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Electric Motor Elektromotor Moteur Électrique

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Electric Motor Elektromotor Moteur Électrique (19) *EP003257138B1* (11) EP 3 257 138 B1 (12) EUROPEAN PATENT SPECIFICATION (45) Date of publication and mention (51) Int Cl.: of the grant of the patent: H02K 21/24 (2006.01) H02K 3/26 (2006.01) (2016.01) (2006.01) 04.12.2019 Bulletin 2019/49 H02K 11/33 H02K 16/04 (21) Application number: 16748477.3 (86) International application number: PCT/AU2016/050060 (22) Date of filing: 03.02.2016 (87) International publication number: WO 2016/127207 (18.08.2016 Gazette 2016/33) (54) ELECTRIC MOTOR ELEKTROMOTOR MOTEUR ÉLECTRIQUE (84) Designated Contracting States: (74) Representative: Lavoix AL AT BE BG CH CY CZ DE DK EE ES FI FR GB Bayerstrasse 83 GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO 80335 München (DE) PL PT RO RS SE SI SK SM TR (56) References cited: (30) Priority: 13.02.2015 AU 2015900464 WO-A1-2006/036201 CN-Y- 201 204 491 JP-A- H0 487 544 JP-A- 2009 153 358 (43) Date of publication of application: US-A- 3 382 570 US-A- 4 585 085 20.12.2017 Bulletin 2017/51 US-A1- 2006 202 584 US-A1- 2006 202 584 US-A1- 2008 272 664 US-A1- 2012 256 422 (73) Proprietor: Electric Vehicle Systems And US-B2- 8 006 789 Technology Pty Ltd Lang Lang VIC 3984 (AU) • SPOONER E ET AL: "’TORUS’: A SLOTLESS, TOROIDAL-STATOR, PERMANENT-MAGNET (72) Inventors: GENERATOR", IEE PROCEEDINGS B. • QUICK, Duncan Richard ELECTRICAL POWER APPLICATIONS, 1271980 Snake Valley, Victoria 3351 (AU) 1, vol. 139, no. 6, 1 November 1992 (1992-11-01), • HEDDITCH, Duncan John pages 497-506, XP000343941, Grantville, Victoria 3984 (AU) Note: Within nine months of the publication of the mention of the grant of the European patent in the European Patent Bulletin, any person may give notice to the European Patent Office of opposition to that patent, in accordance with the Implementing Regulations. Notice of opposition shall not be deemed to have been filed until the opposition fee has been paid. (Art. 99(1) European Patent Convention). EP 3 257 138 B1 Printed by Jouve, 75001 PARIS (FR) 1 EP 3 257 138 B1 2 Description Undervoltage on any single cell therefore leads to battery failure and therefore in a BEV, vehicle failure. The relia- TECHNICAL FIELD bility of the vehicle can only be improved by the use of two or more batteries. [0001] The present invention relates to a low voltage 5 [0009] Document JP 2009/153358 discloses a motor high current permanent magnet DC electromagnetic het- of known type. eropolar motor. [0010] Document US 2006/202584 discloses an axial rotary energy device of known type. BACKGROUND [0011] It is desired to provide an electric motor that 10 alleviates one or more difficulties of the prior art, or that [0002] As global oil reserves decline, the motivation to at least provides a useful alternative. develop battery electric vehicles increases. As a conse- quence, improvements to the range and weight of electric SUMMARY vehicles become economically desirable. [0003] To increase the efficiency of power conversion, 15 [0012] According to the present invention, there is pro- the system voltage in battery powered electric vehicles vided a permanent magnet DC electromagnetic heter- (BEVs) has increased over the past decade from around opolar motor having the characteristics defined in claim 1. 150V, to over 600V. Future systems of over 800V are [0013] Particular embodiments of the present inven- expected. The safety risks of electrocution and fire inher- tion are the subject of the dependent claims, whose con- ent in the presence of such high voltages can be man- 20 tents are to be considered as integrating part of the aged by methods such as chassis short circuit detection present description. and automatic isolation, manually operated high voltage isolators, and insulating gloves worn by emergency serv- BRIEF DESCRIPTION OF THE DRAWINGS ices personnel, but risk management principles would suggest elimination of the problem is a safer solution than 25 [0014] Some embodiments of the present invention either personal protective equipment (PPE) or engineer- are hereinafter described, by way of example only, with ing solutions. Eliminating the problems caused by high reference to the accompanying drawings, wherein: voltage (HV) batteries can be achieved by lowering the system voltage. However, as above-mentioned, design- Figure 1 is side perspective view of an electric motor; ers of BEVs are typically increasing system voltage, not 30 Figure 2a is a side view of the motor shown in Figure decreasing it. Increasing the system voltage reduces 1a; conductor size and cost, and increases the