Motor including embedded permanent-magnet rotor

Claim 2

A rotor of cylindrical configuration for use in a motor having a high torque to size ratio, said rotor having an outer cylindrical peripheral surface and comprising: a central rotor shaft with a center axis; at least first and second retainers securely mounted on said shaft in spaced opposed relation to one another; a plurality of magnetically conductive segments arrayed around said shaft between said first and second retainers with each of said segments spanning a circumferential sector of said cylindrical configuration; magnets disposed between each adjacent pair of said segments for providing magnetic flux through said adjacent segments for linking through a stator disposed around said peripheral surface; each of said segments having an opening extending therethrough in generally spaced parallel relation to said shaft, each of said openings being of a cross-section which is elongated radially, namely having a length as measured parallel to a radial plane through the center axis of said shaft which is significantly greater than the width of said opening as measured normal to such radial plane; and a non-magnetic securing bar extending through each of said openings and engaging the respective segment at the radially inward side of said opening to support said segment at least in a radial direction, each of said securing bars being a separate element spaced from said shaft and being in radial support engagement with said retainers whereby said bars and said retainers support said segments in predetermined positions in said rotor.

Claim 3

The rotor as set forth in claim 1 wherein said non-magnetic securing bars are electrically non-conductive.

Claim 4

The rotor as set forth in claim 1 wherein each of said retainers includes bar supports located at intervals spaced angularly around the axis of said shaft.

Claim 5

The rotor as set forth in claim 3 wherein said bars engage said bar supports.

Claim 6

The rotor as set forth in claim 4 wherein said bar supports are defined by openings in each of said retainers.

Claim 7

The rotor as set forth in claim 1 wherein said magnets are substantially thin plates extending radially of said shaft and being magnetized through their thickness so that their poles are at their major planar side surfaces which face said segments.

Claim 8

The rotor as set forth in claim 6 wherein said magnets extend from closely adjacent the shaft to adjacent the outer cylindrical peripheral surface of said rotor.

Claim 9

The rotor as set forth in claim 1 wherein said openings are disposed symmetrically along a longitudinal center radius of each of said segments.

Claim 10

The rotor as set forth in claim i wherein each of said openings is formed generally in a diamond shape.

Claim 11

The rotor as set forth in claim 1 wherein said shaft is non-magnetic.

Claim 12

The rotor as set forth in claim 1 wherein three or more said retainers mounted on said shaft in spaced relation to one another, said rotor including corresponding sets of said segments and said magnets so arrayed and disposed around said shaft between each adjacent pair of said retainers and supported on said retainers by such securing bars.

Claim 13

The rotor as set forth in claim 11 wherein each of said retainers which is intermediate two other said retainers defines openings therethrough in alignment with said openings through said segments, and each of said bars is a unitary bar which extends through said openings of each said intermediate retainer and is radially supported on each of retainers mounted on said shaft.

Claim 14

The rotor as in claim 1 wherein each of said segments abuts said central rotor shaft.

Claim 15

The rotor as set forth in claim 1 wherein each of said segments has an inner edge proximal to said shaft and an outer edge distal to said shaft and said opening is of a cross-section which extends substantially the full redial length of the respective segment, namely its length from said inner edge to said outer edge.

Claim 16

The rotor as set forth in claim 14 wherein said nonmagnetic securing bars are also electrically non-conductive.

Claim 17

The rotor as set forth in claim 15 wherein said central rotor shaft is non-magnetic.

Claim 18

The rotor as set forth in claim 1 wherein each of said segments has an inner edge closely adjacent said shaft and extends radially outward from said shaft to said peripheral surface.

Claim 19

A rotor of cylindrical configuration for use in a motor having a high torque to size ratio, said rotor having an outer cylindrical peripheral surface and comprising: a central rotor shaft including a center axis; at least first and second retainers securely mounted on said shaft in spaced opposed relation to one another; a plurality of magnetically conductive segments arrayed around said shaft between said first and second retainers with each of said segments spanning a circumferential sector of said cylindrical configuration; magnets disposed between each adjacent pair of said segments and extending radially from closely adjacent said shaft to adjacent the outer peripheral surface of said rotor for providing magnetic flux through each of said segments adjacent thereto for linking through a stator disposed around said peripheral surface, said magnets being formed as substantially thin plates and being magnetized through their thickness so that their poles are at their major planar side surfaces facing said segments; each of said segments having an opening extending therethrough in generally spaced parallel relation to said shaft, each of said openings being of a cross-section which is elongated radially, namely having a length as measured parallel to a radial plane through the center axis of said shaft which is significantly greater than the width of said opening as measured normal to such radial plane; and a non-magnetic and electrically non-conductive securing bar extending through each of said openings and engaging the respective segment at the radially inward side of said opening to support said segment at least in a radial direction, each of said securing bars being spaced from said shaft and being supported by said retainers whereby said bars support said segments in predetermined positions in said rotor.

