US-20260128623-A1 - Electric Motor

US20260128623A1US 20260128623 A1US20260128623 A1US 20260128623A1US-20260128623-A1

Abstract

An example electric motor includes: a stator having (i) a first set of windings configured to generate a radial magnetic flux when electric current is provided thereto, and (ii) a second set of windings configured to generate an axial magnetic flux when electric current is provided thereto; and a rotor comprising (i) a first set of magnets configured to interact with the radial magnetic flux generated by the first set of windings of the stator, and (ii) a second set of magnets configured to interact with the axial magnetic flux generated by the second set of windings of the stator.

Inventors

Siavash Sadeghi

Assignees

SUPERNAL, LLC

Dates

Publication Date: 20260507
Application Date: 20231017

Claims (20)

1 . An electric motor comprising: a stator comprising (i) a first set of windings disposed about a peripheral surface of the stator and configured to generate a radial magnetic flux when electric current is provided thereto, and (ii) a second set of windings disposed about an end face of the stator and configured to generate an axial magnetic flux when electric current is provided thereto; and a rotor comprising (i) a first set of magnets disposed about a respective peripheral surface of the rotor, facing the first set of windings of the stator and configured to interact with the radial magnetic flux generated by the first set of windings of the stator, and (ii) a second set of magnets disposed about a respective end face of the rotor, facing the second set of windings of the stator and configured to interact with the axial magnetic flux generated by the second set of windings of the stator.
2 . The electric motor of claim 1 , wherein the stator comprises: a stator plate; and a stator hub mounted to the stator plate, wherein the first set of windings are disposed in a circular array about a peripheral surface of the stator hub on a first side of the stator plate, and wherein the second set of windings are disposed in a circular array about an end face of the stator plate on a second side of the stator plate, opposite the first side.
3 . The electric motor of claim 2 , wherein the stator hub comprises a bearing housing configured to have a bearing that supports a rotor shaft coupled to the rotor.
4 . The electric motor of claim 1 , wherein the rotor comprises: a rotor cylinder; and a rotor end plate coupled to the rotor cylinder, wherein the first set of magnets are disposed in a circular array about a respective peripheral surface of the rotor cylinder, and wherein the second set of magnets are disposed in a circular array about a respective end face of the rotor end plate.
5 . The electric motor of claim 4 , wherein the first set of magnets are disposed in a circular array about an interior peripheral surface of the rotor cylinder, wherein the second set of magnets are disposed in a circular array about an interior end face of the rotor end plate, wherein the first set of windings are disposed in a circular array about an exterior peripheral surface of the stator, wherein the second set of windings are disposed in a circular array about an exterior end face of the stator, and wherein the rotor cylinder has an open end through which the stator is inserted, such that the stator is disposed, at least partially, within the rotor cylinder.
6 . The electric motor of claim 4 , wherein the rotor further comprises a rotor shaft coupled to the rotor end plate and configured to rotate about a longitudinal axis of the rotor shaft, wherein the radial magnetic flux is perpendicular to the longitudinal axis, and wherein the axial magnetic flux is parallel to the longitudinal axis.
7 . The electric motor of claim 1 , further comprising: a first motor controller comprising: (i) a first inverter board configured to convert DC power to three-phase AC power to drive the first set of windings of the stator, and (ii) a first controller board that is electrically-coupled to the first inverter board, wherein the first controller board generates a first switching signal to operate the first inverter board; and a second motor controller comprising: (i) a second inverter board configured to convert DC power to three-phase AC power to drive the second set of windings of the stator, and (ii) a second controller board that is electrically-coupled to the second inverter board, wherein the second controller board generates a second switching signal to operate the second inverter board.
8 . A system comprising: an electric motor comprising: a stator comprising (i) a first set of windings disposed about a peripheral surface of the stator and configured to generate a radial magnetic flux when electric current is provided thereto, and (ii) a second set of windings disposed about an end face of the stator and configured to generate an axial magnetic flux when electric current is provided thereto, and a rotor comprising (i) a first set of magnets disposed about a respective peripheral surface of the rotor, facing the first set of windings of the stator and configured to interact with the radial magnetic flux generated by the first set of windings of the stator, and (ii) a second set of magnets disposed about a respective end face of the rotor, facing the second set of windings of the stator and configured to interact with the axial magnetic flux generated by the second set of windings of the stator; and at least one motor controller comprising: one or more inverter boards, each inverter board having a semiconductor switching matrix mounted thereon, wherein the semiconductor switching matrix comprises a plurality of semiconductor switching devices configured to convert direct current (DC) power to three-phase alternating current (AC) power to drive windings of the stator, and one or more controller boards that are electrically-coupled to the one or more inverter boards, wherein each controller board comprises a processor configured to generate a switching signal to operate the semiconductor switching matrix of a respective inverter board.
9 . The system of claim 8 , wherein the at least one motor controller comprises: a first inverter board configured to convert DC power to three-phase AC power to drive the first set of windings of the stator; a second inverter board configured to convert DC power to three-phase AC power to drive the second set of windings of the stator; and a controller board that is electrically-coupled to the first inverter board and the second inverter board, wherein the controller board generates a first switching signal to operate the first inverter board and a second switching signal to operate the second inverter board.
10 . The system of claim 8 , wherein the at least one motor controller comprises: a first motor controller comprising: (i) a first inverter board configured to convert DC power to three-phase AC power to drive the first set of windings of the stator, and (ii) a first controller board that is electrically-coupled to the first inverter board, wherein the first controller board generates a first switching signal to operate the first inverter board; and a second motor controller comprising: (i) a second inverter board configured to convert DC power to three-phase AC power to drive the second set of windings of the stator, and (ii) a second controller board that is electrically-coupled to the second inverter board, wherein the second controller board generates a second switching signal to operate the second inverter board.
