Regal Beloit Australia Pty Ltd.

Regal Beloit America, Inc.

Mark Thiele

Greg Heins

Matthew John Turner

Jason Jon Kreidler

Dean James Patterson

Hani Chahine

Subhash Marutirao Brahmavar

Lester Benjamin Manz

Kerry Baker Shelton

Jeffrey William Crosson

Rafal Pawel Rohoza

Anthony Carl Maiorano

Alexander Julian Baer

Pamela Lee

Nathan August Bulman

Steve Long

Jiang Guo Ping

A rotor assembly is disclosed, including a rotatable rotor shaft defining a central axis, the rotor shaft coupled to a rotor core, the rotor core including a plurality of rotor pole pieces circumferentially located about the central axis, each pair of adjacent pole pieces being separated by a space, said rotor core comprising a plurality of core magnets located in the spaces separating the adjacent pole pieces; at least one magnet retainer plate positioned adjacent the rotor core and connected to the rotatable rotor shaft, the at least one magnet retainer plate including a plurality of circumferentially spaced magnet slots and balancing slots located between adjacent magnet slots, the balancing slots configured to receive a balancing weight; and, compression springs located in the balancing slots, each compression spring located adjacent a respective core magnet when the at least one magnet retainer plate is located adjacent the rotor core.

Radial spoked rotor with axial assist magnets

An electric machine includes a housing having an air intake, an air outlet, and defining an air passage therein. The air passage includes a first channel extending from the air intake in a radial direction and a second channel extending in the radial direction to the outlet. The electric machine further includes a motor assembly positioned within the housing that includes a shaft that rotates about a rotational axis that is generally perpendicular to the radial direction. The electric machine further includes an electronics assembly within the housing interior and a heat sink positioned at least partially within the air passage and thermally connected to the electronics assembly. Operation of the motor assembly draws an ambient airflow into the air passage in the radial direction through the air intake, directs the airflow along the heat sink, and exhausts the airflow through the air outlet in the radial direction.

Electric machine including an air cooling system

Embodiments of the present disclosure are directed to a rotor assembly for use in a radial flux electric motor assembly having core magnets rotatable relative to end magnets such that the torque constant of the rotor assembly varies. The plurality of end magnets is positioned over the core magnets when the rotor assembly is at rest and the rotor assembly has a first torque constant at rest. The plurality of end magnets can rotate relative to the core magnets upon application of torque to the rotor assembly.

Variable torque constant electric machines having a radial spoked rotor with axial flux magnet plates and methods thereof

A permanent magnet rotor core includes a plurality of rotor poles circumferentially-spaced about a central axis and including a first rotor pole and an adjacent second rotor pole that each include an outer wall, and wherein the rotor core includes a rotor diameter. The rotor core also includes a plurality of radial apertures alternately-spaced with the plurality of rotor poles. The rotor core also includes a first protrusion extending from the first rotor pole into a first radial aperture of the plurality of radial apertures positioned between the first rotor pole and the second rotor pole. The rotor core further includes a second protrusion extending from the second rotor pole into the first radial aperture such that a circumferential opening is defined between the first protrusion and the second protrusion. The opening extends a first length of between approximately 0.052% and approximately 0.058% of the rotor diameter.

Electric machines having a radially embedded permanent magnet rotor and methods thereof

An electric motor assembly for pumping a fluid through a fluid cavity includes a stator assembly including a plurality of conduction coils configured to transmit heat energy to the fluid within the fluid cavity and a rotor assembly positioned adjacent the stator assembly to define an axial gap therebetween. The stator assembly is configured to impart a first axial force on the rotor assembly. The electric motor assembly also includes an impeller directly coupled to the rotor assembly opposite the stator assembly such that the rotor assembly and the impeller are configured to rotate about an axis. A fluid channeled by the impeller imparts a second axial force on the impeller. The rotor assembly and the impeller are configured to be submerged in the fluid within the fluid cavity.

Centrifugal pump assemblies having an axial flux electric motor and methods of assembly thereof

An electric motor assembly for pumping a fluid through a fluid cavity includes a stator assembly including a plurality of conduction coils configured to transmit heat energy to the fluid within the fluid cavity. The electric motor assembly also includes a rotor assembly positioned adjacent the stator assembly to define an axial gap therebetween. The electric motor assembly also includes an impeller directly coupled to the rotor assembly opposite the stator assembly such that the rotor assembly and the impeller are configured to rotate about an axis. The rotor assembly and the impeller are configured to be submerged in the fluid within the fluid cavity.

