.

18. The hybrid motor of claim 17, wherein the plurality of permanent magnets being adhesively affixed to the rotor cage, the plurality of permanent magnets enveloped by a sleeve to maintain the plurality of permanent magnets on the rotor cage when centrifugal forces act on rotor portion during rotation of the hybrid motor;

and wherein the sleeve comprises a flexible, high strength, magnetically non-permeable material.

19. The hybrid motor of claim 15, wherein at least a portion of the plurality of permanent magnets are implanted within an interior of first rotor portion.

20. The hybrid motor of claim 14, wherein the controller is configured to control the motor speed at any desired rotational speed in a speed range defined by a predetermined minimum speed and a maximum speed;

the predetermined minimum speed defined as a speed at which the controller is capable of determining a magnetic flux along a q-axis and a d-axis without need for an internal sensor mounted on one of the first or second rotor portions.

21. The hybrid motor of claim 14, further comprising a flywheel attached to the common drive shaft to store rotational energy to provide ride-through energy in case of a momentary voltage sag or loss of power.