SWITCHED RELUCTANCE MACHINE WITH EDDY CURRENT LOSS

DAMPENER

Technical Field The present invention relates generally to variable reluctance machines. More particularly, the present invention relates to a type of variable reluctance machine known as a switched reluctance machine and to a component for dampening magnetic eddy currents therein.

Background A switched reluctance machine (motor or generator) is a form of variable reluctance machine. A switched reluctance motor generates torque by exploiting magnetic attraction created between the magnetic poles of the rotor and the stator by energizing the coils. Figure 1 shows a typical switched reluctance drive in schematic form, where the switched reluctance machine 12 having phase windings 16 is connected to a load 19. Other components of a typical system may include a power supply 11, a power converter 13, and an electronic control unit 14.

Such variable reluctance machines are generally constructed from laminations of electrical sheet steel, the resulting structure being used to carry the magnetic flux on which the machine depends for its operation. The structure is laminated to reduce the effect of eddy currents that flow in the steel due to the time rate of change of the flux.

A cross-section of a typical switched reluctance machine is shown in Figures 2 and 3. The machine is doubly salient, i.e. both stator and rotor laminations have magnetically salient poles. In Figure 2 the rotor is shown with a pair of poles fully aligned with the stator poles of Phase A. This represents the position of maximum inductance of the phase. In Figure 3 the rotor has been rotated to the position where an inter-polar axis of the rotor is aligned with the stator poles. This represents the position of minimum inductance. As the rotor rotates, the inductance varies between the extremes of the maximum and minimum inductance. Typically, the rotor and the stator have the same axial length and the flux paths within them are notionally the same at any cross-section along that axial length. The axial lengths of the cores are often denoted as the "active length" of the machine, the end-turns of the windings lying outside the active length at both ends of the machine.

A schematic flux path is shown in dashed lines on Figures 2 and 3 and, while this considerably simplifies the complexity of the actual paths, it illustrates that the flux passes through the back-iron of the rotor as well as through the rotor poles, i.e. the back- iron region of the rotor is an integral part of the magnetic circuit associated with the phase winding. It will also be clear from Figure 3 that the minimum inductance is heavily dependent on the length of the air path from the stator poles to the rotor back iron. Finally, Figure 4 illustrates a longitudinal cross-section of a switched reluctance machine known in the art.

These paths of magnetic flux may extend beyond the electrical machine itself and have negative consequences, including interference with nearby electronic circuits and loss of efficiency of the electrical machine.

Magnetic shielding protects electronic circuits from magnetic field interference. Usually, sources of this interference include permanent magnets, transformers, motors, solenoids, and cables. Magnetic shields provide a path around sensitive areas to deflect magnetic flux. In addition, shielding may contain magnetic flux around a component that generates flux, thereby increasing the efficiency of the component. Three types of materials are used for magnetic shielding - high permeability, medium permeability, and high saturation. One approach of reducing eddy currents is not to use a shield at all; rather, Deodhar et al. (U.S. Pat. App. No. 2007/0029890) suggest removing material from the stator housing to reduce the eddy current presence outside of the variable reluctance machine. However, this approach hinges on the reduction in eddy current by removing the amount of housing material, which may be either non-magnetic or magnetic material.

Summary of the Invention

In one aspect, the present disclosure is directed to . . . In another aspect, the present disclosure is directed to . . .

In yet another aspect, the present disclosure is directed to . . .

Brief Description of the Drawings

Figure 1 is a schematic of a switched reluctance system.

Figure 2 is a cross-sectional view of a variable reluctance machine in the aligned position.

Figure 3 is a cross-sectional view of a variable reluctance machine in the unaligned position.

Figure 4 is a cross-sectional side perspective view of a switched reluctance machine known in the art.

Figure 5A is a cross-sectional side perspective view of a switched reluctance machine according to the disclosure.

Figure 5B is a magnified view of the dotted section of Figure 5A.

