U.S. patent application number 10/609966 was filed with the patent office on 2005-01-20 for magnetically enhanced oil filter apparatus.
Invention is credited to Caiozza, Joseph C..
Application Number | 20050012422 10/609966 |
Document ID | / |
Family ID | 33540991 |
Filed Date | 2005-01-20 |
United States Patent
Application |
20050012422 |
Kind Code |
A1 |
Caiozza, Joseph C. |
January 20, 2005 |
MAGNETICALLY ENHANCED OIL FILTER APPARATUS
Abstract
A DC motor apparatus includes a motor housing assembly which
includes an outer liquid-tight coolant chamber and an inner,
armature-reception chamber portion. Pairs of permanent magnet
stator magnet modules are housed within the liquid-tight coolant
chamber, and shunt members are housed within the liquid-tight
coolant chamber between the stator magnet modules. An armature is
centrally located in the inner, armature-reception chamber portion.
The armature includes at least one pair of armature pole portions
which are wound with same-directional windings. A commutator is
connected to the armature, and the commutator includes commutator
contacts. An adjustable brush advance/retard mechanism includes
roller brushes for contacting the commutator contacts. A liquid
cooling system includes a coolant pump and a coolant fluid radiator
for circulating liquid coolant through the liquid-tight coolant
chamber for cooling the stator magnet modules and the shunt
members.
Inventors: |
Caiozza, Joseph C.; (Long
Beach, NY) |
Correspondence
Address: |
S. Michael Bender
P.O. Box 530399
St. Petersburg
FL
33747
US
|
Family ID: |
33540991 |
Appl. No.: |
10/609966 |
Filed: |
June 30, 2003 |
Current U.S.
Class: |
310/190 ;
310/209; 310/241 |
Current CPC
Class: |
H02K 9/197 20130101;
H02K 23/04 20130101; H02K 23/18 20130101 |
Class at
Publication: |
310/190 ;
310/241; 310/209 |
International
Class: |
H02K 007/10; H02P
015/00; H02K 049/00 |
Claims
What is claimed as being new and desired to be protected by Letters
Patent of the united states is as follows:
1. A DC motor apparatus, comprising: a motor housing assembly which
includes an outer chamber portion and an inner, armature-reception
chamber portion, at least one pair of stator magnet modules housed
within said outer chamber portion, at least one pair of shunt
members housed within said outer chamber portion between said
stator magnet modules, an armature housed in said inner,
armature-reception chamber portion, wherein said armature is
centrally located with respect to said stator magnet modules, such
that said stator magnet modules are arrayed peripherally around
said armature, wherein said armature includes at least one pair of
armature pole portions, wherein both of said at least one pair of
armature pole portions are wound with same-directional windings, a
commutator connected to said armature, wherein said commutator
includes at least one pair of commutator contacts, wherein the
number of pairs of commutator contacts is equal to the number pairs
of said armature pole portions, and a brush advance/retard
mechanism supported by said motor housing assembly, wherein said
brush advance/retard mechanism includes roller brushes for
contacting said commutator contacts.
2. The apparatus of claim 1 wherein said stator magnet modules
include permanent magnets.
3. The apparatus of claim 1 wherein: said motor housing assembly
includes an outer liquid-tight coolant chamber and said inner,
armature-reception chamber portion, said at least one pair of
stator magnet modules are housed within said liquid-tight coolant
chamber, and said at least one pair of shunt members are housed
within said liquid-tight coolant chamber between said stator magnet
modules.
4. The apparatus of claim 3, further including: housing-to-pump
conduits connected to said liquid-tight coolant chamber, a coolant
pump connected to said housing-to-pump conduits, a pump-to-radiator
conduit connected to said coolant pump, a coolant fluid radiator
connected to said pump-to-radiator conduit, and radiator-to-housing
conduits connected between said coolant fluid radiator and said
liquid-tight coolant chamber.
5. The apparatus of claim 1 wherein said shunt members include at
least one north-pole-to-north-pole, module-to-module shunt member
and at least one south-pole-to-south-pole, module-to-module shunt
member.
6. The apparatus of claim 1 wherein said same-directional windings
include right-handed windings.
7. The apparatus of claim 1 wherein said same-directional windings
include left-handed windings.
8. The apparatus of claim 1 wherein said motor housing assembly
includes an outer longitudinal housing portion, an inner
longitudinal housing portion, a first transverse housing portion,
and a second transverse housing portion.
