Hybrid alternator

• US 5,747,909 A
• Filed: 03/14/1996
• Issued: 05/05/1998
• Est. Priority Date: 03/14/1996
• Status: Expired due to Fees

• Current Assignee: Ecoair Corp.
• Original Assignee: Ecoair Corp.
• Inventors: Syverson, Charles D., Francis, Willard P.
• Primary Examiner(s): Stephan, Steven L.
• Assistant Examiner(s): Nguyen, Tran N.
• Application Number:
  US08/616,106
• Time in Patent Office: 782 Days
• Field of Search: 310/156, 310/114, 310/115, 310/261, 310/181, 310/265, 322/10, 322/29, 322/26
• US Class Current: 310/156.56
• CPC Class Codes: H02H 5/042 using temperature dependent resistors
• CPC Class Codes: H02H 7/06 for dynamo-electric generators; for synchronous capacitors
• CPC Class Codes: H02K 1/24 Rotor cores with salient poles ; Variable reluctance rotors
• CPC Class Codes: H02K 1/2713 the magnetisation axis of the magnets being axial, e.g. claw-pole type
• CPC Class Codes: H02K 1/276 Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
• CPC Class Codes: H02K 1/2773 consisting of tangentially magnetized radial magnets
• CPC Class Codes: H02K 16/00 Machines with more than one rotor or stator machines for transmitting mechanical power from a driving shaft to a driven shaft and comprising structurally interrelated motor and generator parts H02K51/00; permanent magnet machines with multiple rotors or stators relatively rotated for vectorially combining the excitation fields or the armature voltages H02K21/029
• CPC Class Codes: H02K 19/36 Structural association of synchronous generators with auxiliary electric devices influencing the characteristic of the generator or controlling the generator, e.g. with impedances or switches
• CPC Class Codes: H02K 19/365 with a voltage regulator
• CPC Class Codes: H02K 21/042 with permanent magnets and field winding both rotating
• CPC Class Codes: H02K 3/51 applicable to rotors only
• CPC Class Codes: H02K 9/06 with fans or impellers driven by the machine shaft
• CPC Class Codes: H02P 2101/45 for motor vehicles, e.g. car alternators
• CPC Class Codes: H02P 9/006 Means for protecting the generator by using control control effected upon generator excitation circuit to reduce harmful effects of overloads or transients H02P9/10
• CPC Class Codes: H02P 9/305 controlling voltage H02P9/302 takes precedence

Abstract

A hybrid alternator comprising a stator, and a rotor mounted for rotation within the stator and separated therefrom by an air gap. The rotor has a rotor core defining a plurality of magnetic poles wherein adjacent ones of the magnetic poles have alternating north and south magnetic fields. The plurality of magnetic poles comprises a plurality of permanent magnet poles and a plurality of electromagnetic poles. Each permanent magnet pole is defined by a permanent magnet. The plurality of permanent magnet poles comprises two (2) sets of diametrically positioned permanent magnet poles. Each permanent magnet is positioned within the rotor perimeter and associated with a pair of adjacent magnetic poles to form adjacent permanent magnet poles. The hybrid alternator also includes a temperature monitoring voltage regulator that provides protection against overheating damage while permitting the alternator to significantly exceed its rated output for short periods of time or in colder ambient temperatures.

Claims

1. A hybrid alternator comprising:

a stator; and

a rotor mounted for rotation within the stator and separated therefrom by an air gap, said rotor having a rotor core including a plurality of rotor field poles defining a plurality of magnetic poles, adjacent ones of the magnetic poles having alternating north and south magnetic fields, the plurality of magnetic poles comprising a plurality of permanent magnet poles and a plurality of electromagnetic poles, each permanent magnet pole being defined by a permanent magnet radially extending from the rotor core, said plurality of permanent magnet poles comprising two sets of diametrically positioned permanent magnet poles, each permanent magnet being positioned within the rotor perimeter between a pair of adjacent rotor field poles to form adjacent permanent magnet poles.

2. The hybrid alternator of claim 1 wherein each set of permanent magnet poles includes three (3) magnets.

3. The hybrid alternator of claim 2 wherein each set of permanent magnet poles comprises four (4) permanent magnet poles and said plurality of electromagnetic poles comprises four (4) electromagnetic poles.