efficiency, Figure 2b is a section view of the motor shown in since the volt drop across IGBTs is lower at lower cur- Figure 2a through the line A - A; rents, reducing losses. Figure 2c is an enlarged view of section "B" of the [0004] BEVs use one or more batteries with cells in 35 motor shown in Figure 2b; series. Series cells require balancing circuits to ensure Figure 2d is an enlarged view of the section "C" of each cell has the same voltage. Typically, one cell bal- the motor shown in Figure 2b; ancer circuit is required across each cell. This means the Figure 3 is an end view of the motor shown in Figure use of very small cells leads to an expensive set of bal- 1; ancers. The function of the balancer circuit is well known 40 Figure 4 is a partly exploded view of the motor shown to those skilled in the art and need not be detailed herein. in Figure 1; Balancers are essential to reliably achieve the desired Figure 5a is a side perspective view of a rotor of the charge - discharge range and a long service life for the motor shown in Figure 1; battery. Figure 5b is a side perspective view of a magnet of [0005] Even with cell charge balancers, the discharge 45 the rotor shown in Figure 9; depth of the cells does still vary with cell age, temperature Figure 6 is a side perspective view of a stator disc and other factors, so eventually with all series strung bat- of the motor shown in Figure 1; teries, a cell will fail, being forced into reverse polarity by Figures 7a to 7c are schematic diagram showing a the other cells, causing failure of the battery pack. circuit for a driver for one bar of the motor shown in [0006] Cell bypassing can be provided to ensure cells 50 Figure 1; do not over or under charge. However, only in very small Figure 8 is a side perspective view of another electric cell batteries, can cell bypassing circuitry be built eco- motor. nomically. Figure 9 is a side view of a stator of the motor shown [0007] For BEVs, cell bypassing is uneconomic, and in Figure 1; the whole battery has to be replaced after around eight 55 Figure 10 is a side perspective view of a sector of years. the stator shown in Figure 9; [0008] All series strung batteries require cell monitor- Figure 11 is a side view of a printed circuit board of ing to detect cell undervoltage and trip out the battery. the stator shown in Figure 9; 2 3 EP 3 257 138 B1 4 Figure 12 is a side perspective view of a battery; cludes a plurality of slots 38 being shaped to receive and Figure 13 is a schematic diagram of a power supply seat therein respective ones of the magnets 16. The rotor for the motor shown in Figure 1; disc 14 includes a central hub 40 including an axially Figure 14 is a side perspective view of the motor extending slot for receiving the shaft 20 therethrough. shown in Figure 1 electrically connected to a power 5 The rotor disc 14 also includes a plurality of support mem- supply system; and bers 42 extending radially between the hub 40 the outer Figure 15 is a schematic diagram of a battery pow- circumferential section 18. Slots 43 are formed between ered electric vehicle. the support members 42 and the outer circumferential section 18. The slots 43 are shaped to assist with drawing DETAILED DESCRIPTION 10 in air axially through the motor 10 and expelling air radially from the motor 10. Airflow generated by slots 43 moving [0015] The brushless direct current (DC) motor 10 air through the motor in this manner help cool the motor shown in Figures 1 to 4, includes a rotor 12 including a 10. The slots also help to reduce the weight of the motor rotor disc 14 and a ring of spaced apart permanent mag- 10. nets 16 coupled around an outer circumferential section 15 [0019] The hub 40 includes a fastener 44 for mating 18 of the rotor disc 14 in the manner shown in Figures with the shaft 20. As shown, the fastener 44 is a female 5a and 5b. The motor 10 also includes a shaft 20 extend- slot shaped to mate with a male protrusion (not shown) ing axially in direction "DA" through the rotor disc 14. The of the shaft 20. Alternatively, the fastener 44 is any other shaft 20 is in mechanical communication with the rotor suitable means for mechanically coupling the rotor 12 to disc 14 such that axial rotation of the rotor disc 14 causes 20 the shaft 20. axial rotation of the shaft 20. As shown in Figure 6, the [0020] As particularly shown in Figures 9 to 11, the motor 10 also includes a stator 22 that includes a stator stator 22 includes the driver switches 30 mounted cir- disc 24 having circumferentially distributed and radially cumferentially around respective bars 28 of the stator directed slots 26 therein that define corresponding radi- disc 24.
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