9. The apparatus of claim 8 wherein said outer longitudinal housing
portion, said inner longitudinal housing portion, a portion of said
first transverse housing portion, and a portion of said second
transverse housing portion define said liquid-tight coolant
chamber.
10. The apparatus of claim 8 wherein said inner longitudinal
housing portion, a portion of said first transverse housing
portion, and a portion of said second transverse housing portion
define said inner, armature-reception chamber portion.
11. The apparatus of claim 1 wherein said brush advance/retard
mechanism includes: a roller brush support plate connected to said
motor housing assembly, wherein said roller brush support plate
includes plate adjustment slots, and wherein said roller brush
support plate includes peripheral plate teeth, plate guide
fasteners received in said plate adjustment slots and connected to
said motor housing assembly, roller brush assemblies connected to
said roller brush support plate, wherein said roller brush
assemblies include said roller brushes and brush bias springs for
biasing said roller brushes against said commutator contacts, plate
drive assembly, supported by said motor housing assembly, for
adjusting said roller brush support plate, wherein aid plate drive
assembly includes a brush advance/retard gear for engaging said
peripheral plate teeth.
12. The apparatus of claim 1 wherein each of said stator magnet
module includes: a plurality of cylindrical magnets, and a
plurality of shunt blocks retaining said cylindrical magnets.
13. The apparatus of claim 1 wherein at least one of said stator
magnet modules includes: a first row of first directional
orientation carrier-embedded magnets, a second row of first
directional orientation carrier-embedded magnets, a row of third
directional orientation carrier-embedded magnets, a row of fourth
directional orientation carrier-embedded magnets, a shunt carrier
block connected between said first row of said first directional
orientation carrier-embedded magnets and said row of fourth
directional orientation carrier-embedded magnets, wherein said
first row of said first directional orientation carrier-embedded
magnets is oriented perpendicular to said row of said fourth
directional orientation carrier-embedded magnets, a shunt carrier
block connected between said row of said fourth directional
orientation carrier-embedded magnets and said second row of said
first directional orientation carrier-embedded magnets, wherein
said row of said fourth directional orientation carrier-embedded
magnets is oriented perpendicular to said second row of said first
directional orientation carrier-embedded magnets, a shunt carrier
block connected between said second row of said first directional
orientation carrier-embedded magnets and said row of said third
directional orientation carrier-embedded magnets, wherein said
second row of said first directional orientation carrier-embedded
magnets is oriented perpendicular to said row of said third
directional orientation carrier-embedded magnets, and a shunt
carrier block connected between said row of said third directional
orientation carrier-embedded magnets and said first row of said
first directional orientation carrier-embedded magnets, wherein
said row of said third directional orientation carrier-embedded
magnets is oriented perpendicular to said first row of said first
directional orientation carrier-embedded magnets.
14. The apparatus of claim 1 wherein at least one of said stator
magnet modules includes: a row of second directional orientation
carrier-embedded magnets, a first row of third directional
orientation carrier-embedded magnets, a second row of third
directional orientation carrier-embedded magnets, a row of first
directional orientation carrier-embedded magnets, a shunt carrier
block connected between said row of said second directional
orientation carrier-embedded magnets and said first row of said
third directional orientation carrier-embedded magnets, wherein
said row of said second directional orientation carrier-embedded
magnets is perpendicular to said first row of said third
directional orientation carrier-embedded magnets, a shunt carrier
block connected between said first row of said third directional
orientation carrier-embedded magnets and said row of said first
directional orientation carrier-embedded magnets, wherein said
first row of said third directional orientation carrier-embedded
magnets is perpendicular to said row of said first directional
orientation carrier-embedded magnets, a shunt carrier block
connected between said row of said first directional orientation
carrier-embedded magnets and said second row of said third
directional orientation carrier-embedded magnets, wherein said row
of said first directional orientation carrier-embedded magnets is
perpendicular to said second row of said third directional
orientation carrier-embedded magnets, a shunt carrier block
connected between said second row of said third directional
orientation carrier-embedded magnets and said second directional
orientation carrier-embedded magnets, wherein said second row of
said third directional orientation carrier-embedded magnets is
perpendicular to said row of said second directional orientation
carrier-embedded magnets.
