Light weight machine with rotor employing permanent magnets and consequence poles

• US 5,705,917 A
• Filed: 09/14/1994
• Issued: 01/06/1998
• Est. Priority Date: 09/14/1994
• Status: Expired due to Fees

• Current Assignee: Powermate Corporation (Pramac America LLC)
• Original Assignee: Coleman Company Incorporated (Newell Brands Inc.)
• Inventors: Scott, Harold C., Davis, Mitchell K., Johnson, G. Weylin, Anderson, William J., Tally, Henry, Bednorz, Ardel R.
• Primary Examiner(s): Stephan, Steven L.
• Assistant Examiner(s): Ponomarenko, Nicholas
• Application Number:
  US08/306,120
• Time in Patent Office: 1,210 Days
• Field of Search: 310/156, 322/1, 322/46
• US Class Current: 322/46
• CPC Class Codes: F02B 2063/045 Frames for generator-engine sets
• CPC Class Codes: F02B 2063/046 Handles adapted therefor, e.g. handles or grips for movable units
• CPC Class Codes: F02B 63/04 for electric generators
• CPC Class Codes: F02B 63/044 the engine-generator unit being placed on a frame or in an housing
• CPC Class Codes: F02B 75/16 Engines characterised by number of cylinders, e.g. single-cylinder engines F02B75/26 takes precedence
• CPC Class Codes: F05C 2201/021 Aluminium
• CPC Class Codes: H02K 1/278 Surface mounted magnets; Inset magnets
• CPC Class Codes: H02K 1/2791 Surface mounted magnets; Inset magnets
• CPC Class Codes: H02K 11/05 Rectifiers associated with casings, enclosures or brackets
• CPC Class Codes: H02K 21/48 Generators with two or more outputs
• 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: H02K 7/1815 structurally associated with reciprocating piston engines general aspects of generating sets, e.g. housing, F02B63/04
• CPC Class Codes: H02M 1/0085 Partially controlled bridges
• CPC Class Codes: H02P 2101/45 for motor vehicles, e.g. car alternators
• CPC Class Codes: H02P 25/188 wherein the motor windings are switched from series to parallel or vice versa to control speed or torque
• CPC Class Codes: H02P 9/04 Control effected upon non-electric prime mover and dependent upon electric output value of the generator
• CPC Class Codes: H02P 9/30 using semiconductor devices

Abstract

A mechanically and electrically efficient, lightweight, portable motor-generator includes a stator having a plurality of windings and a rotor with a body of soft-magnetic material carrying a plurality of permanent, high energy product magnets in a surface near the stator such that relative motion of the rotor and stator causes magnetic flux from the permanent magnets to interact with and induce current in the stator windings. The magnets are mounted in insets formed in the rotor surface which includes portions between the insets to form respective consequence poles. The rotor is a hollow cylinder with the magnets mounted on an internal surface, and the stator is concentrically disposed within the cylinder. The stator includes first and second windings. A first rectification circuit, responsive to signals from the first stator winding, develops a relatively high voltage, low amperage DC signal; and a second rectification circuit, responsive to signals from the second stator winding, develops a relatively low voltage high amperage DC signal. In one preferred embodiment, the first and second windings are 3-phase, and the corresponding phases of the respective 3-phase windings are grouped together as a unit and wound about the core such that the corresponding phases of the respective 3-phase windings coils are wound in continuous thermal contact with each other. Each phase of at least one winding includes a first portion defined by a tap to provide a third voltage output.