Claim 20

A rotor of cylindrical configuration for use in a motor having a high torque to size ratio, said rotor having an outer cylindrical peripheral surface and comprising: a central rotor shaft including a center axis; at least first and second retainers securely mounted on said shaft in spaced opposed relation to one another; a plurality of magnetically conductive segments arrayed around said shaft between said first and second retainers with each of said segments spanning a circumferential sector of said cylindrical configuration; magnets disposed between each adjacent pair of said segments and extending radially from closely adjacent said shaft to adjacent the outer peripheral surface of said rotor for providing magnetic flux through each of said segments adjacent thereto for linking through a stator disposed around said peripheral surface, said magnets being formed as substantially thin plates and being magnetized through their thickness so that their poles are at their major planar side surfaces facing said segments; each of said segments having an opening extending therethrough in generally spaced parallel relation to said shaft, each of said openings being of a cross-section which is elongated radially, namely having a length as measured parallel to a radial plane through the center axis of said shaft which is significantly greater than the width of said opening as measured normal to such radial plane; and a non-magnetic and electrically non-conductive securing bar extending through each of said openings and engaging the respective segment at the radially inward side of said opening to support said segment at least in a radial direction, each of said securing bars being spaced from said shaft and being supported by said retainers whereby said bars support said segments in predetermined positions in said rotor.

Claim 21

The rotor as set forth in claim 18 wherein each of said retainers includes bar supports located at intervals spaced angularly around the axis of said shaft.

Claim 22

The rotor as set forth in claim 19 wherein said bars engage said bar supports.

Claim 23

The rotor as set forth in claim 20 wherein said bar supports are defined by openings in each of said retainers.

Claim 24

The rotor as set forth in claim 14 wherein each of said openings is symmetrically along a longitudinal center radius of the respective segment.

Claim 25

The rotor as set forth in claim 20 wherein each of said openings is generally of a diamond shape.

Claim 26

The rotor as set forth in claim 20 wherein said shaft is non-magnetic.

Claim 27

The rotor as set forth in claim 18 wherein three or more said retainers mounted on said shaft in spaced relation to one another, said rotor including corresponding sets of said segments and said magnets so arrayed and disposed around said shaft between each adjacent pair of said retainers and supported on said retainers by such securing bars.

Claim 28

The rotor as set forth in claim 25 wherein each of said retainers which is intermediate two other said retainers defines openings therethrough in alignment with said openings through said segments, and each of said bars is a unitary bar which extends through said openings of each said intermediate retainer and is radially supported on each of retainers mounted on said shaft.

Claim 29

The rotor as in claim 18 wherein each of said segments abuts said central rotor shaft.

Claim 30

A rotor of cylindrical configuration for use in a motor having a high torque to size ratio, said rotor having an outer cylindrical peripheral surface and comprising: a central rotor shaft with a center axis; at least first and second retainers securely mounted on said shaft in spaced opposed relation to one another; a plurality of magnetically conductive segments arrayed around said shaft between said first and second retainers with each of said segments spanning a circumferential sector of said cylindrical configuration; magnets disposed between each adjacent pair of said segments for providing magnetic flux through segments for linking through a stator disposed around said peripheral surface; each of said segments having an opening extending therethrough in generally spaced parallel relation to said shaft, each of said openings being generally of a diamond shape; and, non-magnetic securing bars extending through each of said openings and being supported by said retainers whereby said bars support said segments in predetermined positions in said

Claim 31

A rotor of cylindrical configuration for use in a motor having a high torque to size ratio, said rotor having an outer cylindrical peripheral surface and comprising: a central rotor shaft with a center axis; at least first and second retainers securely mounted on said shaft in spaced opposed relation to one another; a plurality of magnetically conductive segments arrayed around said shaft between said first and second retainers with each of said segments spanning a circumferential sector of said cylindrical configuration; magnets disposed between each adjacent pair of said segments for providing magnetic flux through segments for linking through a stator disposed around said peripheral surface; each of said segments having an opening extending therethrough in generally spaced parallel relation to said shaft, each of said openings being generally of a diamond shape; and, non-magnetic securing bars extending through each of said openings and being supported by said retainers whereby said bars support said segments in predetermined positions in said

Claim 32

The rotor as set forth in claim 28 wherein each of said segments has an inner edge proximal to said shaft and an outer edge distal to said shaft and said opening is of a cross-section which extends substantially the full radial length of the respective segment, namely its length from said inner edge to said outer edge.

