Patent ID: 12218555

MODE FOR CARRYING OUT THE INVENTION

Hereinafter, a structure of a dual and multiple air gap rotary device according to the present invention will be described with reference to the accompanying drawings.

First, the gist of the present invention may be applied to all of a rotor part of a rotary device such as an electric motor for generating a rotary force as a power is applied and a power generator for generating a power by a rotary force, and a stator structure for applying a three-phase power or generating a power may be substantially the same or similar except for a typical rotor structure of the electric motor or the power generator.

Hereinafter, the present invention will be described by using an embodiment of a rotor device.

According to the present invention, a rotor part of a dual air gap rotary device constantly maintains dual air gaps, and a multiple air gap rotary device includes four or more air gaps and has a support structure with a permanent magnet so as to provide or generate great torque. Each of the dual air gap rotary device and the multiple air gap rotary device may include various embodiments. Hereinafter, the rotary device according to the present invention will be described with reference to the accompanying drawings and embodiments.

Structure of Dual Air Gap Rotary Device

As illustrated inFIG.1, a dual air gap rotary device according to a first embodiment of the present invention includes a rotor part100, a stator part400, an inner support part610, a housing part600, and a bearing700. The stator part400is firmly attached to the inner support part610and the housing part600, and the rotor part100is supported by the bearing700between the stator part400and two inner and outer air gaps500to rotate.

The bearing700includes a rotor and shaft coupling bearing701, a rotor and inner support part coupling bearing702, and a rotator and housing part coupling bearing703. When an inner air gap520is secured because the rotor has a short length to realize a stable structure, the rotor and the inner support part coupling bearing702is not required. In some cases, the bearing700may include only the rotor and shaft coupling bearing701without the rotor and inner support part coupling bearing702and the rotator and housing part coupling bearing703.

Also, the bearing is a component of allowing a member rotating relatively to a member in a fixed state to smoothly rotate. The position, the structure, and the installation number of the bearing700may be determined according to shaft directional support and/or radial directional support at a proper position.

Also, since reference numerals applied in each drawing are applied for convenience, various configurations may be implemented for necessity of the shaft support and/or radial support at a corresponding position.

In the dual air gap rotary device, the rotor part of the dual air gap rotary device may include a rotor-side magnetic force application part110and an end support part121, and the stator part400may include a wire part200through which current flows and an iron core part300through which magnetic flux flows.

The stator part400may include the wire part200through which current flows and the iron core part300through which a magnetic flux flows, the wire part200may include an outer wire210and an inner wire220, and the iron core part300may include an outer iron core310and an inner iron core320.

That is, the stator part400may be divided into an outer stator part330including the outer wire210and the outer iron core310and an inner stator part340including the inner wire220and the inner iron core320.

Here, as illustrated inFIGS.29to32, the stator part400may have a multiple air gap structure of including a stator iron core fixed and coupled to the housing part600and a stator wire wound around the stator iron core and using a rotation center of a rotary shaft150as a concentric circle center instead of including two components of the outer stator part330and the inner stator part340, i.e., a dual air gap structure.

As an outer air gap510is disposed between the outer stator part330and the rotor part100, and an inner air gap520is disposed between the inner stator part340and the rotor part100, two air gaps and furthermore multiple air gaps, i.e., the inner and the outer air gaps500, are configured. Theoretically, when the number of the air gaps increases twice, a power density increases twice.

As the rotor-side magnetic force application part110is installed between the two air gaps of the outer air gap510and the inner air gap520, energy conversion is implemented. That is, in case of an electric motor, electrical energy is converted into mechanical energy, and in case of a power generator, mechanical energy is converted into electrical energy. The rotor-side magnetic force application part110including a permanent magnet and an iron core is required to be structurally firmly coupled with the end support part121so that a constant distance between the outer air gap510and the inner air gap520is maintained.

Here, as illustrated inFIGS.33and34, in the rotor part100, the rotor-side magnetic force application part110including the permanent magnet may further include a support member152coupled to an inner circumferential surface and an outer circumferential surface thereof, so that the rotor-side magnetic force application part110is stably supported.

The rotor-side magnetic force application part110that is the most important portion in energy conversion may use the permanent magnet to electrically generate a large amount of magnetic fluxes, require a robust structure to mechanically transmit a large rotary force, and be firmly connected with the left and right end support parts121to smoothly transmit a rotary force.

As described above, as illustrated inFIGS.1,29,30, and33, the stator part400may include: a central stator part including a stator iron core370installed on the inner support part610disposed at a central portion and extending in a shaft direction in a circumferential direction and a stator wire270wound around the stator iron core370; an outer stator part installed at an outermost portion and including a stator iron core360and a stator wire270wound around the stator iron core370; and at least one intermediate stator part including an inner stator iron core380and an outer stator iron core390, which are respectively installed on an inner circumferential surface and an outer circumferential surface of at least one iron core support part620extending in the shaft direction between the central stator part and the outer stator part to form a concentric circle with the outer stator part, and an inner stator wire280and an outer stator wire290, which are respectively wound around the inner stator iron core380and the outer stator iron core390, so that an inner air gap and an outer air gap have one pair or more, i.e., the dual and multiple air gap structure.

The central stator part may include a stator iron core installed on the inner support part610disposed at the central portion and extending in the shaft direction in the circumferential direction and a stator wire wound around the stator iron core.

The stator iron core may include a predetermined number of protruding teeth installed on an outer circumferential surface of the inner support part610along the circumferential direction so that the stator wire is wound therearound.

Also, the stator wire that is a coil wound around the protruding teeth of the stator iron core may be variously configured.

The outer stator part may be installed at an outermost portion of the rotary device and include a stator iron core and a stator wire wound around the stator iron core.

The stator iron core may be installed at the outermost portion of the rotary device, e.g., an inner circumferential surface of an outer portion630of the housing600and including a predetermined number of protruding teeth installed on an inner circumferential surface of an outermost portion along the circumferential direction so that the stator wire is wound therearound.

Also, the stator wire that is a coil wound around the protruding teeth of the stator iron core may be variously configured.

