Electric Torque Machines Inc.

Motor Excellence LLC

John Dyer

Thomas F Janecek

David G Calley

Tyler Kenneth Williams

Daniel S Cole

Scott Reynolds

Morgan Conklin

J Scott Reynolds

A high efficiency transverse flux motor fan utilizes a transverse flux motor that can provide torque to drive fan blades at a reduced weight over conventional induction and brushless DC motors. A fan incorporating a transverse flux motor may be a residential ceiling fan or high volume low speed fan. Transverse flux motors are ideal for these applications as they have a higher efficiency at low revolutions per minute. A transverse flux motor may have a stator utilizing a ring shaped lamina that has extending members that form a coil channel. A lamina may be a unitary piece of material that is formed from a sheet of metal, thereby providing a very lightweight stator assembly. An exemplary fan may provide an airflow efficiency of more than about 236 L/s*W, (500 CFM/watt), an essential airflow density of more than about 2.36 L/s*g, (5 CFM/gram) and a power density of about 150 W/kg or more.

High efficiency transverse flux motor fan

An electrical machine includes a rotor for rotation about a rotational axis, a coil arranged circumferentially with respect to and encircling the rotational axis, and a stator assembly. The stator assembly includes a unitary lamina comprising a plurality of extending members integral therewith, the extending members being bent to form a plurality of opposing extending members about the coil. The electrical machine is at least one of a transverse flux machine or a commutated flux machine. Methods of manufacturing stators for assembly with rotors to form electrical machines are also disclosed.

Transverse flux stator geometry

An electrical machine includes a rotor with a rotational axis, a coil arranged circumferentially with respect to and fully encircling the rotational axis, and a stator assembly. The stator assembly includes first and second lamination stacks comprising associated pluralities of laminae, the stacks being arranged circumferentially with respect to the rotational axis on opposing sides of the coil for conducting magnetic flux. The stacks are configured with gaps generally radially through the laminae thereof, defining separate circumferential segments in each laminae, to prevent creating a continuous electrical circuit around the rotational axis in the segments. Each laminae has a connecting ring spaced radially from the segments, and beams connecting the segments to the ring as a unitary piece. Back return elements extend axially between the stacks to provide a flux path therebetween, and are positioned circumferentially between adjacent parts of the beams and radially between the segments and the ring.

Segmented stator with controlled eddy current

Electrical machines, for example transverse flux machines and/or commutated flux machines, may be 'balanced' to achieve reduced overall cogging torque via utilization of one or more cogging torque reduction devices. Cogging torque reduction devices may be configured and/or otherwise customized in order to reduce and/or minimize cogging torque in an electrical machine, by generating a counteracting cogging torque waveform that at least partially counteracts and/or cancels the initial cogging torque waveform of the electrical machine.

Cogging torque reduction device for electrical machines

An electrical machine stator assembly comprises: an electroconductive coil arranged circumferentially with respect to the rotational axis; a plurality of pairs of side lamination assemblies arranged circumferentially with respect to the rotational axis; a plurality of pairs of switch lamination assemblies arranged circumferentially with respect to the rotational axis and positioned adjacent ends of side lamination assemblies proximal the rotor; and at least one tooth associated with each switch lamination assembly and proximal the rotor. Each switch lamination assembly comprises a first group of laminated materials aligned generally circumferentially and generally in a first direction with respect to the rotational axis, the first direction being one selected from the group consisting of the axial and radial directions with respect to the rotational axis. Each side lamination assembly comprises a second group of laminated materials aligned generally axially and generally radially with respect to the rotational axis.

Transverse and/or commutated flux systems having multidirectional laminations

Electrical machines, for example transverse flux machines and/or commutated flux machines, may be configured to achieve increased efficiency, increased output torque, and/or reduced operating losses via use of laminated materials in connection with powdered metal materials. For example, stacks of laminated materials may be coupled to powdered metal teeth to form portions of a stator in an electrical machine.

Transverse and/or commutated flux systems having laminated and powdered metal portions

Electrical machines, for example transverse flux machines and/or commutated flux machines, may be configured to achieve increased efficiency, increased output torque, and/or reduced operating losses via use of laminated materials, for example laminated materials configured with cuts and/or segmentations. Segmentations may also assist with manufacturability, mechanical retention of components, and the like.

Transverse and/or commutated flux systems having segmented stator laminations

Electrical machines, for example transverse flux machines and/or commutated flux machines, may be configured to achieve reduced overall cogging torque via implementation of a sixth-phase offset. Individual cogging torque waveforms in the electrical machine may be evenly distributed across one-sixth of a voltage phase or other suitable spacing, resulting in a reduced magnitude and/or increased sinusoidality of the overall cogging torque waveform for the electrical machine.

Transverse and/or commutated flux systems having phase offset

An electrical machine comprising a rotor, a coil and a stator comprising a lamination stack coupled to a tooth, wherein the electrical machine is at least one of a transversal flux machine is described. The electrical machine may be a transversal flux machine such as a transverse or commutated flux machine. A lamination ring is described comprising a plurality of lamination stacks. A lamination stack may comprise a plurality of trenches configured to retain a plurality of teeth. The tooth may comprise a portion of the switching surface, and a portion of a lamination stack may extend to the surface of the tooth to make up a portion of the switching surface. The electrical machine may be configured with a constant air gap, wherein no more than 15% variability in the distance between the stator switching surface and the rotor switching surface.

Electrical machines, for example transverse flux machines and/or commutated flux machines, may be configured to achieve increased efficiency, increased output torque, and/or reduced operating losses via use of extended magnets, overhung rotors, and/or stator tooth overlap. Extended magnets may reduce flux leakage between adjacent flux concentrators. Overhung rotors may reduce flux leakage, and may also facilitate voltage balancing in polyphase devices. Stator tooth overlap may reduce hysteresis losses, for example losses in flux concentrating portions of an electrical machine.

Transverse and/or commutated flux systems configured to provide reduced flux leakage, hysteresis loss reduction, and phase matching

Electrical machines, for example transverse flux machines and/or commutated flux machines, may be configured to be coupled to an electric bicycle or other light electric vehicle. Certain exemplary electrical machines may be configured with a high torque density and/or lower operating losses, providing improved operational characteristics to an e-bike. Moreover, certain exemplary electrical machines may replace a gear cassette on a bicycle, allowing conversion of the bicycle from manual to electric operation.

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Flagstaff, AZ, United States of America

John Dyer