Abstract:
The invention provides slotless electrical motors with grooved core (grooved motors). The motors with grooved core are much easier in production than conventional motors with laminated core. Also, they do not have significant Eddy currents losses due to grooves.

Description:
[0001]    I, Alexei Stadnik, claim priority of provisional application No. 61/460,268 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The design of slotless motor includes coils mounted on the core. The easiest way for producing the core for coils mounting is using the solid metal ring or plate. However, the Eddy currents losses are very high for such motor (Eddy-Current Losses in Laminated and Solid Steel Stator Back Iron in a Small Rotary Brushless Permanent-Magnet Actuator by Johannes J. H. Paulides, Koen J. Meessen, and Elena A. Lomonova—IEEE TRANSACTIONS ON MAGNETICS, VOL. 44, NO. 11 NOVEMBER 2008). To reduce Eddy currents losses in motors, the laminated core for coils mounting is used (Unique Surface-Wound Brushless Servo with Improved Torque Ripple Characteristics by Thomas R. England—IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 24. NO. 6. NOVEMBER/DECEMBER 1988). The process of producing the stack of laminations requires labor and a lot of tooling. 
         [0003]    The motors with grooved core are much easier in production than conventional motors with laminated core. Also, they do not have significant Eddy currents losses due to grooves. 
     
    
     
       DESCRIPTION OF THE FIGURES 
         [0004]    FIG.  1 . 1 —Rotary radial (internal rotor) slotless motor with stator that includes coils and solid or laminated core. 
           [0005]    FIG.  1 . 2 —Invented rotary radial (internal rotor) slotless motor with stator that includes coils and grooved core. 
           [0006]    FIG.  2 —Grooved core for invented rotary radial (internal rotor) slotless motor. 
           [0007]    FIG.  3 . 1 —Rotary radial (external rotor) slotless motor with stator that includes coils and solid or laminated core. 
           [0008]    FIG.  3 . 2 —Invented rotary radial (external rotor) slotless motor with stator that includes coils and grooved core. 
           [0009]    FIG.  4 —Grooved core for invented rotary radial (external rotor) slotless motor. 
           [0010]    FIG.  5 . 1 —Rotary axial slotless motor with stator that includes coils and solid or laminated core. 
           [0011]    FIG.  5 . 2 —Invented rotary axial slotless motor with stator that includes coils and grooved core. 
           [0012]    FIG.  6 —Grooved core for invented rotary axial slotless motor. 
           [0013]    FIG.  7 . 1 —Linear flat slotless motor with forcer that includes coils and solid or laminated core. 
           [0014]    FIG.  7 . 2 —Invented linear flat slotless motor with forcer that includes coils and grooved core. 
           [0015]    FIG.  8 —Grooved core for invented linear flat slotless motor. 
           [0016]    FIG.  9 . 1 —Linear tube (internal magnets) slotless motor with forcer that includes coils and solid or laminated core. 
           [0017]    FIG.  9 . 2 —Invented linear tube (internal magnets) slotless motor with forcer that includes coils and grooved core. 
           [0018]    FIG.  10 —Grooved core for invented tube (internal magnets) slotless motor. 
           [0019]    FIG.  11 . 1 —Linear tube (external magnets) slotless motor with forcer that includes coils and solid or laminated core. 
           [0020]    FIG.  11 . 2 —Invented linear tube (external magnets) slotless motor with forcer that includes coils and grooved core. 
           [0021]    FIG.  12 —Grooved core for invented tube (external magnets) slotless motor. 
       
    
    
     DRAWINGS 
     Reference Numerals 
       [0000]    
       