The number of the at least one intermediate stator part may be determined by the number of the inner air gap and the outer air gap. The at least one intermediate stator part may include the inner stator iron core380and the outer stator iron core390, which are respectively installed on the inner circumferential surface and the outer circumferential surface of the at least one iron core support part620extending in the shaft direction between the central stator part and the outer stator part to form a concentric circle with the outer stator part, and the inner stator wire280and the outer stator wire290, which are respectively wound around the inner stator iron core380and the outer stator iron core390.

That is, in the intermediate stator part, the inner stator wire280installed at a relatively inner circumference side forms an inner air gap532with the rotor-side magnetic force application part110of the rotor part100, and the outer stator wire290installed at an outer circumference side forms an outer air gap533with the rotor-side magnetic force application part110of the rotor part100.

Specifically, the rotor part100may include: a plurality of rotor-side magnetic force application parts110installed to have an inner air gap531with respect to the inner stator wire280of the intermediate stator part disposed at the relatively inner circumference side and an outer air gap532with respect to the outer stator wire290of the intermediate stator part disposed at the outer circumference side; and a pair of end support parts121installed at respective ends of the rotor-side magnetic force application part110.

Here, at least one of the pair of end support parts121, as a side surface143of the rotor part, may be fixed and coupled to the rotary shaft150that is rotatably installed on the housing part600.

The inner support part610disposed at a shaft portion of the rotary shaft of the rotary device according to the present invention may be variously configured.

For example, the inner support part610may rotatably support the rotary shaft150at the shaft portion of the rotary shaft150so as to rotatably support the rotor part100including the rotary shaft150.

To this end, the bearing702is installed at a portion at which the inner support part610supports the rotary shaft150in order to rotatably support the rotary shaft150.

The inner support part610may include all sorts of components as long as the components rotatably support the rotary shaft150at the shaft portion thereof.

Specifically, when the rotary shaft150is installed to cross the shaft portion of the rotary device (reference numeral151), the inner support part610may have a hollow cylinder structure so that the rotary shaft150is inserted therein, and a shaft directional bearing706and a radial directional bearing705may be provided to rotatably support the rotary shaft150as illustrated inFIGS.33and34.

Here, the inner support part610may be disposed at a central portion, and the stator part400may be coupled thereto.

Specifically, the inner iron core320may be coupled to an outer circumference of the inner support part610, and the inner wire220may be wound around the inner iron core320.

The housing part600that is a component including the inner support part610to constitute a main body of the rotary device may be variously configured according to a usage environment of the rotary device. For example, the housing part600may form an outer circumferential surface of the rotary device as illustrated inFIG.1.

As illustrated inFIG.1, the housing600may include a side plate part640obtained by forming the inner support part610in the shaft direction and an outer part630extending from an outer circumference of the side plate part640in the shaft direction to form a longitudinal cross-sectional shape of ‘U’.

The side plate part640that is a component forming the shaft directional side surface and obtained by forming the inner support part610in the shaft direction, may be variously configured.

The outer part630that is a component extending from the outer circumference of the side plate part640in the shaft direction may be variously configured.

The outer iron core360may be coupled to an inner circumferential surface of the outer part630, and the outer wire260may be wound around the outer iron core360.

As illustrated inFIG.33, the outer part630may have a size of allowing the outer iron core360to be coupled to an end thereof in correspondence to the rotor-side magnetic force application part110of the rotary part100for a light weight and a compact size.

Here, as expressed by a dotted line inFIG.33, the outer part630may rotatably support an outer circumferential surface of the rotor part100by using the bearing703for stable support of the rotor part100.

As described above, the stator part400may include the stator iron core fixed and coupled to the housing part600and the stator wire wound around the stator iron core instead of including two components of the outer stator part330and the inner stator part340as illustrated inFIGS.29to32, and 2n (here, n is a natural number of 1 or more) stator iron cores and stator wires may be installed by using the rotation center of the rotary shaft150as a concentric circle center.

Here, the housing600may additionally include an iron core support part620extending in the shaft direction between the inner support part610and the outer part630.

The iron core support part620that is a component extending in the shaft direction between the inner support part610and the outer part630may be variously configured as long as a stator iron core that will be described later is able to be installed.

As illustrated inFIG.30, an end support part support bearing702may be installed on an end of the iron core support part620to rotatably support the end support part121.

The rotary device according to the present invention may have a rotary-type structure such as a wing of a fan on the outer circumference surface of the rotor part100.

Here, the housing600may have a structure in which the outer part6is omitted as illustrated inFIG.34instead of the structure having the ‘U’-shape including the side plate part640and the outer part630inFIG.1.

Here, the rotor part100may include an outer rotary part142rotatably installed by being spaced apart from the stator part400with an inner air gap therebetween and forming the outer circumference of the rotary device and a plurality of magnetic force application parts141to which the outer rotary part142is fixedly installed on an inner circumferential surface thereof in a circumferential direction.

The outer rotary part142that is a component rotatably installed by being spaced apart from the stator part400with the inner air gap therebetween and forming the outer circumference of the rotary device may have various appearances according to use of the rotary device.

For example, the rotary device according to the present invention includes a fan, a plurality of blades10may be coupled to or integrated with the outer rotary part142.

The plurality of magnetic force application parts141that are components in which the outer rotary part142is fixed to the inner circumferential surface in a circumference direction thereof may be variously arranged by using permanent magnets.

In case of an embodiment inFIG.34, the rotary shaft150may be installed to cross the shaft portion of the rotary device (reference numeral151). Here, as illustrated inFIG.34, the inner support part610may have a hollow cylinder structure so that a shaft extension portion151of the rotary shaft150is inserted thereinto, and the shaft directional bearing706and the radial directional bearing705may be provided to rotatably support the rotary shaft150.

Here, the inner support part610may be disposed at a central portion, and the stator part400may be coupled thereto.

Specifically, the inner iron core320may be coupled to an outer circumference of the inner support part610, and the inner wire220may be wound around the inner iron core320.

