Rotor for an axial flux rotating electrical machine having a powdered ferromagnetic core
AssigneeMaxxwell Motors, Inc.
InventorsMichael Cunnyngham, Maksym Pryimak
Life of this patent
Estimating the term…
Abstract
Embodiments involve rotors for axial flux induction rotating electric machines that use a soft magnetic composite for the rotor core. A first embodiment is directed to a rotor for a rotating electrical machine that transmits magnetic flux parallel to a shaft of the rotor. The rotor includes a rotor winding and a plurality of cores. The rotor winding consists of a solid piece of conductive material that comprises a plurality of cavities. Each core is placed in a respective cavity and comprises a highly resistive isotropic ferromagnetic powder.
Claims30
A rotor for an axial flux induction rotating electrical machine, the rotor comprising:
- a rotor winding comprising a plurality of cavities, wherein the rotor winding has a first coefficient of expansion;
- a plurality of cores, each core of the plurality of cores within a respective cavity from the plurality of cavities and comprising ferromagnetic powder, wherein respective grains of the ferromagnetic powder are insulated from one another, wherein the plurality of cores has a second coefficient of expansion different from the first coefficient of expansion;
- and
- a plurality of supports, each support of the plurality of supports attaching a respective core from the plurality of cores to a respective cavity from the plurality of cavities such that the support remains attached to the respective core and the respective cavity at a given operating temperature range of the rotor given the different first and second coefficients of expansion.
A method of manufacturing a rotor for an axial flux induction rotating electrical machine, the method comprising:
- fabricating a rotor winding comprising a plurality of cavities, wherein the rotor winding has a first coefficient of expansion;
- fabricating a plurality of cores, each core within a respective cavity from the plurality of cavities and comprising ferromagnetic powder, wherein respective grains of the ferromagnetic powder are insulated from one another, wherein the plurality of cores has a second coefficient of expansion different from the first coefficient of expansion;
- fabricating a plurality of supports;
- and
- attaching each of the plurality of supports to a respective core from the plurality of cores and a respective cavity from the plurality of cavities such that the support remains attached to the respective core and the respective cavity at a given operating temperature range of the rotor given the different first and second coefficients of expansion.
A rotor for an axial flux induction rotating electrical machine, the rotor made by a method comprising:
- fabricating a rotor winding comprising a plurality of cavities, wherein the rotor winding has a first coefficient of expansion;
- fabricating a plurality of cores, each core within a respective cavity from the plurality of cavities and comprising ferromagnetic powder, wherein respective grains of the ferromagnetic powder are insulated from one another, wherein the plurality of cores has a second coefficient of expansion different from the first coefficient of expansion;
- fabricating a plurality of supports;
- and
- attaching each of the plurality of supports to a respective core from the plurality of cores and a respective cavity from the plurality of cavities such that the support remains attached to the respective core and the respective cavity at a given operating temperature range of the rotor given the different first and second coefficients of expansion.
Dependencies are inferred from the claim text.