Claims

1. A machine comprising a stator and a rotor, the stator including a plurality of windings, and the rotor comprising a body of soft-magnetic material with a plurality of permanent magnets in a surface disposed proximate to the stator, separated from the stator by a predetermined gap distance, such that relative motion of the rotor and stator causes magnetic flux from the permanent magnets to interact with and induce current in the stator windings, wherein the permanent magnets are high energy product magnets with a predetermined surface area, and the permanent magnets are mounted in insets formed in the rotor surface proximate to the stator, the rotor surface proximate to the stator includes portions between the insets to form respective consequence poles, each consequence pole having a predetermined surface area, and the magnets are disposed within the insets, separated from adjacent consequence poles by a predetermined distance, improved wherein:

the surface area of the permanent magnets proximate to the stator is greater than the surface area of the consequence poles proximate to the stator by the ratio of the flux density produced by the permanent magnet to the allowed flux density of the consequence pole;

the permanent magnets have a flux density of at least on the order five kilogauss;

the insets are symmetrically disposed in the rotor surface proximate to the stator, the consequence poles are symmetrically disposed in the rotor surface proximate to the stator and the permanent magnets are centrally disposed within the insets;

the distance separating the permanent magnets from the consequence poles is greater than the distance separating the rotor surface from the stator;

the rotor comprises a hollow cylinder with the magnets mounted on an internal surface of the cylinder, and the stator is concentrically disposed within the cylinder;

the stator is generally annular with a central aperture and the rotor is concentrically disposed for rotation within the aperture, the rotor being adapted for mounting on a shaft journaled through the stator central aperture; and

the stator includes a first winding for generating a relatively high voltage low amperage signal and a second winding for generating a relatively low voltage high amperage signal;

and the machine further including;

a first rectification circuit, responsive to signals from the first stator winding, for generating a relatively high voltage low amperage DC signal; and

a second rectification circuit, responsive to signals from the second stator winding, for generating a relatively low voltage high amperage DC signal.

2. The machine of claim 1 further comprising an engine to rotate the rotor.

3. The machine of claim 1 further improved wherein the stator includes:

a soft magnetic core;

a first 3-phase star winding, each phase of the first winding including a predetermined number of turns corresponding to a first predetermined voltage output; and

a second 3-phase star winding, each phase of the second winding including a predetermined number of turns corresponding to a second predetermined voltage output;

the corresponding phases of the respective 3-phase windings grouped together as a unit and wound about the core such that the corresponding phases of the respective 3-phase windings coils are wound in continuous thermal contact with each other.

4. The machine of claim 3 wherein the first predetermined output voltage is on the order of 110 volts, and the second predetermined output voltage is on the order of 12 volts.

5. The machine of claim 3 further improved wherein each phase of at least one winding includes a first portion defined by a tap to provide a third predetermined voltage output.

6. The machine of claim 5 further comprising:

a switch, for selectively effecting a connection to one of the second or third predetermined voltage outputs; and

a rectification circuit, receptive of signals from the switch for generating DC signals.

7. The machine of claim 5 further improved wherein the first predetermined output voltage is on the order of 110 volts, the second predetermined output voltage is on the order of 24 volts, and the third predetermined output voltage is on the order of 12 volts.

8. The machine of claim 1 wherein the machine includes respective output terminals;

and

means for disabling the rectification circuit in response to a reverse polarity voltage in excess of a predetermined level, across the output terminals.

9. The machine of claim 8 wherein the machine further includes:

means for enabling the rectification circuit in response to voltage in excess of a predetermined level, across the output terminals.

10. The machine of claim 1 further improved wherein:

the second winding includes a first portion defined by a tap to provide a third predetermined voltage output;

and the machine further comprises;

a switch, for selectively effecting a connection between the second rectification circuit and one of the second or third predetermined voltage outputs.

11. The machine of claim 1 further improved in comprising an inverter, responsive to the DC signal, for generating an AC signal.

12. The machine of claim 11 further improved wherein the inverter comprises a variable frequency inverter, responsive to indicia of the current drawn from the inverter, for generating an AC signal having a frequency in accordance with the current drawn.

13. The machine of claim 11 further improved wherein the inverter comprises a variable frequency inverter, responsive to indicia of the DC voltage level, for generating an AC signal having a frequency in accordance with the DC voltage.