4. The hybrid alternator of claim 1 wherein said rotor core defines a plurality of rotor field poles, each of which being associated with a corresponding magnetic pole.

5. The hybrid alternator of claim 1 wherein each of said magnets is formed from a magnetic material chosen from ferrite, neodymium, ceramic and samarium-cobalt.

6. The hybrid alternator of claim 4 wherein each rotor field pole and each magnet has a longitudinal axis substantially parallel to the rotor rotational axis, each rotor field pole and each magnet radially extending from said rotor core, each permanent magnet being mounted between a pair of adjacent rotor field poles to form adjacent permanent magnet poles.

7. The hybrid alternator of claim 4 wherein each magnet is magnetically isolated from said rotor field core.

8. The hybrid alternator of claim 6 wherein each rotor field pole comprises:

a body radially extending from said rotor core to an end surface; and

a rotor field pole shoe mounted to said end surface.

9. The hybrid alternator of claim 8 wherein said rotor field pole bodies are asymmetrically spaced on said rotor core.

10. The hybrid alternator of claim 9 wherein each rotor field pole shoe is asymmetrically attached to a corresponding rotor field pole body in a manner such that said pole shoes are equidistantly spaced in relation to one another.

11. The hybrid alternator of claim 8 wherein each rotor field pole body has a predetermined width and length that corresponds to a specific pole flux.

12. The hybrid alternator of claim 1 wherein each permanent magnet is arranged in a manner such that the direction of magnetization is oriented circumferentially relative to the rotor core rotational axis.

13. The hybrid alternator of claim 10 wherein the pole body of each rotor field pole positioned between one of said magnets and one of said electromagnetic poles has a geometrical shape that corresponds to the summation of flux contributed by said magnet and said electromagnetic pole.

14. The hybrid alternator of claim 1 further comprising a temperature monitoring voltage regulator for controlling bi-directional current flow through a winding of the hybrid alternator, the temperature monitoring voltage regulator comprising:

a voltage monitoring circuit connected to monitor the output voltage of the hybrid alternator, the voltage monitoring circuit producing an error signal indicating that the output voltage of the hybrid alternator should be increased or decreased;

a temperature sensor mounted in thermal contact with the hybrid alternator, the temperature sensor being electrically connected to the voltage monitoring circuit and modifying the error signal to reduce the output voltage of the hybrid alternator above a predetermined temperature;

a switching circuit connected to the winding and arranged to connect the winding in a forward polarity mode in which a forward polarity voltage is applied to the winding and a reverse polarity mode in which a reverse polarity voltage is applied to the winding;

a control circuit connected to the switching circuit, responsive to the error signal of the monitoring circuit, the control circuit controlling the switching circuit to enter the forward polarity mode to increase the output voltage of the alternator, and to enter the reverse polarity mode to decrease the output voltage of the alternator.

15. The hybrid alternator according to claim 14 wherein the temperature sensor comprises a thermistor.

16. The hybrid alternator according to claim 15 wherein the thermistor has a positive temperature coefficient.

17. The hybrid alternator according to claim 14 wherein the temperature sensor has a variable resistance that varies nonlinearly.

18. The hybrid alternator according to claim 14 wherein the switching circuit is arranged to connect the winding in a decay mode in which current induced in the winding when connected in the forward or reverse polarity mode is permitted to decay without inducing damaging voltages in the voltage regulator, and wherein the control circuit controls the switching circuit to enter the decay mode whenever switching away from the forward or reverse polarity mode.

19. The hybrid alternator according to claim 14 wherein the voltage monitoring circuit includes an error amplifier having first and second inputs, the first input being connected to a reference voltage, and the second input being connected to a voltage divider incorporating the temperature sensor.

