Magnet retention system for permanent magnet motors and generators

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Magnet retention system for permanent magnet motors and generators

Hamilton Sundstrand Corporation C. 195673 WO 2008/100373 PCT/US2008/000907

MAGNET RETENTION SYSTEM FOR PERMANENT MAGNET MOTORS AND GENERATORS

BACKGROUND OF THE INVENTION 5 This invention relates generally to rotors for permanent magnet (PM) motors and generators. More particularly, the present invention relates to retention systems for rotor magnets in brushless PM motors and generators.

Brushless PM motors convert electrical energy to kinetic energy by exploiting the electromagnetic relationship between a magnet and an electric field. Conversely, 10 brushless PM generators use electromagnetic relationships to convert kinetic energy to electrical energy. In a typical brushless PM motor, electric current is passed through stationary windings of conductive wires to generate an alternating magnetic field to push and/or pull a magnetic rotor. The magnetic rotor is coupled to a shaft to produce rotational shaft power. In a typical brushless PM generator, a mechanically rotating shaft 15 rotates a magnetic rotor to push electrical current through a stationary coil. The electrical current is then available to provide electric power. Thus, brushless PM motors and generators comprise two main concentrically aligned components: a stator, comprising wire windings, and a rotor, comprising permanent magnets. Brushless PM motors and generators can be configured in a conventional design, with the stator 20 surrounding the rotor, or in an inside out design, with the rotor surrounding the stator. In either case, the rotor is subjected to extremely high rotational speeds, which places significant mechanical loading on the magnets. A rotor of a brushless PM motor or generator must meet multiple requirements in order to efficiently convert electromagnetic power to or from rotational shaft power. 25 First, the rotor must include magnets that are able to convert electromagnetic force to or from mechanical force. Second, the magnets need to be magnetically coupled in order to produce a magnetic flux path between adjacent magnets. Third, the magnets must be connected to a shaft in such a manner to transmit the torque necessary for inputting or outputting the mechanical power. 30 For both conventional and inside out brushless PM motor and generator designs, various prior art systems for retaining the magnets with respect to the rotor have been developed. For example, in inside out brushless PM motor and generator designs, the rotor comprises a disk having a central bore for receiving a shaft and an outer diameter flange for receiving the permanent magnets. The permanent magnets are 1 WO 2008/100373 PCT/US2008/000907 circumferentially arranged around the inner diameter face of the flange such that they will face the wire windings when coupled with the stator. Conventional methods for securing magnets to rotors have relied upon adhesives that immobilize the magnets on the outer flange. Adhesive provides a strong bond that also permits magnetic flux 5 between the magnets. However, adhesive rigidly bonds each magnet to the flange, thus subjecting the magnet to the strain imparted to the rotor during high-speed rotational operation. Thus, the magnets become load-bearing members subject to centrifugal stresses that potentially exceed their stress limitations. Additionally, the bonded magnets become permanently attached to the disk, making it difficult or otherwise infeasible to 10 repair or replace them, wholly or individually, or the rotor disk. Adhesive is also susceptible to failure due to extreme temperatures, aging and chemical exposure. Therefore, there is a need for an improved system for retaining brushless PM motor and generator rotor magnets.

BRIEF SUMMARY OF THE INVENTION 15 The present invention is directed toward a rotor for a brushless permanent magnet generator/motor. The rotor comprises a retention slot extending into a rotor flange for receiving a root of a permanent magnet. The retention slot comprises a base extending axially into the rotor flange, a pair of side walls extending radially from the base, and a pair of lugs projecting from the side wall to engage the root to provide radial and 20 tangential retention of the permanent magnet.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows a cross sectional view of an inside out brushless permanent magnet motor having a rotor and a stator. FIG. 2 shows a perspective view of the rotor of FIG. 1 having a magnet retention 25 system of the present invention. FIG. 3 shows a perspective view of a broach slot connection of the magnet retention system of FIG. 2. FIG. 4 shows a front view of the connection between the broach slot of FIG. 3 and a permanent magnet tang. 30 FIG. 5 shows a cross sectional view of the magnet retention system of FIG. 2 showing inner and outer axial retention means. 2 WO 2008/100373 PCT/US2008/000907

DETAILED DESCRIPTION FIG. 1 shows a cross sectional view of inside out brushless permanent magnet (PM) motor 10 in which the magnet retention system of the present invention is used. Although the invention is described hereinafter with respect to an inside out brushless PM motor, the invention is universally applicable to brushless PM generators and motors in both conventional and inside out configurations. Brushless PM motor 10 includes rotor 12 and stator 14, which are situated inside housing 16. Housing 16 comprises first housing half 16A and second housing half 16B, which are secured together using fasteners 18 to form a hollow annular disk having central bore 20, through which extends centerline CL.

