Electric motor rotor discharge protection

Patent metadata

Field	Value
Publication number	US-11088582-B2
Application number	US-201715827363-A
Country	US
Kind code	B2
Filing date	Nov 30, 2017
Priority date	Jun 7, 2016
Publication date	Aug 10, 2021
Grant date	Aug 10, 2021

Abstract

An electric motor includes a case, a stator having stator windings, a rotor having a rotor shaft, and at least one main rotor bearing coupling the rotor shaft to the case. Common mode charge builds up on the rotor due to imbalances of the stator. The at least one main rotor bearing has a first electrical resistance between the rotor shaft and the case. The electric motor further includes a rotor discharge bearing coupling the rotor shaft to the case. The rotor discharge bearing has a second electrical resistance between the rotor shaft and the case that is less than the first electrical resistance, causing the common mode charge to discharge through the rotor discharge bearing. In a differing embodiment, a rotor discharge brush coupled between the case and the rotor shaft along the longitudinal axis of the rotor shaft discharges the common mode charge.

First claim

The invention claimed is:

1. An electric motor comprising:
a case;
a rotor having a rotor shaft;
a rotor discharge bearing coupling the rotor shaft to the case, wherein the rotor discharge bearing has a first electrical resistance between the rotor shaft and the case which directs rotor discharge through the rotor discharge bearing; and
at least one main rotor bearing coupling the rotor shaft to the case, wherein the at least one main rotor bearing has a second electrical resistance between the rotor shaft and the case, wherein the first electrical resistance is less than the second electrical resistance to direct the rotor discharge through the rotor discharge bearing,
wherein first grease associated with the rotor discharge bearing has a lesser electrical resistance than second grease associated with the at least one main rotor bearing.

2. The electric motor of claim 1 , further comprising:
a stator having stator windings coupled to the case; and
stator drive electronics coupled to the stator which are configured to excite the stator.

3. The electric motor of claim 1 , wherein the rotor discharge bearing couples between an outer surface of the rotor shaft and the case.

4. The electric motor of claim 1 , wherein the rotor discharge bearing couples between an inner surface of the rotor shaft and the case via electrical connection between the rotor discharge bearing and the case.

5. The electric motor of claim 1 , wherein:
the at least one main rotor bearing has a first diameter; and
the rotor discharge bearing has a second diameter that differs from the first diameter.

6. The electric motor of claim 1 , wherein:
the at least one rotor bearing has a first construct; and
the rotor discharge bearing has a second construct that differs from the first construct.

7. The electric motor of claim 1 , wherein:
the at least one main rotor bearing has a first loading; and
the rotor discharge bearing has a second loading that is different from the first loading.

8. The electric motor of claim 1 , both the at least one main rotor bearing and the rotor discharge bearing are configured to rotate about a longitudinal axis of the rotor shaft.

9. A method of operating an electric motor having a case, a rotor having a rotor shaft, and a rotor discharge bearing, the method comprising:
powering the stator to create a rotating magnetic field;
collecting common mode charge on the rotor caused by the rotating magnetic field; and
discharging the common mode charge via the rotor discharge bearing, wherein the at least one main rotor bearing has a first electrical resistance between the rotor shaft and the case which directs the common mode charge through the rotor discharge bearing,
wherein the electric motor further includes at least one main rotor bearing coupling the rotor shaft to the case, wherein the at least one main rotor bearing has a second electrical resistance between the rotor shaft and the case, and wherein the first electrical resistance is less than the second electrical resistance,
wherein first grease associated with the rotor discharge bearing has a lesser electrical resistance than second grease associated with the at least one main rotor bearing.

10. The method of claim 9 , wherein
the rotor discharge bearing couples between an outer surface of the rotor shaft and the case.

11. The method of claim 9 , wherein:
the at least one main rotor bearing has a first diameter; and
the rotor discharge bearing has a second diameter that differs from the first diameter.

12. The method of claim 9 , wherein:
the at least one main rotor bearing has a first construct; and
the rotor discharge bearing has a second construct that differs from the first construct.

13. The method of claim 9 , wherein:
the at least one main rotor bearing has a first loading; and
the rotor discharge bearing has a second loading that is different from the first loading.

14. The electric motor of claim 1 , wherein the first grease represents a first layer of grease associated with the rotor discharge bearing and wherein the second grease represents a second layer of grease associated with the at least one main rotor bearing, and wherein the first layer of grease is of a lesser thickness than the second layer.

15. The electric motor of claim 1 , wherein the rotor discharge bearing is sealed with the first grease, and wherein the first grease is conductive.

16. The method of claim 9 , wherein the first grease represents a first layer of grease associated with the rotor discharge bearing and wherein the second grease represents a second layer of grease associated with the at least one main rotor bearing, and wherein the first layer of grease is of a lesser thickness than the second layer.

17. The method of claim 9 , wherein the rotor discharge bearing is sealed with the first grease, and wherein the first grease is conductive.

Assignees

• Tesla Inc

Inventors

• Graves Scott Michael
• Silva Rodriguez Diego Alberto
• Grendahl Tyler Nils
• Hain Alexander

Classifications

• H01M2220/20

  Batteries in motive systems, e.g. vehicle, ship, plane · CPC title

• H01M10/6567

  Liquids · CPC title

• H01M10/625

  Vehicles · CPC title

• H02P29/62

  for raising the temperature of the motor · CPC title

• H02K11/40

  Structural association with grounding devices · CPC title