Figure 6 is an end-on view of an energized switched reluctance machine's flux lines.

Whenever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. Detailed Description

With reference to the drawings, Figure 5A illustrates a cross- sectional area of a switched reluctance machine comprising a rotor 51 , a stator 52, a housing 53, and a magnetic eddy current dampening component 54 disposed between stator 52 and housing 53. Figure 5B shows a magnified view of the portion indicated in Figure 5A, detailing the magnetic eddy current dampening component 54 disposed between stator 52 and housing 53. As the switched reluctance machine is operated according to conventional practice, magnetic fields are formed in the machine as a result of the various changes in current throughout the machine. For example, Figure 6 is an end-on view of an energized switched reluctance machine, with magnetic fields 61 represented as lines depicting magnetic flux within the machine. In the embodiment shown in Figure 6, stator poles 1,7 (shown as 62) and 4,10 (shown as 63) are energized, which would also cause flux lines to loop through the rotor poles 1,5

(corresponding to 62) and 3,7 (corresponding to 63).

With further reference to Figure 6, magnetic flux lines are shown extending beyond the stator and into magnetic eddy current dampening component 54. The shielding component of the immediate disclosure is designed specifically to dissipate the magnetic flux outside of the stator, thereby increasing the efficiency of the switched reluctance machine.

Magnetic eddy current dampening component 54 comprises a main body being generally cylindrical, having an inner surface, an outer surface, and a wall thickness between the inner surface and the outer surface. The wall thickness is sufficient to dissipate the magnetic flux by at least about 20%, such as by at least about 30%, at least about 40%, at least about 50%, at least about 60%, at least about 70%, at least about 80%, or at least about 90%. Such dissipation can typically be achieved with a wall thickness of between about and about , such as between about and about or between about and about The specific thickness required is determined by the material used to form magnetic eddy current dampening component 54 and its properties. One such property is the relative magnetic permeability of magnetic eddy current dampening component 54. Magnetic permeability, as used herein, is a relative measure of a material's ability or propensity to allow an applied magnetic field to continue beyond the material. In the present disclosure, the main body of magnetic eddy current dampening component 54 comprises a material having relative magnetic permeability of less than about 25 x 10 ^~7 H/m, such as less than about x 10 ^~7 H/m, less than about x 10 ^~7 H/m, less than about x 10 ^"7 H/m, or less than about x 10 ^"7

H/m.

Another important property of the material of magnetic eddy current dampening component 54 is resistivity. Resistivity is important because as the resistivity increases, so does the magnetic field magnitude, δ, outside of magnetic eddy current dampening component 54. The relationship can be shown as:

where

π 10 ^"7 Η/Γη

μ^ ίΐιβ relative permeability of the medium

p = the resistivity of the medium in Qrn

f= the frequency of the wave in Hi

(1)

More specifically, the resistivity of the magnetic eddy current dampening component 54 material is less than about 100 x 10 ^"8 Ω-m, such as less than about 75 x 10 ^"8 Ω-m, less than about 25 x 10 ^"8 Ω-m, or less than about 5 x 10 ^"8 Ω-m. In addition to the above electrical considerations, several mechanical properties of the material used for magnetic eddy current dampening component 54 must be considered, as magnetic eddy current dampening component 54 is disposed between stator 52 and housing 53 and movement or slippage during use is deleterious to performance. Typically, the switched reluctance machine of the immediate disclosure is constructed by press fitting magnetic eddy current dampening component 54 on stator 52. If the press fit is compromised, there may be insufficient force applied between stator 52 and housing 53 to carry an applied torque. Accordingly, a primary consideration is the coefficient of thermal expansion (CTE) of the material, as the material will be cycled through temperatures in the range of 0 °C to 160 °C. The CTE will ideally be as close to the CTE of stator 52 and housing 53 as possible. For example, the

CTE of stator 52 is between about and about , as stator 52 is commonly made of a silicon steel. Also, the CTE of housing 53 is between about and about , as housing 53 is commonly made of cast iron.