Stator 14 comprises a plurality of wire windings wrapped around armature 22 to form circular hoop 24. Input voltage and current is supplied to armature 22 through conduits 26 such that hoop 24 produces an electromagnetic field. Armature 22 is secured to first housing half 16A through, for example, threaded fasteners 28 such that hoop 24 is maintained stationary with respect to housing 16. Armature 22 is circumferentially disposed around bore 20 such that space is provided within housing 16 between the outermost extent of housing 16 and the outermost extent of hoop 24. Armature 22 also allows space between hoop 24 and second housing half 16B such that bore 20 is connected with the space between hoop 24 and the outer extent of housing 16. Rotor 12 is situated within the open space of housing 16 such that it extends from central bore 20 past hoop 24 to interact with the electromagnetic field.

Rotor 12 is comprised of hub 30, disk 32, outer flange 34, a plurality of permanent magnets 36, and outer retention ring 38. Hub 30 is inserted into central bore 20 of housing 16 between housing half 16A and housing half 16B. Hub 30 is supported by rolling element bearings 40A and 40B such that rotor 14 is rotatable with respect to housing 16. Hub 30 includes shaft bore 42, which is concentric with centerline CL, for receiving an output shaft or some other output means. Disk 32 extends radially from hub 30 (concentrically with centerline CL) beyond hoop 24 such that the innermost side of flange 34 faces hoop 24. Permanent magnets 36 are secured to the innermost side of flange 34 using an attachment slot of the present invention and retention ring 38 such that the magnets interact with the electromagnetic field generated by hoop 24. Hoop 24 utilizes the electrical power supplied by conduits 26 and, in conjunction with switching devices and other electrical components, produces an alternating electromagnetic field that exerts pushing and pulling forces on magnets 36. As such, magnets 36 are subjected 3 WO 2008/100373 PCT/US2008/000907 to rotational torque such that rotor 12 rotates on hub 30 about centerline CL. The torque is transmitted through flange 34 and disk 32 to hub 30, which is connectable with an output shaft at bore 42 such that the electrical power input from conduits 26 is converted to rotational shaft power. In order to transmit the rotational torque from magnets 36 to flange 34 in a manner that permits non-destructive removal of magnets 36, magnets 36 are joined with flange 34 through slotted attachments of the magnet retention system of the present invention. FIG. 2 shows a perspective view of rotor 12 of FIG. 1 having the magnet retention system of the present invention. Rotor 12 includes hub 30, disk 32, outer flange 34, a plurality of permanent magnets 36, outer retention ring 38 and center bore 42. Hub 30 and flange 34 extend axially outward from disk 32 in the same direction such that hoop 24 of stator 14 can be inserted between flange 34 and hub 30 within housing 16 in a compact manner. Hub 30 is disposed at the center of rotor 12 and includes bore 42 such that rotational torque applied to rotor 12 can be transmitted to a shaft or some other output means. Rotational torque is transmitted to hub 30 through disk 32 from flange 34. Flange 34 receives input torque from the plurality of permanent magnets 36, disposed about the inner circumference of flange 34. Rotational torque is imparted to the permanent magnets through an alternating electromagnetic field generated by hoop 24. In order to prevent excessive stress from being generated in the permanent magnets during torque transmission, a slotted magnet retention system is used to transmit the torque from the permanent magnets to flange 34.

