Source: https://patents.google.com/patent/US8207642B2/en
Timestamp: 2019-05-24 18:36:57
Document Index: 70144874

Matched Legal Cases: ['Application No. 200480022823', 'Application No. 200480020404', 'Application No. 201010274844', 'Application No. 09707682', 'Application No. 09707682', 'Application No. 2008', 'Application No. 10', 'Application No. 2011']

US8207642B2 - Compact high power alternator - Google Patents
US8207642B2
US8207642B2 US12/848,972 US84897210A US8207642B2 US 8207642 B2 US8207642 B2 US 8207642B2 US 84897210 A US84897210 A US 84897210A US 8207642 B2 US8207642 B2 US 8207642B2
US12/848,972
US20110025152A1 (en
2003-07-10 Priority to US48683103P priority Critical
2004-07-12 Priority to US10/889,980 priority patent/US7122923B2/en
2005-12-06 Priority to US11/295,888 priority patent/US7768166B2/en
2010-08-02 Application filed by Magnetic Applications Inc filed Critical Magnetic Applications Inc
2010-08-02 Priority to US12/848,972 priority patent/US8207642B2/en
2011-02-03 Publication of US20110025152A1 publication Critical patent/US20110025152A1/en
2012-06-26 Publication of US8207642B2 publication Critical patent/US8207642B2/en
This application is a continuation of and claims priority to U.S. patent application Ser. No. 11/295,888, filed Dec. 6, 2005 now U.S. Pat. No. 7,768,166, which is a divisional application of and claims priority to U.S. patent application Ser. No. 10/889,980, filed on Jul. 12, 2004 now U.S. Pat. No. 7,122,923 and also claims priority to U.S. Provisional Application Ser. No. 60/486,831, filed Jul. 10, 2003, by inventors Charles Y. Lafontaine and Harold C. Scott.
Particularly light and compact permanent magnet alternators can be implemented by employing an “external” permanent magnet rotor and an “internal” stator. The rotor comprises a hollow cylindrical casing with high-energy permanent magnets disposed on the interior surface of the cylinder. The stator is disposed concentrically within the rotor casing. Rotation of the rotor about the stator causes magnetic flux from the rotor magnets to interact with and induce current in the stator windings. An example of such an alternator is described in, for example, the aforementioned U.S. Pat. Nos. 5,705,917 issued to Scott et al on Jan. 6, 1998 and 5,929,611 issued to Scott et al on Jul. 27, 1999.
Cylindrical rotor casing 316 is formed of “soft magnetic” (relatively transparent to magnetic flux) material (e.g. lead free steel) of a predetermined outer diameter and thickness. In general, to maximize power output, it is desirable that the diameter DAG (FIG. 4) of the circle defined by the inner surface of magnets 318 (sometimes referred to herein as the air gap diameter) be as large as possible given the applicable overall size constraints for alternator 100. For example, in many automotive applications, alternator 100 must be no more than 5 in. long and 5 in. in diameter in order to fit within the available space. The thickness of casing 316 is suitably chosen to be as thin as possible (to minimize weight and material cost) while still capable of withstanding expected loads and without the flux density from magnets 318 saturating the casing. The thickness of casing 316 is suitably in the range of ⅛ to ½ inch, typically in the range of 3/16 to ¼ inch, and, in the embodiments of FIGS. 1-4, 3/16 inch.
In vehicular applications alternator 110 may be subjected to relatively severe accelerations that tend to cause distortion and/or displacement of rotor 112 due to the moment of inertia inherent in the rotational case. Such accelerations are, due to, for example, engine vibration (particularly diesel engines at startup), cornering, traversing bumpy roads or terrain, and other types of impact. The efficiency of permanent magnet alternator 100 is inversely proportional to the width of “air gap” 412 separating the magnets from the stator. As previously noted, air gap 412 is suitably in the range of 20 to 40 thousands of an inch, and in the embodiments of FIGS. 1-4 on the order of 30 thousands of an inch, e.g., 31 thousands of an inch. Displacement of rotor 112 need only exceed the width of air gap 412 to clause clashing and possibly destructive interference. Further, for a variety of reasons, e.g. to minimize inertia in operation of alternator 100, it is desirable that rotor 112 be as light as possible. Accordingly, rotor 112 tends to be susceptible to distortion due to such forces.