           10 —Stator that includes coils and solid or laminated core, rotary radial (internal rotor) slotless motor. 
           12 —Coils, rotary radial slotless motor. 
           14 —Epoxy 
           16 —Solid or laminated core, rotary radial (internal rotor) slotless motor. 
           18 —Rotor, rotary radial (internal rotor) slotless motor. 
           20 —Bushing, rotary radial (internal rotor) slotless motor. 
           22 —Magnets, rotary radial (internal rotor) slotless motor. 
           24 —Stator that includes coils and grooved core, rotary radial (internal rotor) slotless motor. 
           26 —Grooved core, rotary radial (internal rotor) slotless motor. 
           28 —Grooves, rotary radial (internal rotor) slotless motor. 
           30 —Stator that includes coils and solid or laminated core, rotary radial (external rotor) slotless motor. 
           32 —Solid or laminated core, rotary radial (external rotor) slotless motor. 
           34 —Rotor, rotary radial (external rotor) slotless motor. 
           36 —Bushing, rotary radial (external rotor) slotless motor. 
           38 —Magnets, rotary radial (external rotor) slotless motor. 
           40 —Stator that includes coils and grooved core, rotary radial (external rotor) slotless motor. 
           42 —Grooved core, rotary radial (external rotor) slotless motor. 
           44 —Grooves, rotary radial (external rotor) slotless motor. 
           46 —Stator that includes coils and solid or laminated core, rotary axial slotless motor. 
           48 —Coils, rotary axial slotless motor. 
           50 —Solid or laminated core, rotary axial slotless motor. 
           52 —Rotor, rotary axial slotless motor. 
           54 —Bushing, rotary axial slotless motor. 
           56 —Magnets, rotary axial slotless motor. 
           58 —Stator that includes coils and grooved core, rotary axial slotless motor. 
           60 —Grooved core, rotary axial slotless motor. 
           62 —Grooves, rotary axial slotless motor. 
           64 —Forcer that includes coils and solid or laminated core, linear flat slotless motor. 
           66 —Coils, linear flat slotless motor. 
           68 —Solid or laminated core, linear flat slotless motor. 
           70 —Magnet track, linear flat slotless motor. 
           72 —Magnetic plate, linear flat slotless motor. 
           74 —Magnets, linear flat slotless motor. 
           76 —Forcer that includes coils and grooved core, linear flat slotless motor. 
           78 —Grooved core, linear flat slotless motor. 
           80 —Grooves, linear flat slotless motor. 
           82 —Forcer that includes coils and solid or laminated core, linear tube (internal magnets) slotless motor. 
           84 —Coils, linear tube slotless motor. 
           86 —Solid or laminated core, linear tube (internal magnets) slotless motor. 
           88 —Magnet track, linear tube (internal magnets) slotless motor. 
           90 —Magnetic tube, linear tube (internal magnets) slotless motor. 
           92 —Magnets, linear tube (internal magnets) slotless motor. 
           94 —Forcer that includes coils and grooved core, linear tube (internal magnets) slotless motor. 
           96 —Grooved core, linear tube (internal magnets) slotless motor. 
           98 —Grooves, linear tube (internal magnets) slotless motor. 
           100 —Forcer that includes coils and solid or laminated core, linear tube (external magnets) slotless motor. 
           102 —Solid or laminated core, linear tube (external magnets) slotless motor. 
           104 —Bushing, linear tube (external magnets) slotless motor. 
           106 —Magnet track, linear tube (external magnets) slotless motor. 
           108 —Magnetic tube, linear tube (external magnets) slotless motor. 
           110 —Magnets, linear tube (external magnets) slotless motor. 
           112 —Forcer that includes coils and grooved core, linear tube (external magnets) slotless motor. 
           114 —Grooved core, linear tube (external magnets) slotless motor. 
           116 —Grooves, linear tube (external magnets) slotless motor. 
       