Flange 34 extends circumferentially around the outermost diameter edge of disk 32 and provides a platform onto which permanent magnets 36 can be mounted such that they face hoop 24 of stator 14. In the embodiment shown, rotor 12 includes twenty-eight permanent magnets that are displaced at regular intervals along flange 34. Permanent magnets 36 are mounted to flange 34 through correspondingly shaped retention features to restrain the magnets radially and tangentially. For example, for each magnet 36, flange 34 includes a broach slot into which a magnet tang having a matching profile is inserted. Once inserted, the broach slot/tang interface restricts circumferential and radial movement of the permanent magnets within flange 34. The broach slot/tang interface also permits efficient torque transmission from the permanent magnets to flange 34 without over stressing the magnets. In other embodiments, flange 34 includes a tang for receiving a correspondingly shaped broach slot on each magnet 36. A shoulder positioned at the inner end of the broach slot and retention ring 38 positioned at the outer 4 WO 2008/100373 PCT/US2008/000907 end of the broach slot restrict axial movement of the permanent magnets. Retention ring 38 is secured to flange 34 using fasteners (such as fastener 44) such that ring 38 is repeatably attached and removed from rotor 12. Accordingly, permanent magnets 36 are attached to flange 34 in stress-free manner, and can be removed from flange 34 without 5 causing damage to either rotor 12 or the magnets. FIG. 3 shows a front projection view of the magnet retention system of FIG. 2 showing the connection between magnet retention flange 34 and permanent magnets 36. Rotor 12 includes magnet retention flange 34, to which magnets 36 are connected through a slotted interface. Flange 34 includes broach slots 46 for receiving magnet 10 tangs 48 of magnets 36. Tangs 48 are inserted into slots 46 such that magnets 36 are restrained from moving in both the tangential and radial directions. However, broach slots 46 are also configured such that a magnetic flux path is maintained from magnet to magnet.

Permanent magnets 36 include flux lines FI, F2, F3, F4 and F5, which extend 15 from north pole N to south pole S. Each flux line emits from pole N and returns at pole S. Adjacent flux lines repulse each other such that the flux lines form an outer flux boundary circumscribing each magnet. Each magnet includes a plurality of magnetic flux lines that interact with neighboring magnets and rotor 12. For example, flux line FI extends from the center of each magnet at pole N and bends around the magnet toward 20 pole S. Flux line FI extends out of the magnet toward centerline CL (FIG. 1) of rotor 12. Thus, flux line FI will interact with stator 14 of motor 10. Similarly, each magnet includes a plurality of other flux lines, such as flux lines F2 and F3, that extend from pole N to pole S at various angles to interact with stator 14. Flux lines F4 and F5 extend in the plane of each magnet to interact with permanent magnets on either side of each 25 magnet. Thus, each magnet is positioned on flange 34 of rotor 12 such that it is remains in magnetic contact with hoop 24 when assembled with stator 14. Additionally, each broach slot is disposed along flange 34 such that each magnet is in magnetic contact with two adjacent magnets to complete a magnet flux path around the circumference of rotor 12. Consequently, during operation of motor 10, rotor 12 is able to maintain the 30 requisite electromagnetic interaction with hoop 24 of stator 14 to maintain rotational torque transmission to hub 30.

As mentioned above, tangs 48 are inserted into slots 46 such that magnets 36 are restrained from moving in both the tangential and radial directions. An inner retention shoulder prevents axial movement of magnets 36 toward disk 32, and retention ring 38 5 WO 2008/100373 PCT/US2008/000907 (shown in FIG. 2) is secured to flange 34 at bore 50 to restrain outward axial movement of magnets 36. Flange 34 is configured to provide radial retention to each magnet through the interaction of tangs 48 with slots 46. FIG. 4 shows tang 48 of magnet 36 inserted into broach slot 46, as shown in FIG. 3. Magnet retention flange 34 includes first flange face 52, into which broach slot 36 extends perpendicularly. Rotor 12 rotates about centerline CL of motor 10 such that magnet retention flange 34 would rotate in the plane of FIG. 3. Broach slot 46 includes base 54, first side wall 56, second side wall 58, first side tooth 60 and second side tooth 62. Broach slot 46 extends axially (parallel with centerline CL) into magnet retention flange 34 of rotor 12 such that it opens towards centerline CL. Broach slot 46 extends axially into first face 52 to form base 54. First side wall 56 and second side wall 58 extend radially (perpendicular with centerline CL) from base 54. First side tooth 60 and second side tooth 62 extend in the tangential or circumferential direction from first side wall 56 and second side wall 58, respectively. First side tooth 60 and second side tooth 62 overhang base 54 to narrow a segment of broach slot 46 that is radially displaced from base 54.