Claim 33

An electrical motor including a rotor having a high torque to size ratio, said motor comprising: a stator including a centrally located longitudinal opening; a bearing mechanism fixedly disposed relative to said stator; and a rotor of cylindrical configuration, said rotor having a central shaft supported by said bearing mechanism and disposed at least partially within said centrally located opening of said stator, magnetically conductive segments disposed around said central shaft, each of said segments having an arcuate outer surface distal from said central shaft and an inner edge proximal to said central shaft, each of said segments further defining an opening extending therethrough in generally parallel relation to said central shaft, each of said openings being of a radially elongated cross-section, namely having a length as measured parallel to a radial plane through the center axis of said shaft which is greater than the maximum width of that opening as measured normal to such radial plane, and wherein said cross-section includes a mid-portion having said maximum width and narrows near the outer surface and near the inner edge of the respective segment, magnets located between each adjacent pair of said segments for providing magnetic flux through each of the adjacent segments, said flux linking at least partially through said stator disposed around said segments, and securing bars structurally coupled to and spaced from said shaft and extending through said openings in said segments to retain said segments in predetermined position around said shaft.

Claim 34

An electrical motor including a rotor having a high torque to size ratio, said motor comprising: a stator including a centrally located longitudinal opening; a bearing mechanism fixedly disposed relative to said stator; and a rotor of cylindrical configuration, said rotor having a central shaft supported by said bearing mechanism and disposed at least partially within said centrally located opening of said stator, magnetically conductive segments disposed around said central shaft, each of said segments having an arcuate outer surface distal from said central shaft and an inner edge proximal to said central shaft, each of said segments further defining an opening extending therethrough in generally parallel relation to said central shaft, each of said openings being of a radially elongated cross-section, namely having a length as measured parallel to a radial plane through the center axis of said shaft which is greater than the maximum width of that opening as measured normal to such radial plane, and wherein said cross-section includes a mid-portion having said maximum width and narrows near the outer surface and near the inner edge of the respective segment, magnets located between each adjacent pair of said segments for providing magnetic flux through each of the adjacent segments, said flux linking at least partially through said stator disposed around said segments, and securing bars structurally coupled to and spaced from said shaft and extending through said openings in said segments to retain said segments in predetermined position around said shaft.

Claim 35

The motor as set forth in claim 30 wherein each of said openings extends substantially the full radial length of the segment.

Claim 36

The motor as set forth in claim 31 wherein said securing bars are non-magnetic.

Claim 37

The motor as set forth in claim 32 wherein said securing bars are electrically non-conductive.

Claim 38

The motor as set forth in claim 32 wherein said securing bars have substantially the same cross-sections as said openings.

Claim 39

An electrical motor having a high torque to size ratio, said motor including a rotor having a central longitudinal axis of rotation, a stator defining a centrally located longitudinal opening, and a bearing mechanism fixedly disposed relative to said stator for supporting said rotor at least partially in said stator for rotation about the central longitudinal axis of said rotor, said rotor comprising: magnetically conductive segments disposed around said central longitudinal axis, each of said segments having an arcuate outer surface distal to said axis and an inner surface proximal to said axis, each of said segments defining an opening therethrough in generally parallel relation to said axis; magnets located between each adjacent pair of said segments and being engaged with the adjacent segments for retention therebetween and for providing magnetic flux through each of the adjacent segments, said flux linking at least partially through said stator disposed around said segments; retainers adjacent each end of said segments; and, securing bars spaced from said axis, extending through said openings in said segments and engaging each of the respective segments at a radially inward side of said opening therein, said securing bars engaging and being supported by said retainers to retain said segments in predetermined positions around said axis, each of said securing bars being a separate element, said securing bars holding said segments and magnets radially and maintaining radially inward compressive forces on said segments and thereby forming a prestressed cylindrical structure which includes said bars, retainers, segments and magnets.

