System for an electrical motor with coil assemblies and external radial magnetic elements

Patent metadata

Field	Value
Publication number	US-12149141-B2
Application number	US-202218086508-A
Country	US
Kind code	B2
Filing date	Dec 21, 2022
Priority date	Aug 26, 2019
Publication date	Nov 19, 2024
Grant date	Nov 19, 2024

Abstract

One variation of a system for an electric motor includes a set of coil assemblies defining: an inner radial facet, an outer radial facet, a first axial facet, and a second axial facet opposite the first axial facet. Additionally, each coil assembly in the set of coil assemblies includes a receiving member arranged at the outer radial facet of the coil assembly. Furthermore, the system includes a rotor comprising a set of magnetic elements: encompassing the inner radial facet, the outer radial facet, the first axial facet, and the second axial facet of the set of coil assemblies; and defining a radial magnetic tunnel. The system also includes a housing: engaging the receiving member of each coil assembly, in the set of coil assemblies to couple the housing to the set of coil assemblies; and includes a shaft coupled to the set of magnetic elements.

First claim

We claim:

1. A system for an electric motor comprising:
a stator comprising a set of coil assemblies:
arranged radially about a motor axis;
defining an inner radial facet, an outer radial facet, a first axial facet, and a second axial facet opposite the first axial facet; and
each coil assembly in the set of coil assemblies comprising a receiving member arranged at the outer radial facet of the coil assembly;

a rotor comprising a set of magnetic elements:
encompassing the inner radial facet, the outer radial facet, the first axial facet, and the second axial facet of the set of coil assemblies;
defining a radial magnetic tunnel about the motor axis; and
configured to generate a flux density distribution focused toward the set of coil assemblies;

a housing:
containing the stator and the rotor;
engaging the receiving member of each coil assembly, in the set of coil assemblies, to couple the housing to the stator; and
comprising a shaft coaxial with the motor axis and coupled to the rotor; and

a controller configured to drive current through the set of coil assemblies to generate a toroidal magnetic field tunnel configured to sequentially and magnetically couple the set of magnetic elements contained within the housing.

2. The system of claim 1 :
wherein the housing further comprises:
a base;
a cylindrical body extending from the base; and
a cover:
arranged opposite the base; and
coupled to a distal end of the cylindrical body to define a cavity configured to locate the rotor and the stator within the housing; and
comprising a shaft opening; and

wherein the receiving member of each coil assembly, in the set of coil assemblies, engages an inner radial wall of the cylindrical body to rigidly couple the stator to the housing.

3. The system of claim 1 , wherein the receiving member of each coil assembly, in the set of coil assemblies protrudes outwardly from the outer radial facet and defines a threaded cavity.

4. The system of claim 3 :
wherein the housing further comprises a set of apertures:
radially arranged about a cylindrical body of the housing; and
aligned with the receiving member of each coil assembly, in the set of coil assemblies; and

further comprising a set of fastening members:
received through the set of apertures at the cylindrical body; and
engaging the threaded cavity of the receiving member of each coil assembly in the set of coil assemblies to:
rigidly couple the housing to the stator; and
define an interstice between an inner radial wall of the housing and a subset of outer radial magnetic elements, in the set of magnetic elements, encompassing the outer radial facet of the set of coil assemblies.

5. The system of claim 1 :
wherein the housing further comprises a coupling ring:
interposed between the outer radial facet of the set of coil assemblies and an inner radial wall of the housing;
defining an interstice between the inner radial wall of the housing and a subset of outer radial magnetic elements, in the set of magnetic elements, encompassing the outer radial facet of the set of coil assemblies; and
comprising:
a first set of coupling members radially arranged about an inner radius of the coupling ring and coupled to the receiving member of each coil assembly, in the set of coil assemblies; and
a first set of threaded cavities arranged about an outer radius of the coupling ring; and

further comprising a set of fastening members coupled to the first set of threaded cavities to rigidly couple the housing to the set of coil assemblies.