11 . The system of claim 10 , further comprising: a first power source providing DC power to the first motor controller to be converted by the first inverter board to AC power to drive the first set of windings; and a second power source providing DC power to the second motor controller to be converted by the second inverter board to AC power to drive the second set of windings.
12 . The system of claim 8 , wherein the stator comprises: a stator plate; and a stator hub mounted to the stator plate, wherein the first set of windings are disposed in a circular array about a peripheral surface of the stator hub on a first side of the stator plate, and wherein the second set of windings are disposed in a circular array about an end face of the stator plate on a second side of the stator plate, opposite the first side.
13 . The system of claim 7 , wherein the rotor comprises: a rotor cylinder; and a rotor end plate coupled to the rotor cylinder, wherein the first set of magnets are disposed in a circular array about a respective peripheral surface of the rotor cylinder, and wherein the second set of magnets are disposed in a circular array about a respective end face of the rotor end plate.
14 . The system of claim 13 , wherein the first set of magnets are disposed in a circular array about an interior peripheral surface of the rotor cylinder, wherein the second set of magnets are disposed in a circular array about an interior end face of the rotor end plate, wherein the first set of windings are disposed in a circular array about an exterior peripheral surface of the stator, wherein the second set of windings are disposed in a circular array about an exterior end face of the stator, and wherein the rotor cylinder has an open end through which the stator is inserted, such that the stator is disposed, at least partially, within the rotor cylinder.
15 . The system of claim 13 , wherein the rotor further comprises a rotor shaft coupled to the rotor end plate and configured to rotate about a longitudinal axis of the rotor shaft, wherein the radial magnetic flux is perpendicular to the longitudinal axis, and wherein the axial magnetic flux is parallel to the longitudinal axis.
16 . A vehicle comprising: a propeller or lift rotor; an electric motor configured to drive the propeller or lift rotor, wherein the electric motor comprises: a stator comprising (i) a first set of windings disposed about a peripheral surface of the stator and configured to generate a radial magnetic flux when electric current is provided thereto, and (ii) a second set of windings disposed about an end face of the stator and configured to generate an axial magnetic flux when electric current is provided thereto, and a rotor comprising (i) a first set of magnets disposed about a respective peripheral surface of the rotor, facing the first set of windings of the stator and configured to interact with the radial magnetic flux generated by the first set of windings of the stator, and (ii) a second set of magnets disposed about a respective end face of the rotor, facing the second set of windings of the stator and configured to interact with the axial magnetic flux generated by the second set of windings of the stator; at least one motor controller comprising: (i) one or more inverter boards, each inverter board configured to convert direct current (DC) power to three-phase alternating current (AC) power to drive windings of the stator; and (ii) one or more controller boards that are electrically-coupled to the one or more inverter boards, wherein each controller board comprises a processor configured to operate a respective inverter board; and a plurality of battery modules configured provide DC power to the at least one motor controller to be converted by the one or more inverter boards to AC power.
17 . The vehicle of claim 16 , wherein the at least one motor controller comprises: a first inverter board configured to convert DC power to three-phase AC power to drive the first set of windings of the stator; a second inverter board configured to convert DC power to three-phase AC power to drive the second set of windings of the stator; and a controller board that is electrically-coupled to the first inverter board and the second inverter board, wherein the controller board generates a first switching signal to operate the first inverter board and a second switching signal to operate the second inverter board.
18 . The vehicle of claim 16 , wherein the at least one motor controller comprises: a first motor controller comprising: (i) a first inverter board configured to convert DC power to three-phase AC power to drive the first set of windings of the stator, and (ii) a first controller board that is electrically-coupled to the first inverter board, wherein the first controller board generates a first switching signal to operate the first inverter board; and a second motor controller comprising: (i) a second inverter board configured to convert DC power to three-phase AC power to drive the second set of windings of the stator, and (ii) a second controller board that is electrically-coupled to the second inverter board, wherein the second controller board generates a second switching signal to operate the second inverter board.
19 . The vehicle of claim 18 , wherein the plurality of battery modules comprise: a first battery module providing DC power to the first motor controller to be converted by the first inverter board to AC power to drive the first set of windings; and a second battery module providing DC power to the second motor controller to be converted by the second inverter board to AC power to drive the second set of windings.
20 . A method comprising: providing direct current (DC) power from a first power source to a first motor controller, wherein the first motor controller comprises: (i) a first inverter board configured to convert the DC power to three-phase alternating current (AC) power to drive a first set of windings of a stator of an electric motor, and (ii) a first controller board that is electrically-coupled to the first inverter board, wherein the first controller board generates a first switching signal to operate the first inverter board, wherein the first set of windings are configured to generate a radial magnetic flux when electric current is provided thereto, wherein the stator further comprises a second set of windings configured to generate an axial magnetic flux when electric current is provided thereto, and wherein the electric motor further comprises: a rotor comprising (i) a first set of magnets configured to interact with the radial magnetic flux generated by the first set of windings, and (ii) a second set of magnets configured to interact with the axial magnetic flux generated by the second set of windings; and providing DC power from a second power source to a second motor controller, wherein the second motor controller comprises: (i) a second inverter board configured to convert the DC power to three-phase AC power to drive the second set of windings, and (ii) a second controller board that is electrically-coupled to the second inverter board, wherein the second controller board generates a second switching signal to operate the second inverter board.

