Electric motor

• US 5,661,379 A
• Filed: 09/06/1995
• Issued: 08/26/1997
• Est. Priority Date: 09/06/1995
• Status: Expired due to Term

• Current Assignee: Eltratech, Inc.
• Original Assignee: Johnson Consulting, Inc.
• Inventors: Johnson, Ronald A.
• Primary Examiner(s): Ro, Bentsu
• Application Number:
  US08/524,261
• Time in Patent Office: 720 Days
• Field of Search: 318/139, 318/293, 318/494-498, 318/503, 388/804, 388/811, 388/819
• US Class Current: 318/139
• CPC Class Codes: H02K 3/28 Layout of windings or of connections between windings windings for pole-changing H02K17/06, H02K17/14, H02K19/12, H02K19/32
• CPC Class Codes: H02P 23/28 Controlling the motor by varying the switching frequency of switches connected to a DC supply and the motor phases

Abstract

A fractional-power electric motor is provided to generate varying amounts of output torque supplied to a driven member over a wide range of RPM speeds so as to reduce power consumption on a battery-powered source. The electric motor includes a rotor and a stator assembly. The stator assembly is disposed around the rotor and is inductively coupled to the rotor. The stator assembly further includes a plurality of poles, each having a main winding and at least one fractional-power winding. The main winding and associated at least one fractional-power winding on each of the stator poles are wound so that the magnetic fluxes generated therefrom are added. Power switching circuits are provided for independently energizing the main and fractional-power windings on each of the stator poles. A controller is used to control selectively the frequency and duty cycle energization of the power switching circuits to vary the rotational speed of the rotor and the amounts of torque supplied to the driven member.

Claims

1. A battery-powered electric motor for generating varying amounts of output torque supplied to a driven member over a wide range of RPM speeds so as to reduce power consumption on the battery-powered source comprising:

a rotor having an axis of rotation;

a stator assembly disposed around said rotor and being inductively coupled to said rotor;

said stator assembly having a plurality of poles;

each of said stator poles having a main winding and at least one fractional-power winding;

said main winding and said associated at least one fractional-power winding on each of said stator poles being wound so that the magnetic flux generated in said associated fractional-power winding will be added to the magnetic flux generated by said main winding to produce an increased magnetic field strength;

power switching means for energizing said main and said fractional-power windings on each of said stator poles;

said power switching means being formed of a plurality of winding drive control circuits each one being associated with one of said main windings and said fractional-power windings for independently energizing said main windings and said fractional-power windings;

said plurality of winding drive control circuits including an input terminal connected to the battery source and output terminals for producing A.C. voltage pulses across said windings;

controller means for controlling selectively said power switching means to vary the rotational speed of said rotor and the amounts of torque supplied to the driven member, and

said controller means being coupled to each of said plurality of winding drive control circuits for varying the duty cycle of A.C. voltage pulses defining a pulse width modulated waveform; and

each of said plurality of winding drive control circuits being formed of a plurality of transistors connected in a H-bridge network across said battery source, said plurality of transistors being turned on and off for producing said A.C. voltage pulses with alternating polarity and predetermined width.

2. An electric motor as claimed in claim 1, further comprising a plurality of fractional-power windings disposed on each of said stator poles.

3. An electric motor as claimed in claim 1, wherein said main winding and said at least one fractional-power winding on each of said stator poles are initially energized so as to increase the RPM speed and output torque of said rotor to a full power level and wherein one or more of said main and fractional-power windings are thereafter de-energized so as to reduce the output torque to the desired level.

4. An electric motor as claimed in claim 1, wherein one or more of selected main and fractional-power windings are gradually de-energized by decreasing the pulse width to reduce the duty cycle thereof so as to reduce the output torque to a desired level.

5. An electric motor as claimed in claim 1, further comprising sensing means for detecting the rotational speed of the driven member to produce a feedback signal to said controller means.

6. An electric motor as claimed in claim 1, wherein said plurality of stator poles comprises four poles which are displaced from one another by 90 mechanical degrees about said axis of rotation of said rotor.

7. An electric motor as claimed in claim 1, wherein said main windings and said fractional-power windings are displaced from one another along said axis of rotation of said rotor.

8. An electric motor as claimed in claim 1, wherein said fractional-power windings have a magnetic field strength between 1/8th and 1/20th of the strength of said main windings.

9. An electric motor as claimed in claim 1, wherein said fractional-power windings have a magnetic field strength equal to approximately 1/10th of the strength of said main windings.

10. A method for controlling varying amounts of output torque supplied to a driven member over a wide range of RPM speeds by a battery-powered electric motor so as to reduce power consumption on the battery-power source comprising the steps of:

providing a plurality of stator poles around a rotor;

connecting a main winding and at least one fractional-power winding on each of said stator poles;

winding the main winding and the associated at least one fractional-power winding on each of the stator poles so that the magnetic fluxes generated therefrom will be added;

switching independently the main and the fractional-power windings on each of the stator poles through a plurality of winding drive control circuits each one being associated with one of the main windings and the fractional-power windings;

connecting an input terminal of the plurality of winding drive control circuits to the battery source and generating A.C. voltage pulses across the windings through its output terminals;

controlling selectively the energization of the main and the fractional-power windings to vary the rotational speed of the rotor and the amounts of torque supplied to the driven member;

varying the duty cycle of the A.C. voltage pulses so as to define a pulse-width modulated waveform;

the plurality of winding drive control circuits being formed of a plurality of transistors connected in a H-bridge network across the battery source; and

turning on and off a predetermined pair of the transistors to generate the A.C. voltage pulses with alternating polarity and predetermined width.

11. A method as claimed in claim 10, further comprising the step of disposing a plurality of fractional-power windings on each of the stator poles.

12. A method as claimed in claim 10, further comprising the step of initially energizing the main winding and the at least one fractional-power winding on each of the stator poles so as to increase the RPM speed and output torque of the rotor to a full power level and thereafter de-energizing one or more of selected main and fractional-power windings so as to reduce the output torque to a desired level.

13. A method as claimed in claim 10, further comprising the step of gradually de-energizing one or more of selected main and fractional-power windings by decreasing the duty cycle of AC voltage pulses.

14. A method as claimed in claim 10, further comprising the step of sensing the rotational speed of the driven member and the output torque generated to produce a feedback signal.

15. A battery-powered electric motor for generating varying amounts of output torque supplied to a driven member over a wide range of RPM speeds so as to reduce power consumption on the battery-powered source comprising:

a rotor having an axis of rotation;

a stator assembly disposed around said rotor and being inductively coupled to said rotor;

said stator assembly having a plurality of poles;

each of said stator poles having a main winding and at least one fractional-power winding, said at least one fractional-power winding having a magnetic field strength between 1/8th and 1/20th of said main winding;

said main winding and said associated at least one fractional-power winding on each of said stator poles being wound so that the magnetic flux generated in said associated fractional-power winding will be added to the magnetic flux generated by said main winding to produce an increased magnetic field strength;

power switching means for independently energizing said main and said fractional-power windings on each of said stator poles; and

means for selectively controlling the energization of said power switching means so that said main and said fractional-power windings on each of said stator poles can vary the rotational speed of said rotor and the amounts of torque supplied to the driven member.