Claim 40

An electrical motor having a high torque to size ratio, said motor including a rotor having a central longitudinal axis of rotation, a stator defining a centrally located longitudinal opening, and a bearing mechanism fixedly disposed relative to said stator for supporting said rotor at least partially in said stator for rotation about the central longitudinal axis of said rotor, said rotor comprising: magnetically conductive segments disposed around said central longitudinal axis, each of said segments having an arcuate outer surface distal to said axis and an inner surface proximal to said axis, each of said segments defining an opening therethrough in generally parallel relation to said axis; magnets located between each adjacent pair of said segments and being engaged with the adjacent segments for retention therebetween and for providing magnetic flux through each of the adjacent segments, said flux linking at least partially through said stator disposed around said segments; retainers adjacent each end of said segments; and, securing bars spaced from said axis, extending through said openings in said segments and engaging each of the respective segments at a radially inward side of said opening therein, said securing bars engaging and being supported by said retainers to retain said segments in predetermined positions around said axis, each of said securing bars being a separate element, said securing bars holding said segments and magnets radially and maintaining radially inward compressive forces on said segments and thereby forming a prestressed cylindrical structure which includes said bars, retainers, segments and magnets.

Claim 41

The motor as set forth in claim 37 wherein said opening of each of said segments is of a cross-section which extends substantially the full radial length of the segment, namely the length of the segment from said inner surface to said outer surface, and said securing bars are both non-magnetic and electrically non-conductive.

Claim 42

The motor as set forth in claim 35 further including a central shaft which is disposed along said axis and is rotatably supported in said bearing mechanism, and wherein said retainers are supported on said shaft, and said segments are maintained in compressive engagement with said shaft by said securing bars supported on said retainers.

Claim 43

The motor as set forth in claim 37 wherein each of said openings of each of said segments is of a cross-section which extends substantially the full radial length of the segment, namely the length of the segment from said inner surface to said outer surface, each of said securing bars is non-magnetic and electrically non-conductive, and said shaft is non-magnetic.

Claim 44

The rotor as set forth in claim 35 including a bonding adhesive further securing the components of said rotor together.

Claim 45

The rotor as set forth in claim 35 including a metal bonding adhesive permeating said rotor and bonding the components of said rotor together.

Claim 46

A rotor of cylindrical configuration for an electrical motor having a high torque to size ratio, said rotor comprising: a central shaft; magnetically conductive segments disposed around said central shaft, each of said segments having an arcuate outer surface distal to said central shaft and an inner edge proximal to said central shaft, said segments defining openings therethrough in generally parallel relation to said central shaft; magnets located between each adjacent pair of segments for providing magnetic flux through each of the adjacent segments for linking at least partially through a stator widen disposed around said segments; a plurality of separate securing bars extending through said openings in said segments and each disposed in spaced and generally parallel relation to said shaft, said bars engaging said segments and structurally coupled to said shaft to retain said segments in respective predetermined positions around said shaft, said securing bars maintaining said segments in radial compression against said central shaft, whereby said bars, said shaft, said magnets and said segments form a prestressed rigid rotor structure.

Claim 47

A rotor of cylindrical configuration for an electrical motor having a high torque to size ratio, said rotor comprising: a central shaft; magnetically conductive segments disposed around said central shaft, each of said segments having an arcuate outer surface distal to said central shaft and an inner edge proximal to said central shaft, said segments defining openings therethrough in generally parallel relation to said central shaft; magnets located between each adjacent pair of segments for providing magnetic flux through each of the adjacent segments for linking at least partially through a stator widen disposed around said segments; a plurality of separate securing bars extending through said openings in said segments and each disposed in spaced and generally parallel relation to said shaft, said bars engaging said segments and structurally coupled to said shaft to retain said segments in respective predetermined positions around said shaft, said securing bars maintaining said segments in radial compression against said central shaft, whereby said bars, said shaft, said magnets and said segments form a prestressed rigid rotor structure.

Claim 48

The rotor as set forth in claim 41 wherein each of said securing bars is non-magnetic and electrically non-conductive.

Claim 49

The motor as set forth in claim 42 wherein each of said openings is of a cross-section which extends substantially the full radial length of the segment, namely the length of the segment from said inner surface to said outer surface.

Claim 50

The rotor as set forth in claim 43 wherein said shaft is non-magnetic.

Claim 51

The rotor as set forth in claim 41 wherein each of said openings is of a radially elongated cross-section, namely having a length as measured parallel to a radial plane through the center axis of said shaft which is significantly greater than the maximum width of that opening as measured normal to such radial plane, and each of said bars is of a substantially corresponding cross-sectional configuration.

