Compact high power alternator
First Claim
1. A power conversion apparatus comprising:
- a shaft, a first stator, a second stator, a first rotor and a diametrically opposed second rotor, the shaft, stators, and rotor casings being coaxially disposed with the rotor casings mounted on the shaft, the first and second stators respectively including at least one winding;
wherein the first rotor further comprises a first plurality of permanent magnets coupled to the first rotor and disposed proximate to the first stator, separated from the first stator by a first predetermined gap distance, such that relative motion of the first stator and first rotor causes magnetic flux from the magnets to magnetically interact with the first stator winding;
wherein the second rotor further comprises a second plurality of permanent magnets coupled to the second rotor and disposed proximate to the second stator, separated from the second stator by a second predetermined gap distance, such that relative motion of the second stator and second rotor causes magnetic flux from the magnets to magnetically interact with the second stator winding; and
the respective first and second plurality of permanent magnets have a respective predetermined length beyond a respective predetermined first and second stator face lengths;
a cooling system for directing coolant flow into thermal contact with at least one of the winding and magnets, the cooling system generating sufficient coolant flow through a predetermined flow path at and above a predetermined speed to dissipate heat generated and maintain a temperature of the magnets below a predetermined destructive level;
a first end plate, wherein;
the first rotor is mounted on the first endplate; and
the first stator is mounted for rotation relative to the first endplate;
a second endplate, and an outer casing, wherein;
the first and second rotor casings, first and second stator cores, and outer casing are concentric with the shaft;
the shaft is rotatably coupled to the first and second endplates;
the second rotor is mounted on the second end plate; and
the first and second stator is coupled to the shaft for rotation therewith between the first and second endplates and within the outer casing;
wherein the cooling system comprises a passageway through the first and second stator core and a passageway through the first and second rotor in fluid communication with the first and second stator core passageway;
wherein the first and second rotor passageway is disposed such that coolant flow is directed through a first end plate passageway, into thermal contact with the first stator first winding end turns, through the first stator core passageway, into thermal contact with the first stator second winding end turns, into thermal contact with the second stator first winding end turns, through the second stator core passageway, into thermal contact with the second stator second winding end turns, through a second end plate passageway; and
into thermal contact with the first and second magnets.
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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. Various aspects of the invention provide a means of significantly increasing the output of permanent magnet alternators while addressing the issues of radial loading applied to a permanent magnet alternator rotor. Another aspect of the invention allows for the production of power in two discrete voltages. An aspect of this invention allows for a marked increase in output capability without increasing axial length through the use of magnetic fringing. One aspect of the invention offers an effective means of mounting a skewed stack that eliminates or reduces cogging that is present in a permanent magnet machine without negatively impacting airflow. Another aspect of the invention reduces cogging by radially offsetting opposing magnets of a dual rotor permanent magnet machine.
77 Citations
41 Claims
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1. A power conversion apparatus comprising:
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a shaft, a first stator, a second stator, a first rotor and a diametrically opposed second rotor, the shaft, stators, and rotor casings being coaxially disposed with the rotor casings mounted on the shaft, the first and second stators respectively including at least one winding; wherein the first rotor further comprises a first plurality of permanent magnets coupled to the first rotor and disposed proximate to the first stator, separated from the first stator by a first predetermined gap distance, such that relative motion of the first stator and first rotor causes magnetic flux from the magnets to magnetically interact with the first stator winding; wherein the second rotor further comprises a second plurality of permanent magnets coupled to the second rotor and disposed proximate to the second stator, separated from the second stator by a second predetermined gap distance, such that relative motion of the second stator and second rotor causes magnetic flux from the magnets to magnetically interact with the second stator winding; and the respective first and second plurality of permanent magnets have a respective predetermined length beyond a respective predetermined first and second stator face lengths; a cooling system for directing coolant flow into thermal contact with at least one of the winding and magnets, the cooling system generating sufficient coolant flow through a predetermined flow path at and above a predetermined speed to dissipate heat generated and maintain a temperature of the magnets below a predetermined destructive level; a first end plate, wherein;
the first rotor is mounted on the first endplate; and
the first stator is mounted for rotation relative to the first endplate;a second endplate, and an outer casing, wherein;
the first and second rotor casings, first and second stator cores, and outer casing are concentric with the shaft;
the shaft is rotatably coupled to the first and second endplates;
the second rotor is mounted on the second end plate; and
the first and second stator is coupled to the shaft for rotation therewith between the first and second endplates and within the outer casing;wherein the cooling system comprises a passageway through the first and second stator core and a passageway through the first and second rotor in fluid communication with the first and second stator core passageway; wherein the first and second rotor passageway is disposed such that coolant flow is directed through a first end plate passageway, into thermal contact with the first stator first winding end turns, through the first stator core passageway, into thermal contact with the first stator second winding end turns, into thermal contact with the second stator first winding end turns, through the second stator core passageway, into thermal contact with the second stator second winding end turns, through a second end plate passageway; and
into thermal contact with the first and second magnets. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41)
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Specification