15. The apparatus of claim 1 wherein at least one of said stator
magnet modules includes: a first row of second directional
orientation carrier-embedded magnets, a second row of said second
directional orientation carrier-embedded magnets, a row of fourth
directional orientation carrier-embedded magnets, a row of third
directional orientation carrier-embedded magnets, a shunt carrier
block connected between said first row of said second directional
orientation carrier-embedded magnets and said row of said fourth
directional orientation carrier-embedded magnets, wherein said
first row of said second directional orientation carrier-embedded
magnets is perpendicular to said row of said fourth directional
orientation carrier-embedded magnets, a shunt carrier block
connected between said row of said fourth directional orientation
carrier-embedded magnets and said second row of said second
directional orientation carrier-embedded magnets, wherein said row
of said fourth directional orientation carrier-embedded magnets is
perpendicular to said second row of said second directional
orientation carrier-embedded magnets, a shunt carrier block
connected between said second row of said second directional
orientation carrier-embedded magnets and said row of said third
directional orientation carrier-embedded magnets, wherein said
second row of said second directional orientation carrier-embedded
magnets is perpendicular to said row of said third directional
orientation carrier-embedded magnets, and a shunt carrier block
connected between said row of said third directional orientation
carrier-embedded magnets and said first row of said second
directional orientation carrier-embedded magnets, wherein said row
of said third directional orientation carrier-embedded magnets is
perpendicular to said first row of said second directional
orientation carrier-embedded magnets.
16. The apparatus of claim 1 wherein at least one of said stator
magnet modules includes: a row of second directional orientation
carrier-embedded magnets, a first row of fourth directional
orientation carrier-embedded magnets, a second row of fourth
directional orientation carrier-embedded magnets, a row of first
directional orientation carrier-embedded magnets, a shunt carrier
block connected between said row of said second directional
orientation carrier-embedded magnets and said first row of said
fourth directional orientation carrier-embedded magnets, wherein
said row of said second directional orientation carrier-embedded
magnets is perpendicular to said first row of said fourth
directional orientation carrier-embedded magnets, a shunt carrier
block connected between said first row of said fourth directional
orientation carrier-embedded magnets and said row of said first
directional orientation carrier-embedded magnets, wherein said
second row of said fourth directional orientation carrier-embedded
magnets is perpendicular to said row of said first directional
orientation carrier-embedded magnets, a shunt carrier block
connected between said row of said first directional orientation
carrier-embedded magnets and said second row of said fourth
directional orientation carrier-embedded magnets, wherein said row
of said first directional orientation carrier-embedded magnets is
perpendicular to said second row of said fourth directional
orientation carrier-embedded magnets, and a shunt carrier block
connected between said second row of said fourth directional
orientation carrier-embedded magnets and said row of said second
directional orientation carrier-embedded magnets, wherein said
second row of said fourth directional orientation carrier-embedded
magnets is perpendicular to said row of said second directional
orientation carrier-embedded magnets.
17. The apparatus of claim 1, further including: a tunnel bearing
assembly, supporting said armature, wherein aid tunnel bearing
assembly includes wire-reception channels.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to direct current
(DC) electric motors and, more particularly, to DC electric motors
with motor-cooling features.
[0003] 2. Description of the Prior Art
[0004] It is well known that DC electric motors give off heat when
they operate. With many motors, ambient air is sufficient for
cooling the motors. Even a fan blowing ambient air may also provide
sufficient cooling. However, for a DC electric motor that performs
relatively large amounts of work and generates more heat than can
be sufficiently cooled merely by air, it would be desirable if a DC
electric motor were provided with a liquid cooling system.
[0005] Generally, a conventional DC electric motor has a simple
stator, an armature that includes a pair of armature poles wherein
one armature pole has a right-handed winding, and the other
armature pole has a left-handed winding. Also, such a conventional
DC electric motor includes a commutator that has two commutator
contacts. Also, a conventional DC electric motor includes sliding
brushes.
[0006] With the present invention, a number of improvements over a
conventional DC electric motor are contemplated. For example, it
would be desirable to provide a novel DC electric motor which
provides a stator comprised of a plurality of stator magnet
modules. It is contemplated that multiple stator magnet modules can
provide maximum torque.
[0007] With the present invention, instead of employing an armature
that has only two armature pole portions, it would be desirable to
provide a DC electric motor that has an armature that includes
additional armature pole portions. The use of multiple armature
pole portions will permit the maximizing of the efficiency of
available electric current.