Rotor endcap 714 is contoured to connect the forward end of casing 316 to hub 724, while at the same time providing sufficient space in interior cavity 320 to accommodate stator windings 330. For example, in the embodiment of FIG. 7A, endcap 714 comprises a conical portion 726 (which may include a plurality of apertures (e.g. 3) to, in effect, provide prospective angled cross arms), and a generally annular peripheral portion 728 connecting cross arms 722 to the forward end of casing 316. Peripheral portion 728 extends perpendicularly from casing 316 towards shaft 110 a predetermined distance, suitably in the range of ½ inch to 2 inches, and preferably ¾ inches. Internal chamber 320 thus extends farther forward in the vicinity of the crenellated outer edge of stator core 328, and windings 330.
As previously noted in conjunction with FIGS. 3 and 4, windings 330 are wound through a respective slot 404, outwardly along the side face of core 328 around a predetermined number of teeth 402 forming an end turn 332, then back through another slot 404. More particularly, with reference to FIGS. 9A,10A and 10B, each of windings 330 comprises at least one associated bundle of individual strands of insulated conductive wire (e.g. varnished copper motor wire) In contradistinction to the conventional practice, end turns 332 are loosely wrapped around the side faces of the stator core, with air spaces between the various bundles and the core side face, (rather than drawing the winding end turns tightly against the side face of the stator core to minimize cost and impedance). The inefficiencies inherent in loosely extending the winding end turn beyond the stator has been determined to be insignificant in comparison to the increased cooling capacity provided by exposed surface areas of the open winding structure. Preferably, as best seen in FIG. 10A, respective end turns 332 extend varying distances from stator side face 328, presenting a lattice-like structure to the airflow. End turns 332 suitably extend distances from stator side face 328, ranging from 0 to 1½ inch, and preferably from ¼ to 1 in. For example, adjacent end turns would extend outwardly by incrementally different distances e.g. increments of one half-inch to progressively fan out from the stator. In the embodiment of FIG. 10, a first end turn 1002 is offset from stator side face 328 by approximately a first predetermined distance, e.g. ½ inch. The next adjacent end turn 1004 is offset from stator side face 328 by approximately an incrementally increased distance, e.g. ¾ inch. Likewise, the next adjacent end turn 1006 is offset from stator side face 328 by approximately a further incrementally increased distance, e.g. 1 inch. The pattern is then suitably repeated. This arrangement is equally valid for a skewed core 329 as shown in FIG. 10B.
8. The apparatus of claim 5 wherein at least a portion of rotor endcap is disposed an angle other than 90° relative to the rotor casing, whereby the axial distance between the point of connection of the rotor to the shaft and the magnets is less than the axial length of the rotor casing.
And the apparatus further includes cooling means for dissipating heat and maintaining the temperature of the magnets below the predetermined destructive level over the predetermined operational range of rotational speeds.
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US13/532,243 Division US20120262021A1 (en) 2003-07-10 2012-06-25 Compact high power alternator
US20110025152A1 US20110025152A1 (en) 2011-02-03
US8207642B2 true US8207642B2 (en) 2012-06-26
US10/889,980 Expired - Fee Related US7122923B2 (en) 2003-07-10 2004-07-12 Compact high power alternator
US11/295,888 Expired - Fee Related US7768166B2 (en) 2003-07-10 2005-12-06 Compact high power alternator
US12/848,972 Expired - Fee Related US8207642B2 (en) 2003-07-10 2010-08-02 Compact high power alternator
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US20050035673A1 (en) 2005-02-17
JP4743786B2 (en) 2011-08-10
CN1833345A (en) 2006-09-13
US20110025152A1 (en) 2011-02-03
US20120262021A1 (en) 2012-10-18
WO2005008860A3 (en) 2005-05-19
KR101096469B1 (en) 2011-12-20
CN1833345B (en) 2010-11-03
WO2005008860A2 (en) 2005-01-27
US20060091761A1 (en) 2006-05-04
JP2007524335A (en) 2007-08-23
CA2531634A1 (en) 2005-01-27
KR20060112707A (en) 2006-11-01
EP1649574A2 (en) 2006-04-26
MXPA06000348A (en) 2006-03-28
US7122923B2 (en) 2006-10-17
US7768166B2 (en) 2010-08-03
CN101931277A (en) 2010-12-29
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