Rotor Part when Radial Direction Permanent Magnet is Applied

As illustrated inFIG.2, the rotor part100of the dual air gap rotary device includes the rotor-side magnetic force application part110and the end support part121, and the rotor-side magnetic force application part110includes a radial direction permanent magnet111and a radial direction permanent magnet side surface support part112for supporting the radial direction permanent magnet111. The radial direction permanent magnets111are arranged such that polarities of the permanent magnets are alternated between a ↑ direction and a ↓, direction along a radial direction from a center of the rotor. The radial direction permanent magnet111may be firmly fixed to the radial direction permanent magnet side surface support part112and the end support part121so that the radial direction permanent magnets111are not scattered when the rotor part100rotates.

The end support part121and the radial direction permanent magnet side surface support part112may be made of a magnetic material through which a magnetic flux easily passes or a non-magnetic material.

When the end support part121and the radial direction permanent magnet side surface support part112are made of the same material, a groove to which the radial direction permanent magnet111may be made of one material and processed without a welding work, and the structure of the rotor part100may strongly maintain a degree of precision.

The radial direction permanent magnet111may be prevented from being separated by using an adhesive to fix the radial direction permanent magnet111or by applying an angle between the permanent magnet side surface support part112, the end support part121, and the radial direction permanent magnet111and inserting an adhesive therebetween.

As another method, the radial direction permanent magnet111may be prevented from being separated by fixing the radial direction permanent magnet111to the permanent magnet side surface support part112and the end support part121and then winding a strong fiber thread in a circumferential direction of the outer circumference of the rotor part100or reinforcing an inconel having a high strength in a cylindrical shape.

For reference, the fiber thread or the cylindrical inconel that is a separation preventing means for preventing separation in the radial direction may be used to reinforce a whole or a portion of the outer circumference of the rotor part100. The fiber thread or the cylindrical inconel is not expressed in the drawings for convenience.

FIG.3is a cross-sectional view illustrating the rotor part taken along direction A-A inFIG.2.FIG.3illustrates the radial direction permanent magnet111and the permanent magnet side surface support part112of the rotor-side magnetic force application part110.

FIG.4illustrates a case when the radial direction permanent magnet111is fixed to the permanent magnet side surface support part112and a radial direction vertical permanent magnet support part113. The radial direction vertical permanent magnet support part113is added to further strongly support the radial direction permanent magnet111. When the radial direction vertical permanent magnet support part113is firmly fixed to the permanent magnet side surface support part112and the end support part121through welding or the like, the extremely strong rotor part100may be provided, and the dual air gap rotary device may have a further stable structure.

The radial direction permanent magnets111may be arranged such that the polarities of the permanent magnets are alternated between the ↑ direction and the ↓, direction along the radial direction from the center of the rotor and installed at an inner side and an outer side of the radial direction vertical permanent magnet support part113in the same direction (↑, ↑) or different directions (↑, ↓).

Likewise, the radial direction permanent magnet111may be firmly fixed to the radial direction permanent magnet side surface support part112and the end support part121so that the radial direction permanent magnets111are not scattered when the rotor part100rotates.

The radial direction permanent magnet side surface support part112, the end support part121, and the radial direction vertical permanent magnet support part113may be made of a magnetic material through which a magnetic flux easily passes or a non-magnetic material.

The radial direction permanent magnet111may be prevented from being separated by using an adhesive to fix the radial direction permanent magnet111or by applying an angle between the permanent magnet side surface support part112, the end support part121, and the radial direction vertical permanent magnet support part113and inserting an adhesive therebetween.

As further another method, the radial direction permanent magnet111may be prevented from being separated by fixing the radial direction permanent magnet111to the permanent magnet side surface support part112, the end support part121, and the radial direction vertical permanent magnet support part113and then winding a strong fiber thread in the circumferential direction of the outer circumference of the rotor part100or reinforcing an inconel having a high strength in a cylindrical shape (separation preventing means).

FIG.5is a conceptual view illustrating a structure in which the rotor part supports the permanent magnet inFIG.4.FIG.5shows the permanent magnet side surface support part112, the end support part121, and the radial direction vertical permanent magnet support part113except for the radial direction permanent magnet111. The permanent magnet side surface support part112, the end support part121, and the radial direction vertical permanent magnet support part113may be made of a magnetic material or a non-magnetic material and preferably welded for forming a strong structure. A low speed and small-sized rotary device may be simply manufactured by using only the cylindrical radial direction vertical permanent magnet support part113when the rotor part100has a stable structure without the permanent magnet side surface support part112.

When the end support part121and the cylindrical radial direction permanent magnet side surface support part113are made of the same material, the end support part121and the cylindrical radial direction permanent magnet side surface support part113may be made of one material without a welding work, and the structure of the rotor part100may strongly maintain the degree of precision.

The rotor part100may rotate by a magnetic action of the rotor-side magnetic force application part110, or the rotary shaft150may be coupled to one of a pair of end support parts121so that the rotor-side magnetic force application part110rotates.

When the rotary device according to the present invention is realized by a motor, the rotary shaft150that is a component of outputting a rotary force of the rotor-side magnetic force application part110rotating and driven by a magnetic action of the stator part400to the outside may be variously configured.

For example, the end support part121may have a circular disc shape to be coupled with the rotary shaft150, and the rotary shaft150may be coupled to a center of the circular disc as a separate member or in an integrated manner.

Rotor Part when Circumferential Direction Permanent Magnet is Applied

As illustrated inFIG.6, the rotor part100of the dual air gap rotary device includes the rotor-side magnetic force application part110and the end support part121, and the rotor-side magnetic force application part110includes a circumferential direction permanent magnet114and an iron core115when the circumferential direction permanent magnet is applied for supporting the circumferential direction permanent magnet114. The iron core115when the circumferential direction permanent magnet is applied is required to be made of a magnetic material.

The circumferential direction permanent magnets114may be arranged such that polarities of the permanent magnets are alternated between a →direction and a ← direction along a circumferential direction from a center of the rotor part to focus a magnetic flux to an air gap surface of the iron core115when the circumferential direction permanent magnet is applied, thereby forming a high air gap magnet density and generating a high torque or power.

The radial directional permanent magnet114may be firmly fixed to the circumferential direction permanent magnet114and the end support part121so that the circumferential directional permanent magnets114are not scattered when the rotor part100rotates.