Claim 52

The rotor as set forth in claim 45 wherein each of said openings narrows near the outer surface and the inner edge of the segment.

Claim 53

The rotor as set forth in claim 46 wherein said bars comprise fibers of high tensile strength which are continuous along the length of the respective bar and are bonded by a resin.

Claim 54

The rotor as set forth in claim 47 wherein said bars are pulltruded glass fiber with a resin binder.

Claim 55

The rotor as set forth in claim 41 wherein said magnets are thin plates extending radially of said shaft and being magnetized through their thickness so that their poles are at their major planar side surfaces which face said segments.

Claim 56

The rotor as set forth in claim 49 wherein said magnets extend from adjacent said inner edge to closely adjacent said outer surface of the adjacent segments.

Claim 57

The rotor as set forth in claim 49 wherein said magnets extend from adjacent said inner edge to closely adjacent said outer surface of the adjacent segments substantially throughout the length of said segments.

Claim 58

The rotor as set forth in claim 41 including at least first and second retainers securely mounted on said shaft in spaced opposed relation to one another, said segments being arrayed between said retainers, and said securing bars being supported on said retainers.

Claim 59

An electric motor comprising a rotor as in claim 41, a stator surrounding said segments and a bearing assembly mounting said shaft to said stator for relative rotation between said rotor and said stator.

Claim 60

An electric motor as in claim 53 wherein said shaft is non-magnetic and said magnets are thin plates which extend radially of said rotor from adjacent said shaft to adjacent the outer surfaces of said segments along substantially the entire length of said segments and said plates are magnetized through their thickness so that their poles are at their major planar side surfaces which face said segments.

Claim 61

An electric motor as in claim 54 wherein said openings are of a configuration which is elongated radially of said segments and said securing bars are of a cross-section similar to said configuration of said openings.

Claim 62

The rotor as set forth in claim 41 including a metal bonding adhesive permeating said rotor and bonding the components of said rotor together.

Claim 63

A rotor of cylindrical configuration for use in a motor having a high torque to size ratio, said rotor having an outer cylindrical peripheral surface and comprising: a central rotor shaft with a center axis; at least first and second retainers securely mounted on said shaft in spaced opposed relation to one another; a plurality of magnetically conductive segments arrayed around said shaft between said first and second retainers with each of said segments spanning a circumferential sector of said cylindrical configuration; magnets disposed between each adjacent pair of said segments for providing magnetic flux through each of the adjacent segments for linking through a stator disposed around said peripheral surface; each of said segments having an opening extending therethrough in generally spaced parallel relation to said shaft; and a securing bar which is non-magnetic and electrically non-conductive extending through each of said openings and engaging the respective segment at the radially inward side of said opening therein to support said segment at least in a radial direction, each of said securing bars being spaced from said shaft and being supported by said retainers whereby said bars support said segments in predetermined positions in said rotor.

Claim 64

A rotor of cylindrical configuration for use in a motor having a high torque to size ratio, said rotor having an outer cylindrical peripheral surface and comprising: a central rotor shaft with a center axis; at least first and second retainers securely mounted on said shaft in spaced opposed relation to one another; a plurality of magnetically conductive segments arrayed around said shaft between said first and second retainers with each of said segments spanning a circumferential sector of said cylindrical configuration; magnets disposed between each adjacent pair of said segments for providing magnetic flux through each of the adjacent segments for linking through a stator disposed around said peripheral surface; each of said segments having an opening extending therethrough in generally spaced parallel relation to said shaft; and a securing bar which is non-magnetic and electrically non-conductive extending through each of said openings and engaging the respective segment at the radially inward side of said opening therein to support said segment at least in a radial direction, each of said securing bars being spaced from said shaft and being supported by said retainers whereby said bars support said segments in predetermined positions in said rotor.

Claim 65

The rotor as set forth in claim 57 wherein said retainers are formed with openings therein, and said securing bars extend into said openings to effect such support of said segments.

Claim 66

The rotor as set forth in claim 58 wherein said openings in said segments and in said retainers each is of a cross-sectional configuration which is elongated in a direction extending radially relative to said central shaft, and said bars are of similar radially elongated cross-section.

Claim 67

The rotor as set forth in claim 59 wherein said bars comprise fibers of high tensile strength which are continuous along the length of the respective bar and are bonded by a resin.

Claim 68

The rotor as set forth in claim 60 wherein said bars are pulltruded glass fiber with a resin binder.