Electric machine

Abstract

A rotor for an electric machine having posts extending partially or completely between end irons. Each end iron is formed of a single piece of magnetic material with the posts extending from it, including the other end iron where the posts extend completely between them. Magnets are arranged between the posts with poles facing the posts to concentrate flux. In order to prevent too much of the flux from being drawn into flux paths through the end irons, the total magnetic flux is made to exceed a saturation flux of at least a portion of the flux path. This may be achieved by using interdigitated posts extending only partially between the end irons to provide gaps in the flux path, by providing flux resistors in the end irons to reduce a saturation flux below the total flux, or by using high aspect ratio magnets or posts so that the magnetic flux exceeds a saturation flux of the posts or end irons.

1 . A permanent magnet carrier for an electric motor, the permanent magnet carrier comprising:
 a first end iron;   a second end iron;   an array of posts each extending from one of the first end iron and the second end iron towards the other of the first end iron and the second end iron, the first end iron and the posts extending from the end iron being formed of a first single piece of magnetic material, and the second end iron and the posts extending from the second end iron being formed of the first single piece of magnetic material or of a second single piece of magnetic material;   an array of permanent magnets arranged between the posts of the array of posts, each permanent magnet being magnetized in a direction oriented between a respective pair of posts of the array of posts adjacent to the magnet; and   a support element supporting the first end iron relative to the second end iron,   wherein a supporting structure comprises the first end iron, the second end iron, and the array of posts, the supporting structure defining a first respective flux path between each respective pair of posts through the first end iron, and a second respective flux path between each respective pair of posts through the second end iron, the first respective flux path having a first saturation portion with a first respective saturation flux and the second respective flux path having a second saturation flux, the magnets generating a total magnetic flux in conjunction with the posts that exceeds a sum of the first respective saturation fluxes and the second respective saturation fluxes, and   wherein successive posts of the array of posts extend alternately from the first and second end irons to interdigitate, the first gap or saturation portion of each respective pair of posts being a gap between the first end iron and a post of the pair extending from the second end iron and the second gap or saturation portion of each respective pair of posts being a gap between the second end iron and a port of the pair extending from the first end iron, and   wherein the support element comprises a support ring defining grooves for receiving the posts.   
     
     
         2 . An axial flux motor comprising a permanent magnet carrier of  claim 1  in which the posts extend in a radial direction and the direction oriented between the respective pair of posts is a circumferential direction. 
     
     
         3 . A radial flux motor comprising a permanent magnet carrier of  claim 1  in which the posts extend in an axial direction and the direction oriented between the respective pair of posts is a circumferential direction. 
     
     
         4 . A permanent magnet carrier for an electric motor, the permanent magnet carrier comprising:
 a first end iron;   a second end iron;   an array of posts each extending from one of the first end iron and the second end iron towards the other of the first end iron and the second end iron, the first end iron and the posts extending from the end iron being formed of a first single piece of magnetic material, and the second end iron and the posts extending from the second end iron being formed of the first single piece of magnetic material or of a second single piece of magnetic material; and   an array of permanent magnets arranged between the posts of the array of posts, each permanent magnet being magnetized in a direction oriented between a respective pair of posts of the array of posts adjacent to the magnet, and   wherein a supporting structure comprises the first end iron, the second end iron, and the array of posts, the supporting structure defining a first respective flux path between each respective pair of posts through the first end iron, and a second respective flux path between each respective pair of posts through the second end iron, the first respective flux path having a first saturation portion with a first respective saturation flux and the second respective flux path having a second saturation portion with a second respective saturation flux, the magnets generating a total magnetic flux in conjunction with the posts that exceeds a sum of the first respective saturation fluxes and the second respective saturation fluxes,   wherein the posts connect the first end iron and the second end iron, and the end irons define holes, portions of the end irons around the holes being the first and second saturation portions.   
     
     
         5 . An axial flux motor comprising a permanent magnet carrier of  claim 4  in which the posts extend in a radial direction and the direction oriented between the respective pair of posts is a circumferential direction. 
     
     
         6 . A radial flux motor comprising a permanent magnet carrier of  claim 4  in which the posts extend in an axial direction and the direction oriented between the respective pair of posts is a circumferential direction. 
     
     
         7 . A permanent magnet carrier for an electric motor, the permanent magnet carrier comprising:
 a first end iron;   a second end iron;   an array of posts each extending from one of the first end iron and the second end iron towards the other of the first end iron and the second end iron, the first end iron and the posts extending from the end iron being formed of a first single piece of magnetic material, and the second end iron and the posts extending from the second end iron being formed of the first single piece of magnetic material or of a second single piece of magnetic material; and   an array of permanent magnets arranged between the posts of the array of posts, each permanent magnet being magnetized in a direction oriented between a respective pair of posts of the array of posts adjacent to the magnet, and   wherein a supporting structure comprises the first end iron, the second end iron, and the array of posts, the supporting structure defining a first respective flux path between each respective pair of posts through the first end iron, and a second respective flux path between each respective pair of posts through the second end iron, the first respective flux path having a first saturation portion with a first respective saturation flux and the second respective flux path having a second saturation portion with a second respective saturation flux, the magnets generating a total magnetic flux in conjunction with the posts that exceeds a sum of the first respective saturation fluxes and the second respective saturation fluxes,   wherein the posts connect the first end iron and the second end iron, the permanent magnets having a length in a direction aligned with the posts sufficient to generate a flux exceeding a saturation flux of the end irons so that portions of the end irons connecting between the posts act as the first and second saturation portions.   
     
