High-power low-RPM DC motor

• US 6,194,799 B1
• Filed: 11/15/1999
• Issued: 02/27/2001
• Est. Priority Date: 12/16/1997
• Status: Expired due to Term

• Current Assignee: Magnetic Motors, Inc.
• Original Assignee: Magnetic Motors, Inc.
• Inventors: Miekka, Fred N., Mackie, Peter W.
• Primary Examiner(s): MULLINS, BURTON S
• Application Number:
  US09/440,490
• Time in Patent Office: 470 Days
• Field of Search: 310/179, 310/180, 310/181, 310/184, 310/198, 310/156, 310/68.B, 310/68.C, 310/68.R, 310/254, 310/261, 310/266, 310/268, 310/68.E, 318/254, 318/439, 388/800, 388/924, 388/925
• US Class Current: 310/68.00R
• CPC Class Codes: B60L 2220/18 Reluctance machines
• CPC Class Codes: B60L 50/60 using power supplied by batteries in combination with fuel cells B60L50/75
• CPC Class Codes: H02K 1/08 Salient poles
• CPC Class Codes: H02K 1/2795 the rotor consisting of two or more circumferentially positioned magnets
• CPC Class Codes: H02K 19/103 Motors having windings on the stator and a variable reluctance soft-iron rotor without windings
• CPC Class Codes: H02K 21/02 Details
• CPC Class Codes: H02K 21/14 with magnets rotating within the armatures
• CPC Class Codes: H02K 21/24 with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• CPC Class Codes: H02K 2201/12 Transversal flux machines
• CPC Class Codes: H02K 23/36 having two or more windings; having two or more commutators; having two or more stators
• CPC Class Codes: H02K 23/66 Structural association with auxiliary electric devices influencing the characteristic of, or controlling, the machine, e.g. with impedances or switches
• CPC Class Codes: H02K 29/08 using magnetic effect devices, e.g. Hall-plates, magneto-resistors H02K29/12 takes precedence
• CPC Class Codes: H02K 29/10 using light effect devices
• CPC Class Codes: H02K 29/14 with speed sensing devices H02K29/03 takes precedence
• CPC Class Codes: H02K 3/18 Windings for salient poles
• CPC Class Codes: H02K 3/20 for auxiliary purposes, e.g. damping or commutating
• 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 7/10 Structural association with clutches, brakes, gears, pulleys or mechanical starters
• CPC Class Codes: H02K 7/116 with gears
• CPC Class Codes: H02K 7/14 Structural association with mechanical loads, e.g. with hand-held machine tools or fans with fan or impeller for cooling the machine H02K9/06
• CPC Class Codes: H02K 9/06 : with fans or impellers driven by the machine shaft
• CPC Class Codes: Y02T 10/64 : Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries

Abstract

A high power low RPM direct current electric motor is disclosed whereby the high power output is achieved in one of two ways or both. In the first case, the need for cooling is reduced simultaneously along with an increase in the utilization of the magnetic field present in the motor permanent magnets. This is achieved by wrapping the electromagnet core with windings that are capable of demagnetizing the rotor permanent magnets under stall conditions. Interlocking motor circuitry is provided which prevents the full activation of these motor windings until motor RPM values reach a safe level. This increases motor power while decreasing resistive losses in electromagnet windings. In the second case, the rotary portion consists of a large diameter relatively flat rotor containing permanent magnets and having built in vanes for moving air over the electromagnet stator windings providing forced air cooling.

Claims

1. A direct current (DC) permanent magnet electric motor comprising:

a stationary portion including a plurality of C-shaped electromagnets disposed to define an inner annular channel, each of said electromagnets having poles;

a rotatable portion including;

a shaft rotatable with respect to said stationary portion;

at least one disc mounted to said shaft, said disc having an annular portion rotatably disposed within said inner annular channel of said stationary portion; and

a plurality of permanent magnets each having a direction of magnetization and poles, said plurality of permanent magnets disposed on said annular portion of said disc so that the direction of magnetization thereof is transverse through said disc and so that the poles thereof are aligned in coupling proximity to the poles of said electromagnets;

position circuitry for sensing a position of said plurality of permanent magnets with respect to said plurality of said electromagnets and for providing a signal based on said position of said plurality of electromagnets to cause said rotatable portion to rotate;

each of said plurality of electromagnets including a winding;

said winding of at least one of said electromagnets having a configuration that demagnetizes said permanent magnets at stall conditions; and

electrical interlocking circuitry for allowing said configuration of said winding of said at least one of said electromagnets to be activated when said shaft reaches a preset speed that reduces current in said windings to a level sufficient to prevent demagnetization of said permanent magnets.

