Multi-phase multi-pole electric machine

• US 9,595,859 B2
• Filed: 03/29/2012
• Issued: 03/14/2017
• Est. Priority Date: 03/29/2012
• Status: Active Grant

• Current Assignee: Falco eMotors, Inc.
• Original Assignee: Rakesh K. Dhawan
• Inventors: Dhawan, Rakesh K.
• Primary Examiner(s): Santana, Eduardo Colon
• Assistant Examiner(s): Dhakal, Bickey
• Application Number:
  US13/433,316
• Publication Number:
  US 20130257327A1
• Time in Patent Office: 1,811 Days
• Field of Search: 310179-210, 310/75.C, 310/67.A, 180/65.51
• US Class Current: 1/1
• CPC Class Codes: A61G 5/04 motor-driven A61G5/06 takes precedence; motor-operated rests A61G5/12; for vehicles with handlebars, equipped with three or more wheels B62K5/003, B62K5/023
• CPC Class Codes: A61G 5/1054 Large wheels, e.g. higher than the seat portion
• CPC Class Codes: B60L 15/2036 Electric differentials, e.g. for supporting steering vehicles
• CPC Class Codes: B60L 15/2054 by controlling transmissions or clutches
• CPC Class Codes: B60L 2200/12 Bikes
• CPC Class Codes: B60L 2200/34 Wheel chairs
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 2220/14 Synchronous machines
• CPC Class Codes: B60L 2220/44 Wheel Hub motors, i.e. integrated in the wheel hub
• CPC Class Codes: B60L 2220/58 with more than three phases
• CPC Class Codes: B60L 2240/12 Speed
• CPC Class Codes: B60L 2240/36 Temperature of vehicle components or parts
• CPC Class Codes: B60L 2240/421 Speed
• CPC Class Codes: B60L 2240/423 Torque
• CPC Class Codes: B60L 2250/16 by display
• CPC Class Codes: B60L 2250/24 by lever actuation
• CPC Class Codes: B60L 2250/26 by pedal actuation
• CPC Class Codes: B60L 3/0061 relating to electrical machines
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/20 using propulsion power generated by humans or animals
• CPC Class Codes: B60L 50/51 : characterised by AC-motors
• CPC Class Codes: H02K 11/24 : Devices for sensing torque, or actuated thereby H02K11/27 takes precedence
• CPC Class Codes: H02K 11/33 : Drive circuits, e.g. power electronics H02K11/38 takes precedence
• CPC Class Codes: H02K 21/22 : with magnets rotating around the armatures, e.g. flywheel magnetos
• 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: H02P 25/22 : Multiple windings; Windings for more than three phases
• 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
• CPC Class Codes: Y02T 10/7072 : Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 : Electric energy management in electromobility

Abstract

A multi-phase multi-pole electric machine attached to a vehicle. The multi-phase multi-pole electric machine includes rotor, stator with five phase windings, machine controller, and torque sensors. The machine controller controls the flow of current. The torque sensors senses the torque exerted by the vehicle and transmits the information to the machine controller. The machine controller provides four degree of control through injection of five phase currents and thus providing higher torque.

Claims

1. A multi-phase multi-pole electric machine attached to a wheel of a vehicle, the wheel having spokes, said multi-phase multi-pole machine comprising:

a stator core comprising an axle, said stator core comprising;

a stator lamination, said stator lamination comprising;

a first, a second, a third, a fourth and a fifth retention elements are located around an inner circumference of the stator lamination;

a first, a second, a third, a fourth and a fifth protrusion elements covering the first, the second, the third, the fourth and the fifth retention elements;

a first groove is located between the first retention element and the second retention element, said first grove located immediately adiacent to the second retention element in a clockwise direction than the first retention element;

a second groove is located between the third retention element and the fourth retention element, said second grove located approximately in the middle between the third retention element and the fourth retention element;

a third groove is located between the fifth retention element and the first retention element, said third groove located immediately adiacent to the fifth retention element in a counter clock-wise direction than the first retention element;

a rotor attached to said stator core, said rotor comprising;

two identical covers, wherein each cover having plurality of spoke holes directly attached to the spokes of the wheel of said vehicle for rotating around said axle;

a connecting pipe disposed between said one or more two identical covers rotated around the stator core;

a back-iron directly attached to the inner perimeter of said connecting pipe;

a plurality of rotor magnets attached to inner perimeter of said back-iron, and further separated from said stator core by an air gap; and

wherein the two identical covers rotate along with the spoke holes with the rotation of the rotor at the same speed.