The end support part121may be made of a magnetic material through which a magnetic flux easily passes or a non-magnetic material.

The circumferential direction permanent magnet114may be prevented from being separated by using an adhesive to fix the circumferential direction permanent magnet114or by applying an angle between the iron core115when the circumferential direction permanent magnet is applied, the end support part121, and the circumferential direction permanent magnet114and inserting an adhesive therebetween (separation preventing means).

As another method, the circumferential direction permanent magnet114may be prevented from being separated by fixing the iron core115when the circumferential direction permanent magnet is applied and the end support part121and then winding a strong fiber thread in the circumferential direction of the outer circumference of the rotor part100or reinforcing an inconel having a high strength in a cylindrical shape (separation preventing means).

For reference, the fiber thread or the cylindrical inconel that is a separation preventing means for preventing separation in the radial direction may be used to reinforce a whole or a portion of the outer circumference of the rotor part100. The fiber thread or the cylindrical inconel is not expressed in the drawings for convenience.

When the end support part121and the iron core115when the circumferential direction permanent magnet is applied are made of the same material, a groove to which the circumferential direction permanent magnet114may be made of the same material and processed without a welding work, and the structure of the rotor part100may strongly maintain the degree of precision.

FIG.7is a cross-sectional view illustrating the rotor part taken along direction A-A inFIG.6.FIG.7illustrates the circumferential direction permanent magnet114and the iron core115when the circumferential direction permanent magnet is applied for supporting the circumferential direction permanent magnet114and allowing magnetic flux flows through the air gap, which constitute the rotor-side magnetic force application part110.

FIG.8is a view illustrating a laminated iron core and a support part when the rotor part permanent magnet inFIG.6has a groove insertion shape. InFIG.8, the rotor part100of the rotary device includes the rotor-side magnetic force application part110and the end support part121, and the rotor-side magnetic force application part110includes a groove inserted type circumferential direction permanent magnet116, a laminated iron core117when the circumferential direction permanent magnet is applied, and a rotor part support part118when the circumferential direction permanent magnet is applied.

The groove inserted type circumferential direction permanent magnet116forms a stronger structure for groove insertion to the end support part121to generate a magnetic flux and sustain a rotary force.

In general, a high frequency current is required to obtain a high rotation number in the rotary device. However, the laminated iron core117when the circumferential direction permanent magnet is applied may be applied to reduce a loss in a high frequency but vulnerable in terms of a structure.

To compensate this, the rotor part support part118when the circumferential direction permanent magnet is applied may be welded to the end support parts121disposed at left and right sides thereof. Thus, the rotor part100of the dual air gap rotary device that is operated in high speed and extremely strong may be obtained. The rotor part support part118when the circumferential direction permanent magnet is applied may be made of a magnetic material or a non-magnetic material. The magnetic material may generate a torque or a power greater than that of the non-magnetic material.

The laminated iron core117when the circumferential direction permanent magnet is applied and the rotor part support part118when the circumferential direction permanent magnet is applied may be firmly fixed so that the groove inserted type circumferential direction permanent magnets116are not scattered when the rotor part100rotates.

The groove inserted type circumferential direction permanent magnet116may be prevented from being separated by using an adhesive to fix groove inserted type circumferential direction permanent magnet116or by applying an angle between the laminated iron core117when the circumferential direction permanent magnet is applied, the end support part121, and the groove inserted type circumferential direction permanent magnet116and inserting an adhesive therebetween (separation preventing means).

As further another method, the groove inserted type circumferential direction permanent magnet116may be prevented from being separated by fixing the groove inserted type circumferential direction permanent magnet116to the laminated iron core117when the circumferential direction permanent magnet is applied, the end support part121, and the rotor part support part118when the circumferential direction permanent magnet is applied and then winding a strong fiber thread in the circumferential direction of the outer circumference of the rotor part100or reinforcing an inconel having a high strength in a cylindrical shape (separation preventing means).

For reference, the fiber thread or the cylindrical inconel that is a separation preventing means for preventing separation in the radial direction may be used to reinforce a whole or a portion of the outer circumference of the rotor part100. The fiber thread or the cylindrical inconel is not expressed in the drawings for convenience.

FIG.9is a conceptual view illustrating a structure in which the rotor part supports the permanent magnet inFIG.8. The extremely strong rotor part100may be configured when the rotor part support part118when the circumferential direction permanent magnet is applied is welded to the end support part121. InFIG.9, four rotor part support parts118when the circumferential direction permanent magnet is applied are arranged by 90°. However, the rotor part support parts118when the circumferential direction permanent magnet is applied may be arranged by 120°, 60°, 30°, or 15° according to cases. When the rotor part support part118when the circumferential direction permanent magnet is applied and the end support part121are made of the same material and processed without the welding work, the structure of the rotor part100may strongly maintain the degree of precision.

FIG.10is a cross-sectional view illustrating the rotor part taken along direction A-A inFIG.8.FIG.10illustrates the groove inserted type circumferential direction permanent magnet116, the laminated iron core117when the circumferential direction permanent magnet is applied, and the rotor part support part118when the circumferential direction permanent magnet is applied, which constitute the rotor-side magnetic force application part110. InFIG.10, four rotor part support parts118when the circumferential direction permanent magnet is applied are arranged by 90°.

FIG.11is a conceptual view illustrating a laminated iron core, a divided type circumferential direction permanent magnet, and a support part of the rotor part inFIG.6. The rotor part100having a further strong structure may be configured by welding a divided type circumferential direction permanent magnet120between end support parts121.

This structure is configured by installing the divided type circumferential direction permanent magnet120between divided type circumferential direction permanent magnets119as illustrated inFIG.11. The divided type circumferential direction permanent magnet120may be made of a magnetic material or a non-magnetic material.

An adhesive (separation preventing means) may be used to firmly fix the laminated iron core117when the circumferential direction permanent magnet is applied, the divided type circumferential direction permanent magnet119, the divided type circumferential direction permanent magnet120, and the end support part121and particularly fix the divided type circumferential direction permanent magnets119to each other for preventing scattering.