Description

CROSS-REFERENCE TO RELATED APPLICATION The present application claims priority to U.S. Provisional Application No. 63/417,359 filed Oct. 19, 2022, the contents of which are hereby incorporated by reference in its entirety. BACKGROUND Many systems involving machinery or vehicles are being electrified. Particularly, electric motors are used to drive rotary components such as propellers, wheels, or any other rotary component. An electric motor is a machine that transforms electrical energy into mechanical energy by the action of magnetic fields generated in its coils. They are usually called rotating electric machines and are composed of a stator and a rotor, some of which can function as motors or generators. In many applications, it may be desirable to reduce the weight and size of electric motors without reducing power output. It is may thus be desirable to have a highly-efficient, power dense, light-weight, and compact electric motor. It is with respect to these and other considerations that the disclosure made herein is presented. SUMMARY The present disclosure describes implementations that relate to an electric motor, and, more particularly, to an electric motor having a stator with a first set of windings providing a radial magnetic flux and a second set of windings providing an axial magnetic flux. In a first example implementation, the present disclosure describes an electric motor. The electric motor comprises: a stator comprising (i) a first set of windings disposed about a peripheral surface of the stator and configured to generate a radial magnetic flux when electric current is provided thereto, and (ii) a second set of windings disposed about an end face of the stator and configured to generate an axial magnetic flux when electric current is provided thereto; and a rotor comprising (i) a first set of magnets disposed about a respective peripheral surface of the rotor, facing the first set of windings of the stator and configured to interact with the radial magnetic flux generated by the first set of windings of the stator, and (ii) a second set of magnets disposed about a respective end face of the rotor, facing the second set of windings of the stator and configured to interact with the axial magnetic flux generated by the second set of windings of the stator. In a second example implementation, the present disclosure describes a system. The system includes the electric motor of the first example implementation. The system further includes: at least one motor controller comprising: (i) one or more inverter boards, each inverter board having a semiconductor switching matrix mounted thereon, wherein the semiconductor switching matrix comprises a plurality of semiconductor switching devices configured to convert direct current (DC) power to three-phase alternating current (AC) power to drive windings of the stator, and (ii) one or more controller boards that are electrically-coupled to the one or more inverter boards, wherein each controller board comprises a processor configured to generate a switching signal to operate the semiconductor switching matrix of a respective inverter board. In a third example implementation, the present disclosure describes a vehicle. The vehicle includes a propeller or lift rotor and the electric motor of the first example implementation configured to drive the propeller or lift rotor. The vehicle further includes at least one motor controller comprising: (i) one or more inverter boards, each inverter board configured to convert direct current (DC) power to three-phase alternating current (AC) power to drive windings of the stator; and (ii) one or more controller boards that are electrically-coupled to the one or more inverter boards, wherein each controller board comprises a processor configured to operate a respective inverter board. The vehicle also includes a plurality of battery modules configured provide DC power to the at least one motor controller to be converted by the one or more inverter boards to AC power. In a fourth example implementation, the present disclosure describes a method. The method includes providing direct current (DC) power from a first power source to a first motor controller, wherein the first motor controller comprises: (i) a first inverter board configured to convert the DC power to three-phase alternating current (AC) power to drive a first set of windings of a stator of an electric motor, and (ii) a first controller board that is electrically-coupled to the first inverter board, wherein the first controller board generates a first switching signal to operate the first inverter board, wherein the first set of windings are configured to generate a radial magnetic flux when electric current is provided thereto, wherein the stator further comprises a second set of windings configured to generate an axial magnetic flux when electric current is provided thereto, and wherein the electric motor further comprises: a rotor comprising (i) a firs