2. The multi-phase multi-pole electric machine according to claim 1, further comprises a machine controller located inside the electric machine and connected to said stator core to control the flow of current.

3. The multi-phase multi-pole electric machine in claim 2, wherein said machine controller further comprises:

a micro controller to generate a signal;

an inverter receives said signal from said microcontroller, said inverter manipulates said signal to control electrical current flow to said stator core;

a temperature sensor to measure the temperature of said machine controller and said five phase winding;

a communication interface to transmit input commands to said micro controller;

a torque sensor to measure torque exerted by an operator of the vehicle and manipulate the controller output based on the measured torque; and

multiple current sensors to monitor battery current and various winding currents and to manipulate the controller output based on these currents.

4. The multi-phase multi-pole electric machine according to claim 1 further comprises a torque sensor attached to a stationary axle, said torque sensor to sense the torque exerted and transmit the information to said machine controller.

5. The multi-phase multi-pole electric machine according to claim 1 further comprises a removable disc adaptor attached to a brake mechanism of said vehicle, wherein said vehicle has pedals.

6. The multi-phase multi-pole electric machine according to claim 1 further comprises a removable external gear adaptor, said gear adaptor is attached to gear mechanism.

7. The multi-phase multi-pole electric machine in claim 1 further comprises one or more rotor position sensors to sense the position of said rotor and configured for a 5-phase motor.

8. The multi-phase multi-pole electric machine in claim 1 further comprises ten or a multiple of ten semi conductor switches connected to said machine controller and said five phase windings.

9. A multi-phase multi-pole electric machine attached to a vehicle with pedals and a wheel with spokes said multiphase multi-pole machine comprising:

a stator core comprising an axle;

a rotor attached to said stator core, said rotor comprising;

two identical covers, wherein each cover having plurality of spoke holes directly attached to the spokes of the wheel of said vehicle for rotating around said axle;

a connecting pipe disposed between said two identical covers rotated around the stator core; and

a back-iron directly attached to the inner perimeter of said connecting pipe;

a plurality of rotor magnets attached to inner perimeter of said back-iron, and further separated from said stator core by an air gap;

connecting pipe; and

wherein the two identical covers rotate along with the spoke holes with the rotation of the rotor at the same speed;

wherein stator core attached to the said rotor, said stator core comprising;

a stator lamination, said stator lamination comprising;

a first, a second, a third, a fourth and a fifth retention elements are located around an inner circumference of the stator lamination;

a first, a second, a third, a fourth and a fifth protrusion elements covering the first, the second, the third, the fourth and the fifth retention elements;

a first groove is located between the first retention element and the second retention element, said first grove located immediately adiacent to the second retention element in a clockwise direction than the first retention element;

a second groove is located between the third retention element and the fourth retention element, said second grove located approximately in the middle between the third retention element and the fourth retention element;

a third groove is located between the fifth retention element and the first retention element, said third groove located immediately adjacent to the fifth retention element in a counter clock-wise direction than the first retention element;

plurality of stator poles separated by stator slots;

five phase winding wound around said stator poles;

stator plates attached to said plurality of stator poles; and

wherein said axle passes through the central aperture of said stator plates;

a machine controller connected to said stator core to control the flow of current; and

a torque sensor attached to said axle, said torque sensor to sense the torque exerted and transmits the information to said machine controller.

10. The multi-phase multi-pole electric machine in claim 9 wherein said machine controller further comprises:

a micro controller to generate a signal;

an inverter receives said signal from said microcontroller, said inverter manipulates said signal to control electrical current flow to said stator core;

a temperature sensor to measure the temperature of said machine controller and said five phase winding; and

a communication interface to transmit input commands to said micro controller.

11. The multi-phase multi-pole electric machine according to claim 9 further comprises one or more semi conductor switches connected to said machine controller and said five phase windings.