Accordingly, the CTE of the material of magnetic eddy current dampening component 54 is between about 10.00 x 10 ^"6 /°C and about 19.00 x 10 ^"6 /°C, such as between about 12.00 x 10 ^"6 /°C and about 17.00 x 10 ^"6 /°C or between about 13.00 x 10 ^"6 /°C and about 15.00 x 10 ^"6 /°C.

Another important mechanical property of the material used for magnetic eddy current dampening component 54 is the yield strength of the material. This is another important property for maintaining a press fit that can withstand the stress and torque loads applied to the interface between stator 52 and magnetic eddy current dampening component 54 and to the interface between housing 53 and magnetic eddy current dampening component 54. In short, a higher yield strength will result in a more robust design. For example, the material of magnetic eddy current dampening component 54 must result in a yield strength above about , such as above about , or above about In one embodiment of the present disclosure, the material used for magnetic eddy current dampening component 54 is an aluminum alloy.

Regarding the above properties, the magnetic permeability of viable aluminum alloys is between about 12.00 x 10 ^"7 H/m and about 13.00 x 10 ^"7 H/m, such as about 12.5 x 10 ^"7 H/m. The resistivity of viable aluminum alloys is between about 2.5 x 10 ^"8 Ω-m and about 3.0 x 10 ^"8 Ω-m, such as about 2.8 x 10 ^"8 Ω-m. The CTE of viable aluminum alloys is between about 2.2 x 10 ^{" 5} and about 2.5 x 10 ^"5 . Finally, the yield strength of viable aluminum alloys is between about 125 N/mm ² and about 135 N/mm ² .

In another embodiment of the present disclosure, the material used for magnetic eddy current dampening component 54 is a stainless steel alloy, such as A317 stainless steel. Regarding the above properties, the magnetic permeability of viable stainless steel alloys is between about 12.00 x 10 ^"7 H/m and about 13.00 x 10 ^"7 H/m, such as about 12.5 x 10 ^"7 H/m. The resistivity of viable stainless steel alloys is between about 70 x 10 ^"8 Ω-m and about 75 x 10 ^"8 Ω-m, such as about 72 x 10 ^"8 Ω-m. The CTE of viable stainless steel alloys is between about 1.5 x 10 ^{" 5} and about 1.8 x 10 ^"5 . Finally, the yield strength of viable stainless steel alloys is between about 285 N/mm ² and about 295 N/mm ² .

Industrial Applicability

Magnetic eddy current dampening component 54 addresses the pervasive problem of inefficiency in switched reluctance machines resulting from magnetic flux extending beyond the housing of the machine. By dissipating this external flux, the efficiency of the machine will increase at least, according to testing and modeling, %, possibly even as high as %.

To manufacture the switched reluctance machine of this disclosure, a rotor and stator are combined in a typical fashion. Magnetic eddy current dampening component 54 is then slid over the stator and press fit onto the stator. A housing for the switched reluctance machine is then press fit onto magnetic eddy current dampening component 54.

Switched reluctance machines according to the present disclosure may be used in a variety of heavy machinery, trucks, or automobiles that rely on some form of electric power for propulsion. Examples include hybrid vehicles, both with and without energy storage capability, and fully electric powered vehicles.

Although the present inventions have been described with reference to exemplary embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the sprit and scope of the invention. For example, although different exemplary embodiments may have been described as including one or more features providing one or more benefits, it is contemplated that the described features may be interchanged with one another or alternatively be combined with one another in the described exemplary embodiments or in other alternative embodiments. Because the technology of the present invention is relatively complex, not all changes in the technology are foreseeable. The present invention described with reference to the exemplary embodiments and set forth in the flowing claims is manifestly intended to be as broad as possible. For example, unless specifically otherwise noted, the claims reciting a single particular element also encompass a plurality of such particular elements.