Alternatively, each of the laminated iron core117when the circumferential direction permanent magnet is applied, the divided type circumferential direction permanent magnet119, the divided type circumferential direction permanent magnet support part120, and the end support part121may be angled to form a groove insertion shape, and an adhesive is inserted thereto to prevent separation thereof.

As further another method, each of the laminated iron core117when the circumferential direction permanent magnet is applied, the divided type circumferential direction permanent magnet119, the divided type circumferential direction permanent magnet support part120, and the end support part121may be wound by a strong fiber thread in the circumferential direction of the outer circumference thereof or reinforced by an inconel having a high strength in a cylinder shape to prevent separation thereof (separation preventing means).

In case of rotating at an extremely high speed, the laminated iron core117when the circumferential direction permanent magnet is applied, the divided type circumferential direction permanent magnet119, the divided type circumferential direction permanent magnet support part120, and the end support part121may be welded to each other, attached by applying a groove insertion shaped angle therebetween and inserting an adhesive therebetween, and then wound by a strong fiber thread in the circumferential direction of the outer circumference thereof or reinforced by an inconel having a high strength in a cylinder shape to prevent separation thereof (separation preventing means).

FIG.12is a conceptual view illustrating the divided type circumferential direction permanent magnet support part120of the rotor part inFIG.11. The divided type circumferential direction permanent magnet support part120may be welded between the end support parts121to form the rotor part100having a further strong structure.

When the divided type circumferential direction permanent magnet support part120and the end support part121are made of the same material and processed without the welding work, the structure of the rotor part100may strongly maintain the degree of precision.

FIG.13is a cross-sectional view taken along direction A-A inFIG.11and illustrating the laminated iron core117when the circumferential direction permanent magnet is applied, the divided type circumferential direction permanent magnet119, and the divided type circumferential direction permanent magnet support part120.

FIG.14is a conceptual view illustrating the rotor part support part118when the circumferential direction permanent magnet is applied inFIG.11. The rotor part support part118when the circumferential direction permanent magnet is applied and the divided type circumferential direction permanent magnet support part120are welded between the end support parts121to form the rotor part100stronger than a case when the rotary device has a large size and rotates at a high speed. That is, the rotor-side magnetic force application part110includes the laminated iron core117when the circumferential direction permanent magnet is applied, the rotor part support part118when the circumferential direction permanent magnet is applied, the divided type circumferential direction permanent magnet119, the divided type circumferential direction permanent magnet support part120, in which a portion of the laminated iron core117when the circumferential direction permanent magnet is applied is replaced by the rotor part support part118when the circumferential direction permanent magnet is applied.

The rotor part support part118when the circumferential direction permanent magnet is applied and the divided type circumferential direction permanent magnet support part120are welded between the end support parts121to form the strong rotor-side magnetic force application part110.

In this case, each of the end support part121, the rotor part support part118when the circumferential direction permanent magnet is applied, and the divided type circumferential direction permanent magnet support part120may be made of all of a magnetic material or a non-magnetic material.

InFIG.14, four rotor part support parts118when the circumferential direction permanent magnet is applied may be arranged by 90°. The rotor part support parts118when the circumferential direction permanent magnet is applied may be arranged by 120°, 60°, 30°, or 15° according to cases.

In case of rotating at an extremely high speed, the end support part121, the rotor part support part118when the circumferential direction permanent magnet is applied, and the divided type circumferential direction permanent magnet support part120are welded, then the laminated iron core117when the circumferential direction permanent magnet is applied and the divided type circumferential direction permanent magnet119are angled to form a groove insertion shape and attached by inserting an adhesive therebetween, and then wound by a strong fiber thread in the circumferential direction of the outer circumference thereof or reinforced by an inconel having a high strength in a cylinder shape to prevent separation thereof (separation preventing means).

FIG.15is a conceptual view illustrating a structure of supporting the rotor part permanent magnet ofFIG.14.FIG.15specifically illustrates the rotor part support parts118when the circumferential direction permanent magnet is applied and the divided type circumferential direction permanent magnet support part120.

When the end support part121, the rotor part support part118when the circumferential direction permanent magnet is applied, and the divided type circumferential direction permanent magnet support part120are made of the same material and processed without the welding work, the structure of the rotor part100may strongly maintain the degree of precision.

FIG.16is a cross-sectional view taken along direction A-A inFIG.14and specifically illustrating the laminated iron core117when the circumferential direction permanent magnet is applied, the rotor part support part118when the circumferential direction permanent magnet is applied, the divided type circumferential direction permanent magnet119, the divided type circumferential direction permanent magnet support part120.

FIG.17illustrates a state in which a circumferential direction permanent magnet applied laminated iron core131when fixed between the end support parts121by a bridge in order to stabilize the structure when the laminated iron core117when the circumferential direction permanent magnet is applied rotates and form a further strong structure of the end support part inFIG.8. A fixing bridge132is installed between the end support parts so that a magnetic flux easily passes through the circumferential direction permanent magnet applied laminated iron core131and the structure is stabilized.

FIG.18is a conceptual view illustrating the fixing bridge132between the end support parts121and the rotor part support part118when the circumferential direction permanent magnet is applied. When the strong structure of the rotor part is not obtained by using only the rotor part support part118when the circumferential direction permanent magnet is applied, the fixing bridge132is added between the end support parts to reinforce the structure. The fixing bridge132is fixed between the end support parts through welding or processing when connected with the end support parts121.

When the rotor part support part118when the circumferential direction permanent magnet is applied, the end support part121, and the fixing bridge132between the end support parts are made of the same material and processed without the welding work, the structure of the rotor part100may strongly maintain the degree of precision.

FIG.19is a cross-sectional view illustrating the rotor part taken along direction A-A inFIG.17and showing the groove inserted type circumferential direction permanent magnet116, the rotor part support part118when the circumferential direction permanent magnet is applied, the circumferential direction permanent magnet applied laminated iron core131when fixed between the end support parts by the bridge, and the fixing bridge132between the end support parts. The further strong structure is obtained by additionally installing the fixing bridge132between the end support parts inFIG.10.