2. A motor as claimed in claim 1 wherein said motor is a brushless motor.

3. A direct current (DC) permanent magnet electric motor comprising:

a stationary portion including at least one electromagnet having at least one winding and poles when said winding is electrically energized;

a rotatable portion including;

a shaft rotatable with respect to said stationary portion;

at least one disc mounted to said shaft, said disc having a radial plane including an annular portion rotatably disposed within said stationary portion; and

a plurality of permanent magnets each having a direction of magnetization and poles, said plurality of permanent magnets being disposed on said annular portion of said disc so that the direction of magnetization thereof is transverse through said disc and so that the poles thereof are aligned in coupling proximity to the poles of said electromagnets;

position circuitry for sensing a position of said plurality of permanent magnets with respect to said plurality of electromagnets and for providing a signal based on said position to said at least one of said electromagnets to cause said rotatable portion to rotate;

each of said at least one of said electromagnets having poles facing perpendicular to said radial plane of said annular portion of said disc;

said winding of at least one of said electromagnets having a configuration that demagnetizes said permanent magnets at stall conditions; and

electrical interlocking circuitry for allowing said configuration of at least one of said electromagnets to be activated when said shaft reaches a preset speed that reduces current in said windings to a level sufficient to prevent demagnetization of said permanent magnets.

4. A motor as claimed in claim 3 wherein said motor is a brushless motor.

5. A direct current (DC) permanent magnet electric motor comprising:

a stationary portion including a plurality of electromagnets facing outward in a radial direction, each of said electromagnets having poles when electrically energized;

a rotatable portion including;

a shaft rotatable with respect to said stationary portion;

a housing fixedly attached to one end of said shaft and circumscribing said shaft, said housing having an inner surface and an outer surface; and

a plurality of permanent magnets each attached to said inner surface portion of said housing and having a pole, said poles of said permanent magnets facing inward in a radial direction and alternating with each successive of said permanent magnets and so that the poles thereof are aligned in coupling proximity to the poles of said electromagnets;

position circuitry for sensing a position of said plurality of permanent magnets with respect to said plurality of said electromagnets and for providing a signal based on said position of said plurality of electromagnets to cause said rotatable portion to rotate;

each of said plurality of electromagnets including a winding, said winding of at least one of said electromagnets having a configuration that demagnetizes said permanent magnets at stall conditions; and

electrical interlocking circuitry for allowing said configuration of said winding of said at least one of said electromagnets to be activated when said shaft reaches a preset speed that reduces current in said winding to a level sufficient to prevent demagnetization of said permanent magnets.

6. A motor as claimed in claim 5 further comprising current-limiting circuitry for protecting said permanent magnets from demagnetization.

7. A motor as claimed in claim 5 wherein said motor is a brushless motor.

8. A motor as claimed in claim 5 further comprising a turbofan fixedly attached on one end of said housing.

9. A motor as claimed in claim 5 wherein said outer surface of said housing includes gear teeth.

10. A motor as claimed in claim 5 wherein said outer surface of said housing includes teeth for engagement to a cog belt.

11. A motor as claimed in claim 5 wherein said outer surface of said housing includes a means for mounting a vehicle tire.

12. A permanent magnet electric motor comprising;

rotatable portion including;

a shaft; and

a plurality of permanent magnets each attached to said shaft and having a direction of magnetization and poles;

said poles of said permanent magnets facing outward in a radial direction and alternating with each successive of said permanent magnets;

a stationary portion including;

a housing for rotatably supporting said shaft and having an inner surface; and

a plurality of electromagnets each attached to said inner surface of said housing, having a direction of magnetization and poles when electrically energized, and including a winding;

said poles of said electromagnets facing inward in a radial direction and alternating with each successive of said electromagnets; and

said winding of at least one of said electromagnets having a configuration that demagnetizes said permanent magnets at stall conditions;

electrical interlocking circuitry for allowing said configuration of said winding of said at least one of said electromagnets to be activated when said shaft reaches a preset speed that reduces current in said winding to a level sufficient to prevent demagnetization of said permanent magnets; and

position circuitry for sensing a position of said plurality of permanent magnets with respect to said plurality of electromagnets to cause said rotatable portion to rotate.

13. A motor as claimed in claim 12 wherein said permanent magnets are further protected from demagnetization by the addition of current limiting circuitry.

14. A motor as claimed in claim 12 wherein said motor is a brushless motor.

15. A motor as claimed in claim 12 wherein said electrical interlocking circuitry is fixedly attached to said motor.

16. A motor as claimed in claim 12 wherein each said winding includes two or more twisted wire strands.

17. A motor as claimed in claim 12 wherein each said winding includes a first layer of electromagnet wire connected to a first motor tap and a second layer of wire connected to a second motor tap, said wire of said first layer having a thickness greater than said wire of said second layer.

18. A motor as claimed in claim 12 wherein said windings are electrically isolated from each other.