A rotor module for an axial flux electric machine includes a back iron segment configured for attachment to a rotor base and a plurality of permanent magnets attached to the back iron segment. The back iron segment has a length less than a circumference of the rotor base. Each permanent magnet attached to the back iron segment has an opposite magnetic pole orientation from each adjacent permanent magnet attached to the back iron segment. A plurality of rotor modules is coupled to the rotor base to form a rotor for the axial flux electric machine.

Modular rotors for axial flux electric machines

An electric motor assembly includes a bearing assembly including a rotating component and at least one stationary component. The electric motor assembly also includes an impeller coupled to the rotating component. The impeller includes an inlet and an outlet and is configured to direct a fluid between the inlet and the outlet. The electric motor assembly also includes a rotor assembly directly coupled to the impeller. A fluid flow channel is defined between the rotating component and the at least one stationary component. The flow channel includes a first end proximate the impeller outlet and a second end proximate the impeller inlet.

A hydrodynamic bearing assembly includes a first member including a first engaging surface. The first member is stationary in a non-operating mode of the bearing assembly and rotates about an axis in an operational mode of the bearing assembly. The first member includes a first bore and a shaft positioned within the first bore and including an end surface. The hydrodynamic bearing assembly also includes a second member including a second bore and a second engaging surface positioned adjacent the first engaging surface. The second member is stationary in both the non-operating mode and the operational mode of the bearing assembly. The hydrodynamic bearing assembly further includes a spacer member positioned within the second bore and is configured to engage the first member to define a first gap between the first engaging surface and the second engaging surface in the non-operational mode.

Hydrodynamic bearing assembly and method of assembling the same

A rotor for an electric machine includes a circular rotor base having a first surface, a second surface, and a circumferential outer edge extending from the first surface to the second surface, a plurality of magnets disposed proximate the circumferential outer edge of the circular rotor base, and a plurality of flux guides. Each magnet has a first surface and a second surface. The first surface of each magnet is attached to the first surface of the circular rotor base, and the second surface of each magnet defines a first shape. Each flux guide is attached to the second surface of a different magnet and has a first surface attached to the second surface of a first respective magnet and a second surface opposite the first surface. The second surface of each flux guide defines a second shape different than the first shape of the magnets.

Magnetic flux guides for electric machines

A hydrodynamic bearing assembly includes a first stationary component, a shaft coupled to the first stationary component, and a second stationary component coupled to the shaft opposite the first stationary component. The hydrodynamic bearing assembly also includes a rotating component coupled to the shaft between the first stationary component and the second stationary component. The rotating component includes a first end surface including a first diameter and an opposing second end surface including a second diameter that is greater than the first diameter.

A stator for an axial flux machine includes a back iron, a plurality of stator teeth extending from the back iron, and a plurality of tooth tips attached to the stator teeth. The back iron and the stator teeth include a first material. Each stator tooth has a first end proximate the back iron and a second end. Each tooth tip is attached to the second end of a different stator tooth. The tooth tips include a second material different than the first material.

Composite stator for axial flux electric machines and methods of assembling the same

A stator module pack for an axial flux electric machine is provided. The stator module pack includes a housing for attachment to a stator base and a plurality of stator modules attached to the housing. Each stator module includes a core having at least one winding disposed thereon. A plurality of stator module packs is coupled to a stator base to form a stator of the axial flux electric machine.

Modular stator for axial flux electric machines and methods of assembling the same

A stator module pack for an axial flux electric machine includes a housing for attachment to a stator base, a plurality of stator modules attached to the housing, and a drive unit attached to the housing. Each stator module includes a core having at least one winding disposed thereon. The drive unit is electrically connected to at least one stator module. A plurality of stator module packs and a plurality of drive units are coupled to the stator base to form a stator of the axial flux electric machine.

Modular stator drive units for axial flux electric machines

A hydrodynamic bearing assembly includes a first member including a first engaging surface. The first member is stationary in a non-operating mode of the bearing assembly and rotates about an axis in an operational mode of the bearing assembly. The hydrodynamic bearing assembly also includes a second member including a bore and a second engaging surface positioned adjacent the first engaging surface. The second member is stationary in both the non-operating mode and the operational mode of the bearing assembly. The hydrodynamic bearing assembly further includes a spacer member positioned within the bore and is configured to engage the first member to define a first gap between the first engaging surface and the second engaging surface in the non-operational mode.

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Cape Woolamai, Australia

Mark Thiele