The fixing bridge132between the end support parts may be positioned at a center of the circumferential direction permanent magnet applied laminated iron core131and made of a material through which a magnetic flux flows such as general steel material or stainless steel material.

Although the fixing bridge132between the end support parts has a circular shape inFIG.19, the fixing bridge132between the end support parts may have various shapes such as a circular shape, an oval shape, a triangular shape, a rectangular shape, and a pentagonal shape to stably fix the circumferential direction permanent magnet applied laminated iron core131when fixed between the end support parts by the bridge.

FIG.20is a view illustrating a case of including only the circumferential direction permanent magnet applied laminated iron core131when fixed between the end support parts by the bridge and the fixing bridge132between the end support parts and omitting the rotor part support part118when the circumferential direction permanent magnet is applied inFIG.17. In this case, the structure may have a relatively weak strength, but a manufacturing work may be simply performed.

FIG.21is a conceptual view illustrating a state in which the end support part121is fixed by using only the fixing bridge132between the end support parts.

When the end support part121and the fixing bridge132between the end support parts are made of the same material and processed without the welding work, the structure of the rotor part100may strongly maintain the degree of precision.

FIGS.22ato22dare cross-sectional views illustrating the rotor part taken along direction A-A inFIG.20as embodiments of the rotor part inFIG.20.

As a first embodiment, the magnetic force application part110of the rotor part100may include: a plurality of laminated iron cores131installed between a pair of end support parts121disposed opposite to each other and spaced apart from each other in a circumferential direction; a plurality of fixing bridges132connected with the pair of end support parts121to fix the laminated iron cores132; and a circumferential direction permanent magnet116installed between the laminated iron cores131that are adjacent to each other as illustrated inFIG.22a.

The fixing bridge132may be positioned at a center of the laminated circumferential direction permanent magnet applied laminated iron core131to minimize reduction of a rotary force and made of a material through which a magnetic flux flows such as iron, stainless steel, and a composite material.

Also, the fixing bridge132may be fixed by various coupling methods such as bolting, welding, coupling using an adhesive.

Although the fixing bridge132has a circular shape, the fixing bridge132may have various shapes such as a circular shape, an oval shape, a triangular shape, a rectangular shape, and a pentagonal shape to stably fix the circumferential direction permanent magnet applied laminated iron core131when fixed between the end support parts by the bridge.

As a second embodiment that is a modified example ofFIG.22a, the magnetic force application part110of the rotor part100may include: a hollow cylinder shaped laminated iron core133in which a plurality of insertion grooves116ato which permanent magnets116are inserted are formed; and the permanent magnets116inserted to the insertion holes116aformed in the laminated iron core133as illustrated inFIG.22b.

The laminated iron core133that is one iron core may have a hollow cylinder shape in which the plurality of insertion holes116ato which permanent magnets116are inserted are formed.

Also, a plurality of fixing bridges132for fixing the laminated iron core133may be inserted between the permanent magnets116.

As the permanent magnet116is inserted to the insertion hole116aof the laminated iron core133, the permanent magnet116may prevent an outer air gap510and an inner air gap520from being exposed.

As a third embodiment that is a modified example ofFIG.22b, the magnetic force application part110of the rotor part100may include: a hollow cylinder shaped laminated iron core133in which a plurality of insertion grooves116ato which permanent magnets116are inserted are formed; and the permanent magnets116inserted to the insertion grooves116formed in the laminated iron core133as illustrated inFIG.22c.

That is, as the insertion groove116ais recessed from the outer circumferential surface, the permanent magnet116may be inserted to be exposed toward the outer circumferential surface.

As a fourth embodiment that is a modified example ofFIG.22b, a laminated iron core135of the magnetic force application part110of the rotor part100may be configured such that the plurality of insertion grooves116ato which the permanent magnet116is inserted are exposed to the inner circumferential surface, i.e., the inner air gap520. That is, the permanent magnet116may be exposed to the inner circumferential surface, i.e., the inner air gap520.

As illustrated inFIG.22b, the laminated iron core133in which the groove inserted type circumferential direction permanent magnet116is not in contact with the outer air gap510and the inner air gap520, the laminated iron core133in which the groove inserted type circumferential direction permanent magnet116contacts only the outer air gap510, and the laminated iron core135in which the groove inserted type circumferential direction permanent magnet116contacts only the inner air gap520have a great advantage in that the laminated iron core is simply assembled, and scattering of the permanent magnets is prevented although the rotary torque is slightly reduced.

The groove inserted type circumferential direction permanent magnet116illustrated inFIGS.22bto22dmay have various shapes such as a rectangular shape, a rhombus shape, an oval shape, and a pentagonal shape to increase a torque and reduce a torque ripple and a cogging torque.

Also, a composite material may be wound around the outer circumferential surface of the laminated iron core inFIGS.22bto22d, particularly,FIG.22c, to prevent separation of the permanent magnet116while rotating.

Cooling Structure

The dual air gap rotary device includes a cooling device provided to each of the outer wire210and the inner wire220for reducing temperature increase because the dual air gap rotary device generates more heat from the outer wire210and the inner wire220than a typical rotary device.

FIG.1shows a cooling structure. A cooling structure of the outer wire210includes an outer wire cooling fan850, a refrigerant flow hole860for cooling the outer wire, and a cooling structure of the inner wire220includes an inner wire cooling fan830, a refrigerant passage810for cooling the inner wire installed at a center of the inner support part610, a refrigerant passage nozzle820for cooling the inner wire installed at the center of the inner support part, and a refrigerant flow hole840for cooling the inner wire. Also, the refrigerant flow hole840for cooling the inner wire may be defined in the rotor part100to dissipate heat of the inner wire220.

The outer wire210is cooled as refrigerant (air or liquid) flows to the refrigerant flow hole860for cooling the outer wire through the outer wire cooling fan850when the rotor part100rotates. In some cases, the outer wire210may be cooled as the cooling refrigerant forcedly flows from the outside to the refrigerant flow hole860for cooling the outer wire without the outer wire cooling fan850.

