Compact high power alternator
First Claim
1. Compact, high power, power conversion apparatus comprising a shaft, a stator, and a rotor, the shaft, stator, and rotor being coaxially disposed with the rotor mounted on the shaft, the stator including at least one winding, and the rotor including a plurality of permanent magnets 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 magnets to magnetically interact with the stator winding, wherein:
- the shaft has a predetermined diameter and includes a shaft tapered portion disposed between the ends of the shaft at a predetermined position relative to the stator, the diameter of the shaft tapered portion varying in accordance with a predetermined taper from a minimum diameter greater than the predetermined diameter to a predetermined maximum diameter greater than the shaft predetermined diameter;
the rotor includes a hub and a central through-bore having the predetermined taper corresponding to that of the shaft tapered portion of the shaft, the diameter of the tapered through-bore varying in accordance with the predetermined taper from a minimum through-bore diameter greater than the shaft predetermined diameter to a predetermined maximum through-bore diameter; and
the rotor hub is disposed with the shaft journaled and extending through the hub through-bore, with the shaft tapered portion received in the through-bore with interior surface of the through bore and exterior surface of the shaft tapered portion in mating contact, wherein cooperation of the tapered rotor bore in surface contact with the shaft tapered portion positions the rotor both axially and radially with respect to the shaft and stator, coupling the rotor to the shaft for rotation therewith.
0 Assignments
0 Petitions
Accused Products
Abstract
An apparatus for converting between mechanical and electrical energy, particularly suited for use as a compact high power alternator for automotive use and “remove and replace” retrofitting of existing vehicles. The apparatus includes a rotor with permanent magnets, a stator with a winding, and a cooling system. Mechanisms to prevent the rotor magnets from clashing with the stator by minimizing rotor displacement, and absorbing unacceptable rotor displacement are disclosed. Various open and closed cooling systems are described. Cooling is facilitated by, for example, loosely wrapping the winding end turns, use of an asynchronous airflow source, and/or directing coolant through conduits extending through the stator into thermal contact with the windings.
39 Citations
25 Claims
-
1. Compact, high power, power conversion apparatus comprising a shaft, a stator, and a rotor, the shaft, stator, and rotor being coaxially disposed with the rotor mounted on the shaft, the stator including at least one winding, and the rotor including a plurality of permanent magnets 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 magnets to magnetically interact with the stator winding, wherein:
-
the shaft has a predetermined diameter and includes a shaft tapered portion disposed between the ends of the shaft at a predetermined position relative to the stator, the diameter of the shaft tapered portion varying in accordance with a predetermined taper from a minimum diameter greater than the predetermined diameter to a predetermined maximum diameter greater than the shaft predetermined diameter; the rotor includes a hub and a central through-bore having the predetermined taper corresponding to that of the shaft tapered portion of the shaft, the diameter of the tapered through-bore varying in accordance with the predetermined taper from a minimum through-bore diameter greater than the shaft predetermined diameter to a predetermined maximum through-bore diameter; and the rotor hub is disposed with the shaft journaled and extending through the hub through-bore, with the shaft tapered portion received in the through-bore with interior surface of the through bore and exterior surface of the shaft tapered portion in mating contact, wherein cooperation of the tapered rotor bore in surface contact with the shaft tapered portion positions the rotor both axially and radially with respect to the shaft and stator, coupling the rotor to the shaft for rotation therewith. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17)
-
-
18. Compact, high power, power conversion apparatus comprising:
-
first and second endplates;
the endplates comprising a central hub, and outer portion, and a connecting portion connecting the outer portion to the central hub;a shaft rotatably coupled to the first and second endplate hubs, the shaft having a predetermined diameter and including a tapered projecting portion disposed at a predetermined position between the first and second endplate hubs, the diameter of the tapered projecting portion varying, in accordance with a predetermined change in diameter per unit axial length, from a minimum diameter to a predetermined maximum diameter greater than the shaft predetermined diameter; an outer casing having a cylindrical interior surface disposed concentric with the shaft between the first and second endplate outer portions; a stator comprising a core and at least one conductive winding, the core including a central aperture of predetermined cross section and a peripheral portion having respective radially extending side faces and a generally cylindrical outer peripheral surface, the core peripheral portion having a predetermined number of slots formed therein extending between the side faces, successive slots separated by intervening portions of the core peripheral portion, the winding being wound around the core peripheral portion through respective slots separated by a predetermined number of intervening portions of the core peripheral portion, forming end turns between the respective slots, the stator core being fixed to the second endplate, disposed such that the core outer peripheral surface is concentric with the shaft, with the shaft extending through the stator central aperture; a rotor comprising a hub, a cylindrical casing, and a connecting portion attaching the cylindrical casing to the hub, the rotor hub including a tapered central through-bore, the diameter of the tapered through-bore varying, in accordance with the predetermined change in diameter per unit axial length of the shaft tapered projecting portion, from a minimum diameter greater than the shaft predetermined diameter to a predetermined maximum diameter, the rotor hub being disposed with the shaft extending through the hub through-bore, with the shaft tapered portion received in the through-bore with interior surface of the through bore and exterior surface of the shaft tapered portion in mating contact, cooperation of the tapered rotor bore and tapered projecting shaft portion positioning the rotor both axially and radially with respect to the shaft and stator core peripheral surface, coupling the rotor to the shaft for rotation therewith, the rotor cylindrical casing being disposed concentric with the shaft, outer casing and stator core peripheral surface, and within the outer casing between the first and second endplates, spaced apart from the interior surface of the outer casing by a predetermined distance, the rotor including a predetermined number of permanent magnets disposed on the interior of the casing concentric with the stator core outer peripheral surface, the stator core being received within the interior of the rotor casing proximate to the rotor magnets, separated from the magnets by a predetermined gap distance, such that relative motion of the rotor and stator causes electromagnetic interaction between the magnets and the stator winding; the first and second endplates, shaft tapered projecting portion, rotor hub tapered through-bore, and outer casing cooperating to maintain the alignment of the shaft, rotor and stator. - View Dependent Claims (19, 20, 21, 22, 23, 24, 25)
-
Specification