20. A hybrid alternator comprising:

a stator having a stator winding; and

a rotor mounted for rotation within the stator and separated therefrom by an air gap, said rotor including;

a rotor core defining a plurality of rotor field poles asymmetrically positioned about the rotor core, each rotor field pole comprising a body radially extending from said rotor core to an end surface,

a plurality of permanent magnets, each of which being positioned within the rotor perimeter, radially extending from the rotor core and mounted between a pair of adjacent rotor field poles to form adjacent permanent magnet poles, said plurality of permanent magnet poles comprising two (2) diametrically positioned sets of permanent magnet poles, each set of permanent magnet poles comprising four (4) adjacent permanent magnet poles, each permanent magnet being arranged in a manner such that the direction of magnetization is oriented circumferentially relative to the rotor core rotational axis, the permanent magnets being magnetically isolated from said rotor core;

a rotor winding associated with the remaining rotor field poles to define a plurality of electromagnetic poles, said plurality of electromagnetic poles comprising two (2) diametrically positioned sets of electromagnetic poles, each set of electromagnetic poles comprising two (2) adjacent electromagnetic poles, said electromagnetic and permanent magnet poles defining a plurality of magnetic poles, adjacent ones of said magnetic poles having alternating north and south magnetic fields, and

a plurality of rotor field pole shoes, each of which being asymmetrically mounted to said end surface of a corresponding one of said pole bodies, said rotor field shoes being equidistantly spaced from one another.

21. The hybrid alternator of claim 20 wherein the rotor field pole body of each rotor field pole positioned between one of said magnets and one of said electromagnetic poles has a geometrical shape that corresponds to the summation of flux contributed by said magnet and said electromagnetic pole.

22. The hybrid alternator of claim 20 wherein each of said magnets is formed from a magnetic material chosen from ferrite, neodymium, ceramic and samarium-cobalt.

23. A hybrid alternator system comprising:

a hybrid alternator comprising;

a stator having a stator winding, and

a rotor mounted for rotation within the stator and separated therefrom by an air gap, said rotor having a rotor core including a plurality of rotor field poles defining a plurality of magnetic poles, adjacent ones of the magnetic poles having alternating north and south magnetic fields, the plurality of magnetic poles being consecutively arranged in a direction that is circumferential of the rotor core, at least two of the magnetic poles being adjacent permanent magnet poles having a permanent magnet radially extending from the rotor core and located between the at least two adjacent permanent magnet poles, the remaining magnetic poles comprising a plurality of electromagnetic poles, each electromagnetic pole being defined by a wound field, the permanent magnet being physically remote from the wound fields; and

a temperature monitoring voltage regulator comprising;

a voltage monitoring circuit connected to monitor the output voltage of the hybrid alternator, the voltage monitoring circuit producing an error signal indicating that the output voltage of the hybrid alternator should be increased or decreased,

a temperature sensor mounted in thermal contact with the hybrid alternator, the temperature sensor being electrically connected to the voltage monitoring circuit and modifying the error signal to reduce the output voltage of the hybrid alternator above a predetermined temperature,

a switching circuit connected to the rotor winding and arranged to connect the rotor winding in a forward polarity mode in which a forward polarity voltage is applied to the rotor winding and a reverse polarity mode in which a reverse polarity voltage is applied to the rotor winding, and

a control circuit connected to the switching circuit, responsive to the error signal of the monitoring circuit, the control circuit controlling the switching circuit to enter the forward polarity mode to increase the output voltage of the alternator, and to enter the reverse polarity mode to decrease the output voltage of the alternator.

24. A hybrid alternator comprising:

a stator; and

a rotor mounted on a rotor shaft for rotation within the stator and separated therefrom by an air gap, said rotor including;

a plurality of rotor field poles radially extending outward relative to the rotor shaft,

a permanent magnet radially extending outward relative to the rotor shaft, the permanent magnet being located between two adjacent rotor field poles from among the plurality of rotor field poles, the permanent magnet supplying magnetic flux to the two adjacent rotor field poles to form permanent magnet poles, a magnetic circuit being formed by magnetic flux extending through the permanent magnet, out one of the two adjacent rotor field poles, across the air gap, into the stator, back across the air gap, into the other of the two adjacent rotor field poles and back to the permanent magnet,

a plurality of windings corresponding to the rotor field poles not adjacent to the permanent magnet, each winding being disposed about its corresponding field pole and supplying magnetic flux to its corresponding field pole to form an electromagnetic pole, a magnetic circuit being formed through each winding by magnetic flux extending through said winding, out its corresponding rotor field pole, across the air gap into the stator, back across the air gap into rotor field poles on adjacent opposite sides of the corresponding rotor field pole and back to the corresponding rotor field pole.