Brushless permanent magnet motor/generator with axial rotor decoupling to eliminate magnet induced torque losses

• US 7,863,789 B2
• Filed: 10/19/2006
• Issued: 01/04/2011
• Est. Priority Date: 10/19/2005
• Status: Active Grant

• Current Assignee: Dura-Trac Motors, Inc.
• Original Assignee: Dura-Trac Motors, Inc.
• Inventors: Zepp, Lawrence P., Medlin, Jerry W.
• Primary Examiner(s): Leung; Quyen
• Assistant Examiner(s): Scheuermann; David W.
• Application Number:
  US11/583,590
• Publication Number:
  US 20070096581A1
• Time in Patent Office: 1,538 Days
• Field of Search: 310/90, 310/114, 310/190, 310/191, 310/209, 310/266
• US Class Current: 310/90
• CPC Class Codes: H02K 21/024 Radial air gap machines
• CPC Class Codes: H02K 7/12 with auxiliary limited movement of stators, rotors or core parts, e.g. rotors axially movable for the purpose of clutching or braking

Abstract

A permanent magnet motor/generator that includes a stator, a rotor provided with a plurality of permanent magnets at a peripheral surface thereof and having a central axis which coincides with the central axis of the stator, a rotatable shaft upon which the rotor is coupled, and an actuator for moving the rotor with respect to the stator axially along the rotatable shaft a sufficient distance to completely decouple the rotor from the stator so as to eliminate magnet induced torque drag. When the permanent magnet/generator is used in parallel hybrid vehicles, the ability to completely decouple the rotor from the stator greatly improves range and efficiency. In addition, by progressively engaging the rotor with the stator a desired voltage output can be obtained upon deceleration.

Claims

1. A permanent magnet motor/generator that comprises:

a housing;

a stator located in the housing in a fixed position with respect to the housing, the stator having a plurality of stator magnetic poles and windings for generating a rotating filed in the stator magnetic poles, said stator having a central axis;

a rotatable shaft extending through the housing and having a central axis which coincides with the central axis of the stator;

a rotor located in the housing and movably positioned on the rotatable shaft the rotor provided with a plurality of permanent magnets at a peripheral surface thereof and having a central axis which coincides with the central axis of the stator; and

an actuator for moving the rotor axially along the rotatable shaft within the housing so as to move the rotor while the stator is maintained in a fixed position with respect to the housing, the rotor being moved a sufficient distance relative to the stator to completely decouple the rotor from the stator so as to eliminate magnet induced torque drag.

2. A permanent magnet motor/generator according to claim 1, further comprising a constant velocity bearing which couples the rotor to the rotatable shaft.

3. A permanent magnet motor/generator according to claim 1, further comprising a plurality of ball bearings between the rotor and rotatable shaft.

4. A permanent magnet motor/generator according to claim 3, wherein the rotatable shaft is provided with a plurality of axial grooves for receiving the plurality of ball bearings therein.

5. A permanent magnet motor/generator according to claim 1, further comprising a thrust bearing assembly which couples the actuator to the rotor.

6. A permanent magnet motor/generator according to claim 1, further including a housing for housing the stator and rotor, in which at least a portion of the housing is made from a material having a high electrical resistance so as to reduce eddy loss currents and lower lowering cogging torque drive.

7. A permanent magnet motor/generator according to claim 6, wherein the material having a high electrical resistance comprises non-magnetic stainless steel.

8. A permanent magnet motor/generator according to claim 6, wherein the housing is further provided with slots that reduce eddy loss currents.

9. The permanent magnet motor/generator according to claim 1, in combination with a parallel hybrid vehicle.

10. The permanent magnet motor/generator according to claim 1, in combination with a wind powered generator.

11. A method of method of operating a permanent magnet motor/generator so as to eliminate magnet induced torque drag which method comprises:

providing permanent magnet motor/generator that includes;

i) a housing;

ii) a stator located in the housing in a fixed position with respect to the housing, the stator having a plurality of stator magnetic poles and windings for generating a rotating filed in the stator magnetic poles, said stator having a central axis;

iii) a rotatable shaft extending through the housing and having a central axis which coincides with the central axis of the stator; and

iv) a rotor located in the housing and movably positioned on the rotatable shaft, the rotor provided with a plurality of permanent magnets at a peripheral surface thereof and having a central axis which coincides with the central axis of the stator; and

b) moving the rotor axially along the rotatable shaft within the housing so as to move the rotor while the stator is maintained in a fixed position with respect to the housing, the rotor being moved a sufficient distance relative to the stator to completely decouple the rotor from the stator so as to eliminate magnet induced torque drag.

12. A method of method of operating a permanent magnet motor/generator according to claim 11, wherein the permanent magnet motor/generator is incorporated into a vehicle.

13. A method of method of operating a permanent magnet motor/generator according to claim 12, wherein the rotor is progressively engaged with the stator as the vehicle is decelerated so as to control generated voltage output.

14. A method of method of operating a permanent magnet motor/generator according to claim 11, wherein the permanent magnet motor/generator is incorporated into a wind powered generator.

15. A parallel hybrid vehicle which comprises:

an internal combustion engine and

a permanent magnetic motor/generator, wherein the permanent magnet motor/generator includes;

a housing;

a stator located in the housing in a fixed position with respect to the housing, the stator having a plurality of stator magnetic poles and windings for generating a rotating filed in the stator magnetic poles, said stator having a central axis;

a rotatable shaft extending through the housing and having a central axis which coincides with the central axis of the stator;

a rotor located in the housing and movably positioned on the rotatable shaft, the rotor provided with a plurality of permanent magnets at a peripheral surface thereof and having a central axis which coincides with the central axis of the stator; and

an actuator for moving the rotor axially along the rotatable shaft within the housing so as to move the rotor while the stator is maintained in a fixed position with respect to the housing, the rotor being moved a sufficient distance relative to the stator to completely decouple the rotor from the stator so as to eliminate magnet induced torque drag.

16. A parallel hybrid vehicle according to claim 15, further comprising a controller that provides active control of rotor position.

17. A parallel hybrid vehicle according to claim 16, wherein the controller progressively engages the rotor with the stator as the vehicle is decelerated so as to control generated voltage output.

18. A parallel hybrid vehicle according to claim 16, wherein the controller fully decouples the rotor from the stator during constant speed operation of a vehicle.

19. A parallel hybrid vehicle according to claim 15, wherein the vehicle further includes a transmission and a drive shaft and the permanent magnet motor/generator is coupled between the transmission and the drive shaft.

20. A parallel hybrid vehicle according to claim 15, wherein the vehicle further includes a drive shaft and transmission having a housing and the permanent magnet motor/generator is housed in the housing of the transmission.