     
         8 . An axial flux motor comprising a permanent magnet carrier of  claim 7  in which the posts extend in a radial direction and the direction oriented between the respective pair of posts is a circumferential direction. 
     
     
         9 . A radial flux motor comprising a permanent magnet carrier of  claim 7  in which the posts extend in an axial direction and the direction oriented between the respective pair of posts is a circumferential direction. 
     
     
         10 . The permanent magnet carrier of  claim 7  in which the magnets have a ratio of magnet length in the direction aligned with the posts to magnet width in the direction oriented between the respective pair of posts greater than 4/1, 5/1, 6/1, 7/1, 8/1, 9/1, 10/1, 11/1, 12/1, 13/1, 14/1, 15/1, or 16/1. 
     
     
         11 . The permanent magnet carrier of  claim 7  in which the posts have a ratio of post length to post width greater than 4/1, 5/1, 6/1, 7/1, 8/1, 9/1, 10/1, 11/1, 12/1, 13/1, 14/1, 15/1, or 16/1. 
     
     
         12 . The permanent magnet carrier of  claim 7  in which each post of the array of posts has a respective cross section and the first end iron has a first end iron cross section and each post connects to the first end iron with no part of the connection having substantially lower cross section than a lowest of the respective cross section and the first end iron cross section. 
     
     
         13 . The permanent magnet carrier of  claim 12  in which the first end iron cross section is equal to or greater than each respective cross section of the posts of the array of posts. 
     
     
         14 . The permanent magnet carrier of  claim 12  in which the second end iron has a second end iron cross section and each post of the array of posts connects to the second end iron with no part of the connection having substantially lower cross section than a lowest of the respective cross section and the second end iron cross section. 
     
     
         15 . The permanent magnet carrier of  claim 14  in which the second end iron cross section is greater than or equal to each respective cross section of the posts of the array of posts. 
     
     
         16 . The permanent magnet carrier of  claim 7  in which each magnet extends substantially the full length of a space between successive posts. 
     
     
         17 . A permanent magnet carrier for an electric motor, the permanent magnet carrier comprising:
 a first end iron;   a second end iron;   an array of posts each extending from one of the first end iron and the second end iron towards the other of the first end iron and the second end iron, the first end iron and the posts extending from the end iron being formed of a first single piece of magnetic material, and the second end iron and the posts extending from the second end iron being formed of the first single piece of magnetic material or of a second single piece of magnetic material; and   an array of permanent magnets arranged between the posts of the array of posts, each permanent magnet being magnetized in a direction oriented between a respective pair of posts of the array of posts adjacent to the magnet, and   wherein a supporting structure comprises the first end iron, the second end iron, and the array of posts, the supporting structure defining a first respective flux path between each respective pair of posts through the first end iron, and a second respective flux path between each respective pair of posts through the second end iron, the first respective flux path having a first saturation portion with a first respective saturation flux and the second respective flux path having a second saturation portion with a second respective saturation flux, the magnets generating a total magnetic flux in conjunction with the posts that exceeds a sum of the first respective saturation fluxes and the second respective saturation fluxes,   wherein the posts connect the first end iron and the second end iron, the permanent magnets having a length in a direction aligned with the posts sufficient to generate a flux exceeding a saturation flux of the posts so that the posts act as the first and second saturation portions.   
     
     
         18 . An axial flux motor comprising a permanent magnet carrier of  claim 17  in which the posts extend in a radial direction and the direction oriented between the respective pair of posts is a circumferential direction. 
     
     
         19 . A radial flux motor comprising a permanent magnet carrier of  claim 17  in which the posts extend in an axial direction and the direction oriented between the respective pair of posts is a circumferential direction. 
     
     
         20 . A permanent magnet carrier for an electric motor, the permanent magnet carrier comprising:
 a first end iron having first tabs;   a second end iron having second tabs;   an array of posts each extending from one of the first end iron and the second end iron towards the other of the first end iron and the second end iron, the first end iron and the posts extending from the end iron being formed of a first single piece of magnetic material, and the second end iron and the posts extending from the second end iron being formed of the first single piece of magnetic material or of a second single piece of magnetic material; and   an array of permanent magnets arranged between the posts of the array of posts, each permanent magnet being magnetized in a direction oriented between a respective pair of posts of the array of posts adjacent to the magnet,   wherein a supporting structure comprises the first end iron, the second end iron, and the array of posts, the supporting structure defining a first respective flux path between each respective pair of posts through the first end iron, and a second respective flux path between each respective pair of posts through the second end iron, the first respective flux path having a first saturation portion with a first respective saturation flux and the second respective flux path having a second saturation portion with a second respective saturation flux, the magnets generating a total magnetic flux in conjunction with the posts that exceeds a sum of the first respective saturation fluxes and the second respective saturation fluxes, and   wherein the first and second tabs retain the permanent magnets.   
     
     
         21 . An axial flux motor comprising a permanent magnet carrier of  claim 20  in which the posts extend in a radial direction and the direction oriented between the respective pair of posts is a circumferential direction. 
     
     
         22 . A radial flux motor comprising a permanent magnet carrier of  claim 20  in which the posts extend in an axial direction and the direction oriented between the respective pair of posts is a circumferential direction.