6. The system of claim 1 , wherein each coil assembly, in the set of coil assemblies, further comprises:
a first bobbin defining:
a first aperture; and
a first winding receiving slot about an exterior of the first bobbin;

a second bobbin:
arranged opposite the first bobbin;
defining a second aperture in alignment with the first aperture; and
defining a second winding receiving slot about an exterior of the second bobbin;

a stator pole:
formed of a ferrous material;
interposed between the first bobbin and the second bobbin;
defining a third aperture in alignment with the first aperture and the second aperture to define a pole tunnel segment; and
comprising the receiving member arranged at an outer radial side of the stator pole; and

a winding:
coiled about the first winding receiving slot and the second winding receiving slot; and
comprising a first set of leads coupled to the controller.

7. The system of claim 1 :
wherein the rotor further comprises:
an inner rotor core:
arranged within an inner radius of the set of coil assemblies;
defining a set of inner slots arranged about the inner rotor core; and
comprising a subset of inner radial magnetic elements, in the set of magnetic elements, arranged at the set of inner slots and facing the inner radial facet of the set of coil assemblies; and

an outer rotor core comprising;
a first outer plate:
coupled to the inner rotor core;
defining a first set of outer slots; and
comprising a first subset of axial magnetic elements, in the set of magnetic elements, arranged at the first set of outer slots and facing the first axial facet of the set of coil assemblies;

a second outer plate:
arranged opposite the first outer plate;
defining a second set of outer slots; and
comprising a second subset of axial magnetic elements, in the set of magnetic elements, arranged at the second set of outer slots and facing the second axial facet of the set of coil assemblies;

an outer radial wall:
interposed between the first outer plate and the second outer plate;
defining a set of outer slots arranged about the outer radial wall; and
comprising a subset of outer radial magnetic elements, in the set of magnetic elements, arranged at the set of outer slots and facing the outer radial facet of the set of coil assemblies; and

wherein the shaft is rigidly coupled to the inner rotor core.

8. The system of claim 1 , wherein the set of magnetic elements comprises:
a set of inner radial magnetic elements:
arranged in a first Halbach array configuration about the inner radial facet of the stator; and
defining a first flux density distribution focused toward the inner radial facet;

a set of outer radial magnetic elements:
arranged in a second Halbach array configuration, in alignment with the first Halbach array configuration, about the outer radial facet of the stator; and
defining a second flux density distribution focused toward the outer radial facet;

a first set of axial magnetic elements:
arranged in a third Halbach array configuration about the first axial facet of the stator; and
defining a third flux density distribution focused toward the first axial facet; and

a second set of axial magnetic elements:
arranged in a fourth Halbach array configuration, in alignment with the third Halbach array configuration, about the second axial facet of the stator;
defining a fourth flux density distribution focused toward the second axial facet; and
cooperating with the set of inner radial magnetic elements, the set of outer radial magnetic elements, and the first set of axial magnetic elements to form a magnetic flux tunnel enveloping the set of coil assemblies.

9. The system of claim 1 :
wherein the stator further comprises:
a first yoke segment extending radially about the motor axis; and
a second yoke segment:
coupled at a first end and a second end of the first yoke segment;
extending radially about the motor axis; and
cooperating with the first yoke segment to define a cylindrical yoke of the stator; and

wherein the set of coil assemblies comprises:
a first subset of coil assemblies defining a first

Assignees

• Linear Labs Llc
• Linear Labs Inc

Inventors

• Hatch Erik Christopher
• Paulraj Anto Joseph Barigala Charles
• Hariri Abla

Classifications

• H02K15/32

  Manufacture of terminal arrangements; Connecting the terminals to external circuits · CPC title

• H02K2211/03

  Machines characterised by circuit boards, e.g. pcb · CPC title

• H02K2203/12

  Machines characterised by the bobbins for supporting the windings · CPC title

• H02K2201/12

  Transversal flux machines · CPC title

• H02K21/145

  having an annular armature coil (with homopolar co-operation H02K21/20) · CPC title