     
       DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0076]    Rotary Radial (Internal Rotor) Slotless Motor with Grooved Core. 
         [0077]    Rotary radial (internal rotor) slotless motor with stator that includes coils and solid or laminated core for coils mounting is shown on  FIG. 1.1 . Stator  10  consists of coils  12  encapsulated in epoxy  14  and solid or laminated core  16 . Rotor  18  consists of bushing  20  and magnets  22 . 
         [0078]    The invented rotary radial (internal rotor) slotless motor construction includes stator  24  consisted of coils  12  encapsulated in epoxy  14 , and grooved core  26  ( FIG. 1.2 ). The grooved core replaces conventional solid or laminated core  16 . It is much easier in production than laminated core and do not have significant Eddy currents losses due to grooves. 
         [0079]    The grooved core  26  for rotary radial (internal rotor) slotless motor is shown on  FIG. 2 . It is made of solid oriented or non-oriented, ferromagnetic or non-ferromagnetic material or compound. Grooves  28  are made perpendicular the rotation axis (parallel to motor rotation), corkscrew direction, spiral direction or other direction. The exact dimensions, direction and quantity of grooves depend on electromechanical design and are subject for optimization. 
         [0000]    Rotary Radial (External Rotor) Slotless Motor with Grooved Core. 
         [0080]    Rotary radial (external rotor) slotless motor with stator that includes coils and solid or laminated core for coils mounting is shown on  FIG. 3.1 . Stator  30  consists of coils  12  encapsulated in epoxy  14  and solid or laminated core  32 . Rotor  34  consists of bushing  36  and magnets  38 . 
         [0081]    The invented rotary radial (external rotor) slotless motor construction includes stator  40  consisted of coils  12  encapsulated in epoxy  14 , and grooved core  42  ( FIG. 3.2 ). The grooved core replaces conventional solid or laminated core  32 . It is much easier in production than laminated core and do not have significant Eddy currents losses due to grooves. 
         [0082]    The grooved core  42  for rotary radial (external rotor) slotless motor is shown on  FIG. 4 . It is made of solid oriented or non-oriented, ferromagnetic or non-ferromagnetic material or compound. Grooves  44  are made perpendicular the rotation axis (parallel to motor rotation), corkscrew direction, spiral direction, or other direction. The exact dimensions, direction and quantity of grooves depend on electromechanical design and are subject for optimization. 
         [0000]    Rotary Axial Slotless Motor with Grooved Core. 
         [0083]    Rotary axial slotless motor with stator that includes coils and solid or laminated core for coils mounting is shown on  FIG. 5.1 . Stator  46  consists of coils  48  encapsulated in epoxy  14  and solid or laminated core  50 . Rotor  52  consists of magnetic plate  54  and magnets  56 . 
         [0084]    The invented rotary axial slotless motor construction includes stator  58  consisted of coils  48  encapsulated in epoxy  14 , and grooved core  60  ( FIG. 5.2 ). The grooved core replaces conventional solid or laminated core  50 . It is much easier in production than laminated core and do not have significant Eddy currents losses due to grooves. 
         [0085]    The grooved core  60  for rotary axial slotless motor is shown on  FIG. 6 . It is made of solid oriented or non-oriented, ferromagnetic or non-ferromagnetic material or compound. Grooves  62  are made perpendicular the rotation axis (parallel to motor rotation), corkscrew direction, spiral direction or other direction. The exact dimensions, direction and quantity of grooves depend on electromechanical design and are subject for optimization. 
         [0000]    Linear Flat Slotless Motor with Grooved Core. 
         [0086]    Linear flat slotless motor with forcer that includes coils and solid or laminated core for coils mounting is shown on  FIG. 7.1 . Forcer  64  consists of coils  66  encapsulated in epoxy  14  and solid or laminated core  68 . Magnet track  70  consists of magnetic plate  72  and magnets  74 . 
         [0087]    The invented linear flat slotless motor construction includes forcer  76  consisted of coils  66  encapsulated in epoxy  14 , and grooved core  78  ( FIG. 7.2 ). The grooved core replaces conventional solid or laminated core  68 . It is much easier in production than laminated core and do not have significant Eddy currents losses due to grooves. 
         [0088]    The grooved core  78  for linear flat slotless motor is shown on  FIG. 8 . It is made of solid oriented or non-oriented, ferromagnetic or non-ferromagnetic material or compound. Grooves  80  are made along the core length (parallel to motor moving direction) or other direction. The exact dimensions, direction and quantity of grooves depend on electromechanical design and are subject for optimization. 
         [0000]    Linear Tube (Internal Magnets) Slotless Motor with Grooved Core. 
         [0089]    Linear tube (internal magnets) slotless motor with forcer that includes coils and solid or laminated core for coils mounting is shown on  FIG. 9.1 . Forcer  82  consists of coils  84  and solid or laminated core  86 . Magnet track  88  consists of magnetic tube  90  and magnets  92 . 
         [0090]    The invented linear tube (internal magnets) slotless motor construction includes forcer  94  consisted of coils  84  and grooved core  96  ( FIG. 9.2 ). The grooved core replaces conventional solid or laminated core  86 . It is much easier in production than laminated core and do not have significant Eddy currents losses due to grooves. 
         [0091]    The grooved core  96  for linear tube (internal magnets) slotless motor is shown on  FIG. 10 . It is made of solid oriented or non-oriented, ferromagnetic or non-ferromagnetic material or compound. Grooves  98  are made along the core length (parallel to motor moving direction), or other direction. The exact dimensions, direction and quantity of grooves depend on electromechanical design and are subject for optimization. 
         [0000]    Linear Tube (External Magnets) Slotless Motor with Grooved Core. 
         [0092]    Linear tube (external magnets) slotless motor with forcer that includes coils and solid or laminated core for coils mounting is shown on  FIG. 11.1 . Forcer  100  consists of coils  84 , solid or laminated core  102  and bushing  104 . Magnet track  106  consists of magnetic tube  108  and magnets  110 . 
         [0093]    The invented linear tube (external magnets) slotless motor construction includes forcer  112  consisted of coils  84 , grooved core  114  and bushing  104  ( FIG. 11.2 ). The grooved core replaces conventional solid or laminated core  102 . It is much easier in production than laminated core and do not have significant Eddy currents losses due to grooves. 
         [0094]    The grooved core  114  for linear tube (external magnets) slotless motor is shown on  FIG. 12 . It is made of solid oriented or non-oriented, ferromagnetic or non-ferromagnetic material or compound. Grooves  116  are made along the core length (parallel to motor moving direction), or other direction. The exact dimensions, direction and quantity of grooves depend on electromechanical design and are subject for optimization.