Electrical machine

Patent metadata

Field	Value
Publication number	US-12567772-B2
Application number	US-202318490327-A
Country	US
Kind code	B2
Filing date	Oct 19, 2023
Priority date	Sep 8, 2023
Publication date	Mar 3, 2026
Grant date	Mar 3, 2026

Abstract

An electrical machine includes a rotationally-fixed stator defining a rotational axis of the electrical machine and having a plurality of stator magnetic poles, the stator magnetic poles disposed about the rotational axis. The electrical machine also has a rotor rotatably mounted coaxially with the rotational axis and axially spaced from the stator, the rotor having a plurality of permanent magnets facing the stator magnetic poles. Each stator magnetic pole includes a plurality of ferromagnetic laminations in a lamination stack that extends from a radially-inward extent to a radially-outward extent relative to the rotational axis, and a ferromagnetic composite pole portion affixed to the radially-outward extent or the radially-inward extent of the lamination stack of the stator magnetic pole.

First claim

What is claimed is:

1 . An electrical machine comprising:
a rotationally-fixed stator defining a rotational axis of the electrical machine and having a plurality of stator magnetic poles, the stator magnetic poles disposed about the rotational axis; and a rotor rotatably mounted coaxially with the rotational axis and axially spaced from the stator, the rotor including a plurality of permanent magnets facing the stator magnetic poles; wherein each stator magnetic pole comprises a plurality of ferromagnetic laminations in a lamination stack that extends from a radially-inward extent to a radially-outward extent relative to the rotational axis, and a ferromagnetic composite pole portion affixed to the radially-outward extent or the radially-inward extent of the lamination stack of the stator magnetic pole.

2 . An electrical machine as recited in claim 1 , wherein each stator magnetic pole comprises ferromagnetic composite pole portions affixed to both the radially-outward extent and the radially-inward extent of the lamination stack of the stator magnetic pole.

3 . An electrical machine as recited in claim 2 , wherein the ferromagnetic composite pole portions comprise soft magnetic composite.

4 . An electrical machine as recited in claim 2 , wherein the ferromagnetic composite pole portions comprise polymer composite.

5 . An electrical machine as recited in claim 1 , wherein each stator magnetic pole has electrical windings disposed thereabout that define areas of mechanical interface between the electrical windings and the ferromagnetic composite pole portion of the stator magnetic pole, wherein the ferromagnetic composite pole portion is rounded in the areas of mechanical interface.

6 . An electrical machine as recited in claim 2 , wherein each stator magnetic pole has electrical windings disposed thereabout that define areas of mechanical interface between the electrical windings and the molded ferromagnetic pole portions of the stator magnetic pole, wherein the molded ferromagnetic portions are rounded in the areas of mechanical interface.

7 . An electrical machine as recited in claim 1 , wherein the ferromagnetic composite pole portion is located in an area of fringing of magnetic fields generated by the permanent magnets of the rotor.

8 . An electrical machine as recited in claim 2 , wherein the ferromagnetic composite pole portions are located in areas of fringing of magnetic fields generated by the permanent magnets of the rotor.

9 . A vehicle comprising:
an eletrical machine as recited in claim 1 ;
a source of DC electrical energy;
an inverter coupled to the source of DC electrical energy and to the electrical machine; and
an inverter controller coupled to the inverter to control the electrical machine as a motor to provide propulsion for the vehicle.

10 . An electrical machine comprising:
a rotationally-fixed stator defining a rotational axis of the electrical machine and having a plurality of stator magnetic poles disposed about the rotational axis; and a rotor rotatably mounted coaxially with the rotational axis and axially spaced from the stator, the rotor including a plurality of permanent magnets facing the stator magnetic poles; wherein each stator magnetic pole comprises a plurality of ferromagnetic laminations stacked in a first lamination stack that extends from a radially-inward extent to a radially-outward extent relative to the rotational axis, and a pole portion affixed to the radially-outward extent or the radially-inward extent of the first lamination stack, the pole portion including a second plurality of ferromagnetic laminations stacked in a second lamination stack that extends in a different direction than the first lamination stack of the stator magnetic pole; wherein for each stator magnetic pole: the stator magnetic pole has electrical windings disposed thereabout that define areas of mechanical interface between the electrical windings and the second lamination stack of the stator magnetic pole; and the second lamination stack of the stator magnetic pole is rounded in the areas of mechanical interface.

11 . An electrical machine as recited in claim 10 , wherein each stator magnetic pole comprises a second pole portion affixed to the radially-outward extent or the radially-inward extent of the first lamination stack, the second pole portion comprising a third plurality of ferromagnetic laminations stacked in a different direction than the first lamination stack of the stator magnetic pole.

12 . An electrical machine as recited in claim 10 , wherein the pole portion is located in areas of fringing of magnetic fields generated by the permanent magnets of the rotor.

13 . An electrical machine as recited in claim 11 , wherein the pole portion and the second pole portion are located in areas of fringing of magnetic fields generated by the permanent magnets of the rotor.

14 . An electrical machine as recited in claim 10 , further comprising a second rotor rotatably mounted coaxially with the rotational axis and axially spaced from the stator, the second rotor comprising a second plurality of permanent magnets facing the stator magnetic poles.

15 . An electrical machine comprising:
a rotationally-fixed stator having stator magnetic poles that comprise ferromagnetic laminations; a rotor rotatably disposed relative to the stator and separated therefrom by an air gap, the rotor including permanent magnet rotor poles facing the stator magnetic poles and generating magnetic fields; and nonlaminated ferromagnetic pole portions affixed to the stator magnetic poles in areas of fringing of the magnetic fields generated by the permanent magnet rotor poles.

16 . An electrical machine as recited in claim 15 , wherein the nonlaminated ferromagnetic pole portions comprise ferromagnetic composite material.

17 . An electrical machine as recited in claim 15 , wherein the nonlaminated ferromagnetic pole portions comprise soft magnetic composite.

18 . An electrical machine as recited in claim 15 , further comprising electrical windings disposed about each stator magnetic pole.

19 . An electrical machine as recited in claim 15 , further comprising a second rotor rotatably disposed relative to the stator and separated therefrom by a second air gap, the second rotor comprising second permanent magnet poles facing the stator magnetic poles and generating magnetic fields.

20 . A vehicle comprising:
the electrical machine of claim 15 ; a source of DC electrical energy; an inverter coupled to the source of DC electrical energy and to the electrical machine; and an inverter controller coupled to the inverter to control the electrical machine as a motor to provide propulsion for the vehicle.

Assignees

• Gm Global Tech Operations Llc

Inventors

• Fedida Vincent
• Yao Jian
• Duan Chengwu

Classifications

• H02K21/24 Primary

  with magnets axially facing the armatures, e.g. hub-type cycle dynamos · CPC title

• B60L50/60

  using power supplied by batteries (in combination with fuel cells B60L50/75) · CPC title

• H02K1/146 Primary

  consisting of a generally annular yoke with salient poles · CPC title

• H02K16/02

  Machines with one stator and two {or more} rotors · CPC title

• H02K1/165

  Shape, form or location of the slots · CPC title