Likewise, the inner wire220may be cooled as the refrigerant (air or liquid) flows to the refrigerant passage810for cooling the inner wire installed at the center of the inner support part, the refrigerant passage nozzle820for cooling the inner wire installed at the center of the inner support part, and the refrigerant flow hole840for cooling the inner wire through the inner wire cooling fan830when the rotor part100rotates.

In some cases, the inner wire220may be cooled as the cooling refrigerant forcedly flows from the outside to the refrigerant passage810for cooling the inner wire installed at the center of the inner support part, the refrigerant passage nozzle820for cooling the inner wire installed at the center of the inner support part, and the refrigerant flow hole840for cooling the inner wire without the inner wire cooling fan830. Also, each of the refrigerant flow hole840for cooling the inner wire and the refrigerant flow hole860for cooling the outer wire may be provided in plurality for easy cooling.

When an extremely high output is necessary according to purposes of an electric motor and a power generator, an extremely high input current may be necessary, and thus the wire may have an extremely high temperature. Here, the temperature of the wire may be remarkably reduced by respectively installing an outer wire cooling pipe870and an inner wire cooling pipe880to the outer iron core310and the inner iron core320and circulating the refrigerants through the outer wire cooling pipe870and the inner wire cooling pipe880for cooling. In some cases, the outer wire cooling pipe870and the inner wire cooling pipe880may be replaced by heater pipes.

FIG.23is a conceptual view illustrating the refrigerant passage810for cooling the inner wire installed at the center of the housing part600and the inner support part and the refrigerant passage nozzle820for cooling the inner wire installed at the center of the inner support part, which are paths through which the cooling refrigerants flow. Although one refrigerant passage810for cooling the inner wire is provided inFIG.23, the refrigerant passage810for cooling the inner wire may be provided in plurality when the shaft has an enough diameter. Likewise, the refrigerant passage nozzle820for cooling the inner wire installed at the center of the inner support part may be provided in plurality.

FIG.24is a detail view illustrating the inner wire cooling fan830inFIG.1. The inner wire cooling fan830includes a wing831of the inner wire cooling fan and a wing support part832of the inner wire cooling fan. In terms of a structure, the wing831of the inner wire cooling fan is installed inside the wing support part832of the inner wire cooling fan.

When the rotor part100rotates, the refrigerant may flow in one direction or both directions according to a direction of the wing831of the inner wire cooling fan, and the number and shape of the wing831of the fan may be variously provided.

FIG.25is a detail view illustrating the outer wire cooling fan850inFIG.1. The outer wire cooling fan850includes a wing851of the outer wire cooling fan and a wing support part852of the outer wire cooling fan. In terms of a structure, the wing851of the outer wire cooling fan is installed on an outer circumference of the wing support part852of the outer wire cooling fan.

Likewise, when the rotor part100rotates, the refrigerant may flow in one direction or both directions according to a direction of the wing851of the outer wire cooling fan, and the number and shape of the wing851of the fan may be variously provided.

FIG.26is a detail view illustrating the refrigerant flow hole840for cooling the inner wire220, the inner wire cooling fan830, and the outer wire cooling fan850and additionally illustrating a structure of the bearing700. The refrigerant flow hole840for cooling the inner wire that is a hole for dissipating heat of the inner wire may have various shapes.

A position of each of the inner wire cooling fan830and the outer wire cooling fan850may be changed as necessary.

Bearing Structure

FIG.26is a detail view illustrating the structure of the bearing700of the rotor part100inFIG.1.

The bearing700of the rotor part100includes a rotor and shaft coupling bearing701for rotatably supporting the rotary shaft150, a rotor and inner support part coupling bearing702, and a rotor and housing part coupling bearing703. When the rotor has a stable structure, the rotor and inner support part coupling bearing702is not necessary.

Particularly, when the rotor-side magnetic force application part110of the electric motor has a short length, the rotor part100may be supported by the rotor and shaft coupling bearing701capable of simultaneously supporting in the shaft direction and the radial direction without the rotor and inner support part coupling bearing702and the rotor and housing part coupling bearing703.

In this case, the bearing may simply support the rotor part100by using only one rotor and shaft coupling bearing701.

The rotor and housing part coupling bearing703may be one selected from an outer circumference-side installed bearing703-1in the rotor and housing part coupling bearing, an end installed bearing703-2in the rotor and housing part coupling bearing, and an inner circumference-side installed bearing703-3in the rotor and housing part coupling bearing.

FIG.27is a cross-sectional view taken along direction A-A inFIG.26.FIG.27is a structural view illustrating a partial type bearing703-11and an entire type bearing703-12in the rotor and housing part coupling bearing. Since the rotor and housing part coupling bearing703is directly installed to the circumference of the rotor part100, a small bearing is sufficient when the rotary device has a small diameter. Likewise, when the rotor part100has a large circumference, a big bearing is necessary. In this case, the partial type bearing703-11may be used for the outer circumference-side installed bearing703-1in the rotor and housing part coupling bearing inFIG.27.

That is, the partial type bearing703-11is used for the outer circumference-side installed bearing703-1in the rotor and housing part coupling bearing in a left case, and the entire type bearing703-12is used for the outer circumference-side installed bearing703-1in the rotor and housing part coupling bearing in a right case. Likewise, each of the end installed bearing703-2in the rotor and housing part coupling bearing and the inner circumference-side installed bearing703-3in the rotor and housing part coupling bearing may use the partial type bearing or the entire type bearing.

FIG.28shows another bearing type. An inner support part vertical bearing704may be installed in a vertical shaft direction of the inner support part and the housing part600. In this case, the bearing may have a size similar to that of the rotor and shaft coupling bearing701. In some cases, likewise, the inner wire220may be cooled through the refrigerant passage810for cooling the inner wire installed at the center of the inner support part, the refrigerant passage nozzle820for cooling the inner wire installed at the center of the inner support part, the inner wire cooling fan830, and the refrigerant flow hole840for cooling the inner wire.

Multiple Air Gap Structure

FIG.29is a view illustrating a quadruple air gap structure when four air gaps are provided to further increase the output. That is, a first air gap531, a second air gap532, a third air gap533, and a fourth air gap534are provided to generate more power, and a maximum rotary force is generated in a given space. The configuration of the rotor, the bearing supporting structure, and the cooling method may include all of the cases suggested in the present invention.