Magnet 36 includes tang 48, which generally refers to the portion of magnet 36 situated below first side tooth 60 and second side tooth 62. Magnet 36 also includes first tang tooth 64 and second tang tooth 66 that extend in the tangential or circumferential direction out from tang 48. Tang 48 of magnet 36, including first tang tooth 64 and second tang tooth 66, is shaped to match the shape of broach slot 46. In the embodiment shown, broach slot 46 comprises a T-shaped slot and side walls 56 and 58 comprise rounded walls. Correspondingly, teeth 64 and 66 comprise rounded nubs having a profile matching that of side walls 56 and 58. In other embodiments of the present invention, broach slot 46 and tang 48 comprise different shapes. Teeth 64 and 66 can comprise any shape for interlocking with the side walls 56 and 58 and teeth 60 and 62 of slot 46. For example, slot 46 and tang 48 can comprises a fir tree type configuration as is commonly used in gas turbine engines to radially retain blades in a rotor disk.

Magnet 36 is inserted into broach slot 46, such that first side tooth 60 overhangs first tang tooth 64, and second side tooth 62 overhangs second tang tooth 66 to prevent magnet 36 from breaking loose during operation of motor 10. Although tang 48 is shaped to match the shape of broach slot 46, a small amount of slop or play is permitted in the interaction between tang 48 and slot 46 to avoid producing stress concentrations in magnet 36 during operation of motor 10. (The space shown between tang 48 and slot 46 6 WO 2008/100373 PCT/US2008/000907 in FIG. 3 is exaggerated for illustrative purposes.) During operation of motor 10, rotor 12 is subjected to rotational forces by the electromagnetic field generated by stator 14. Typically, motor 12 rotates at high enough speeds such that rotor 12 is subjected to considerable centrifugal force. In an inside out configuration motor, such as that of motor 10, the centrifugal force tends to open up slot 46, causing teeth 60 and 62 to grow apart. As such, during operation of motor 10, magnet 36 is forced outward while teeth 60 and 62 are forced apart.

Side teeth 60 and 62 overhang tang teeth 64 and 66 by a sufficient length to avoid the possibility of magnet 36 radially dislodging from slot 46. While motor 10 operates at speed, magnet 36 is held in place by frictional force generated between magnet 36 and rotor flange 34. This frictional force is proportional to the centrifugal force acting on rotating magnets 36. In one embodiment, first side tooth 60 overhangs first tang tooth 64 by a length greater than about the distance first side tooth 60 grows away from second side tooth 62 during operation of motor 10. Likewise, second side tooth 62 overhangs second tang tooth 66 by a length greater than about the distance first side tooth 60 grows away from second side tooth 62 during operation of motor 10. Additionally, to avoid fracturing of magnet 36, slot 46 is slightly oversized such that any twisting or bending of rotor 12 during operation of motor 10 does not transmit stress to magnet 36. Magnet 36 is permitted free movement within slot 46 such that teeth 60 and 62 are prevented from pulling on teeth 64 and 66 as broach slot 46 tends to open up during operation. Magnet 36 is thus ultimately restrained from exiting slot 46, however, is not rigidly attached to rotor 12. Thus, unnecessary production of tensile or compressive stress in magnet 36 is avoided.

Additionally, tang 48 is configured to transmit torque to flange 34 of rotor 12. Magnet 36 is subjected to rotational forces by the alternating electromagnetic field generated by stator 14. The force of the applied field is transmitted from magnet 36 through flange 34 and to hub 30 such that useful rotational output can be obtained. Teeth 64 and 66 interact with wall 56 and 58, respectively, to efficiently transmit torque from magnet 36 to flange 34. As described above, teeth 64 and 66 comprise rounded projections such that they mesh with rounded walls 60 and 62. Thus, the tangential component of the rotational force applied to magnet 36 is effectively transmitted to broach slot 46. Thus, little energy is lost in the transmission of torque from magnet 36 to broach slot 46, and rotor 12 is efficiently rotated. 7 WO 2008/100373 PCT/US2008/000907

Thus, tang 48 is loosely fit within broach slot to restrain movement of magnet 36 in the radial direction 46, to prevent stress build up in magnet 36, and to transmit torque to flange 34. Rotor 12 is fitted with other restraints for preventing axial withdrawal of magnet 36 from slot 46 during operation of motor 10. Ring 38 (shown in phantom in 5 FIG. 4), which is secured to bore 50 of flange 34 by fastener 44, provides a barrier strip spanning the distance between teeth 60 and 62 to prevent axial dislodgment of magnet 36. FIG. 5 shows a cross sectional view of the magnet retention system of the present invention as taken along section 5-5 of FIG. 2, showing inner and outer axial retention 10 means. Rotor 12 includes magnet retention flange 34, which extends parallel to centerline CL from disk 32 at first side 68, which includes inner axial retention shoulder 70. Flange 34 extends from first side 68 to second side 70, to which outer axial retention ring 38 is attached. Flange 34 also includes fastener 44, fastener bore 50, base 54 of broach slot 46, stress relief notch 74 and bushing 76. Magnet 36 is secured between 15 shoulder 70 and ring 38 to restrain axial movement of magnet 36, e.g. in the direction of centerline CL.

Permanent magnet 36 is inserted into broach slot 46 at second side 70 such that it extends along base 54. Magnet 36 is inserted into slot 46 such that it contacts inner retention shoulder 70. Inner retention shoulder 70 extends around the circumference of 20 flange 34 between first side 68 and second side face 70. Inner retention shoulder comprises a lip or a barrier to prevent magnet 36 from sliding through broach slot 46 once inserted. Stress relief notch 74 is provided between shoulder 70 and base 54 to prevent stress concentration from occurring in flange 34 during high speed rotation of rotor 12. 25 After magnet 36 is inserted into broach slot 46 to meet shoulder 70, outer retention ring 38 is affixed to second face 72 to prevent magnet 36 from retreating out of slot 46. Outer retention ring 38 covers face 72 and extends over a lower portion of magnet 36. Ring 38 is secured to flange 34 by threaded fastener 44, which extends through an opening in ring 38 and into bore 50. Bore 50 includes self-locking helical 30 coil insert 76, into which fastener 44 is threaded. Ring 38 includes notch 78 that enables the inner diameter of ring 38 to act as a spring-like element. Thus, when ring 38 is fastened to flange 34, the inner diameter of ring 38 pre-loads magnet 36 such that it is biased against shoulder 70. Notch 78 also permits ring 38 to span any variance in the alignment of second face 72 and magnet 36 such that ring 38 will be pulled flush with 8 WO 2008/100373 PCT/US2008/000907 magnet 36. Thus, ring 38 is prevented from applying pressure directly to the edge of magnet 36, where stress concentration can readily produce fracture of magnet 36.

As explained above, magnet 36 is maintained within flange 34 such that it is able to magnetically interact with adjacent magnets and the coil winding of stator 14 during 5 operation of motor 12. Shoulder 70, ring 38, and broach slot 46 immobilize magnet 36 within flange 34 without overstressing magnet 36. Thus, the incidence of fracture of magnet 36 is greatly reduced with the retention system of the present invention. However, due to extreme operating conditions of motor 10, rough handling of rotor 12, or other such similar occurrences, it is possible that magnet 26B may become damaged. 10 The magnet retention system of the present invention, as described above, provides a means for removing the permanent magnets from rotor 12. Magnets can be removed from flange 34 by simply removing ring 38 after unthreading fastener 44. Individual magnets can be removed without damaging adjacent or other magnets, or without damaging rotor 12. Individual magnets are therefore easily removed such as might be 15 required for replacement if the magnet becomes damaged or demagnetized, or simply for maintenance or cleaning. Thus, the present invention provides a magnet retention system that reduces the incidence of magnet breakage and provides improved maintenance capabilities.

Although the invention has been described with respect to flange 34 having 20 broach slots and magnets 36 having tangs, other configurations of the magnet retention system of the present invention can also be used. For example, in another embodiment, magnets 36 can be configured with broach slots, and flange 34 can be configured with mating tangs. In other embodiments, magnets 36 and flange 34 include mating male and female components that have correspondingly shaped geometric profiles to restrain radial 25 and tangential movement of magnets 36 with respect to rotor 12.

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