FIG.30is a view illustrating a sextuple air gap structure when six air gaps are provided.

That is, a first air gap531, a second air gap532, a third air gap533, a fourth air gap534, a fifth air gap535, a sixth air gap536are provided. In this case, also, the configuration of the rotor, the bearing supporting structure, and the cooling method may include all of the cases suggested in the present invention. Here, when a high output rotary device having eight air gaps, ten air gaps or more is necessary, an octuple, decuple or more air gap structure may be realized.

Power Conversion Device and Rotary Device Integrated Type

FIG.31is a view illustrating a case when the dual air gap rotary device includes a power conversion device910therein when a space exists in the middle of the rotary device.FIG.31shows a power conversion device and the rotary device integrated type. Since the rotary device suggested in the patent uses the permanent magnet, the rotary device requires the power conversion device. Here, since the power conversion device is installed in the dual air gap rotary device, a space for the power conversion device may be saved. The two air gaps include a rotary device integrated first air gap941and a power conversion device and rotary device integrated second air gap942.

In case of the electric motor, a power is supplied to the power conversion device910through a power conversion device input power cable920, and the power conversion device910supplies the power to the wire of the stator part through a first stator input power cable931and a second stator input power cable932by applying a control algorithm.

In case of the power generator, a generated power is supplied to the power conversion device910through the first stator input power cable931and the second stator input power cable932, and the power conversion device910supplies the power to the outside through the power conversion device output power cable920by applying the control algorithm. In this case, the configuration of the rotor, the bearing supporting structure, and the cooling method may include all of the cases suggested in the present invention.

FIG.32is a view illustrating a case when the quadruple air gap rotary device includes the power conversion device910therein.FIG.32shows the power conversion device and rotary device integrated type. Four air gaps include a power conversion device and rotary device integrated first air gap941, a power conversion device and rotary device integrated second air gap942, a power conversion device and rotary device integrated third air gap943, and a power conversion device and rotary device integrated fourth air gap944.

In case of the electric motor, a power is supplied to the power conversion device910through a power conversion device input power cable920, and the power conversion device910supplies the power to the wire of the stator part through a first stator input power cable931, a second stator input power cable932, a third stator input power cable933, and a fourth stator input power cable934by applying a control algorithm. In case of the power generator, a generated power is supplied to the power conversion device910through the first stator input power cable931, the second stator input power cable932, the third stator input power cable933, and the fourth stator input power cable934, and the power conversion device910supplies the power to the outside through the power conversion device output power cable920by applying the control algorithm.

When a high output rotary device having six air gaps, eight air gaps, ten air gaps, twelve air gaps or more include the power conversion device910, the electric motor supplies the power to the power conversion device910through the power conversion device input power cable920, and the power conversion device910supplies the power to the wire of the stator part through the first stator input power cable931, the second stator input power cable932, the third stator input power cable933, the fourth stator input power cable934, and the fifth, sixth, seventh, eighth, and more stator input power cables.

In case of the power generator, a generated power is supplied to the power conversion device910through the first stator input power cable931, the second stator input power cable932, the third stator input power cable933, the fourth stator input power cable934, and the fifth, sixth, seventh, eighth, and more stator input power cables, and the power conversion device910supplies the power to the outside through the power conversion device output power cable920by applying the control algorithm.

In this case, the configuration of the rotor, the bearing supporting structure, and the cooling method may include all of the cases suggested in the present invention.

The above-disclosed subject matter is to be considered illustrative, and not restrictive, and the appended claims are intended to cover all such modifications, enhancements, and other embodiments, which fall within the true spirit and scope of the present invention. Thus, to the maximum extent allowed by law, the scope of the present invention is to be determined by the broadest permissible interpretation of the following claims and their equivalents, and shall not be restricted or limited by the foregoing detailed description.

DESCRIPTION OF REFERENCE NUMERALS

100: Rotor part110: Rotor-side magnetic force application part111: Radial direction permanent magnet112: Radial direction permanent magnet side surface support part113: Radial direction vertical permanent magnet support part114: Circumferential direction permanent magnet115: Iron core when the circumferential direction permanent magnet is applied116: Groove inserted type circumferential direction permanent magnet117: Laminated iron core when the circumferential direction permanent magnet is applied118: Rotor part support part when the circumferential direction permanent magnet is applied119: Divided type circumferential direction permanent magnet120: Divided type circumferential direction permanent magnet support part121: End support part131: Circumferential direction permanent magnet applied laminated iron core132: Fixing bridge200: Wire part210: Outer wire220: Inner wire300: Iron core part310: Outer iron core320: Inner iron core330: Outer fixing part340: Inner fixing part400: Stator part500: Inner and outer air gaps510: Outer air gap520: Inner air gap531-536: First to sixth air gaps600: Housing part610: Inner support part700: Bearing701: Rotor and shaft coupling bearing702: Rotor and inner support part coupling bearing703: Rotator and housing part coupling bearing703-1: Outer circumference-side installed bearing in the rotor and housing part coupling bearing703-2: End installed bearing in the rotor and housing part coupling bearing703-3: Inner circumference-side installed bearing in the rotor and housing part coupling bearing703-11: Partial type bearing in the rotor and housing part coupling bearing703-12: Entire type bearing in the rotor and housing part coupling bearing704: Inner support part vertical bearing in the vertical shaft810: Refrigerant passage for cooling the inner wire installed at the center of the inner support part820: Refrigerant passage nozzle for cooling the inner wire installed at the center of the inner support part830: Inner wire cooling fan831: Wing of the inner wire cooling fan832: Wing support part of the inner wire cooling fan840: Refrigerant flow hole for cooling the inner wire850: Outer wire cooling fan851: Wing support part of the outer wire cooling fan852: Wing support part of the outer wire cooling fan860: Refrigerant flow hole for cooling the outer wire870: Outer wire cooling pipe880: Inner wire cooling pipe910: Power conversion device920: Power conversion device input or output power cable931˜4: First to fourth stator input or output power cables941˜944: Power conversion device and rotary device integrated first to fourth air gaps