[0008] With the present invention, instead of having opposite
armature pole portions that have opposite winding configurations,
such as right-handed winding and left-handed winding, it has been
discovered beneficial to have opposite armature pole portions to
have the same winding configurations. That is, both opposite
armature pole portions can have either right-handed windings or
left-handed windings.
[0009] With the present invention, instead of using conventional
sliding brushes, the invention employs roller brushes. Roller
brushes last longer than sliding brushes.
[0010] In addition, instead of employing a conventional bearing for
the armature, the present invention provides a tunnel bearing
assembly which puts the bearings close to the armature for better
stability and load supporting.
[0011] Conventionally, brushes are retained in fixed positions with
respect to the commutator contacts. That is, even with different
motor speeds and different loads, the relative positions between
the commutator contacts and the brushes do not change. In this
respect, it would be desirable if a brush advance/retard mechanism
were provided. Such a brush advance/retard mechanism would allow
for maximum performance at different motor speeds and loads.
[0012] Thus, while the foregoing body of prior art indicates it to
be well known to use DC electric motors, the above discussion
indicates that the prior art does not teach or suggest a DC motor
apparatus which has the following combination of desirable
features: (1) is provided with a liquid cooling system; (2)
provides a stator comprised of a plurality of stator magnet
modules; (3) has an armature that includes additional armature pole
portions; (4) has opposite armature pole portions having the same
winding configurations; (5) employs roller brushes; (6) provides a
tunnel bearing assembly; and (7) provides a brush advance/retard
mechanism. The foregoing desired characteristics are provided by
the unique liquid cooled DC motor apparatus of the present
invention as will be made apparent from the following description
thereof. Other advantages of the present invention over the prior
art also will be rendered evident.
SUMMARY OF THE INVENTION
[0013] To achieve the foregoing and other advantages, the present
invention, briefly described, provides a DC motor apparatus which
includes a motor housing assembly which includes an outer chamber
portion and an inner, armature-reception chamber portion. At least
one pair of stator magnet modules are housed within the outer
chamber portion, and at least one pair of shunt members are housed
within the outer chamber portion between the stator magnet modules.
The stator magnet modules include permanent magnets. An armature is
housed in the inner, armature-reception chamber portion, wherein
the armature is centrally located with respect to the stator magnet
modules, such that the stator magnet modules are arrayed
peripherally around the armature. The armature includes at least
one pair of armature pole portions, and the at least one pair of
armature pole portions are wound with same-directional windings. A
commutator is connected to the armature, and the commutator
includes at least one pair of commutator contacts. The number of
pairs of commutator contacts is equal to the number pairs of the
armature pole portions. A brush advance/retard mechanism is
supported by the motor housing assembly, and the brush
advance/retard mechanism includes roller brushes for contacting the
commutator contacts.
[0014] The multiple armature pole portions provide maximizing the
efficiency of available electric current. The multiple stator
magnet modules provide for maximum torque. The brush advance/retard
mechanism allows for maximum performance at different motor speeds
and loads. The roller brushes last longer than conventional sliding
brushes.
[0015] Preferably, the DC motor apparatus of the invention includes
a liquid cooling system. More specifically, the motor housing
assembly includes an outer liquid-tight coolant chamber and the
inner, armature-reception chamber portion. The stator magnet
modules are housed within the liquid-tight coolant chamber, and the
shunt members are housed within the liquid-tight coolant chamber
between the stator magnet modules. In addition, housing-to-pump
conduits are connected to the liquid-tight coolant chamber. A
coolant pump is connected to the housing-to-pump conduits. A
pump-to-radiator conduit is connected to the coolant pump. A
coolant fluid radiator is connected to the pump-to-radiator
conduit, and radiator-to-housing conduits are connected between the
coolant fluid radiator and the liquid-tight coolant chamber.
[0016] Preferably, the shunt members include at least one
north-pole-to-north-pole, module-to-module shunt member and at
least one south-pole-to-south-pole, module-to-module shunt member.
The same-directional windings of the armature pole portions can
include right-handed windings, or the same-directional windings can
include left-handed windings.
[0017] Preferably, the motor housing assembly includes an outer
longitudinal housing portion, an inner longitudinal housing
portion, a first transverse housing portion, and a second
transverse housing portion. In this respect, the outer longitudinal
housing portion, the inner longitudinal housing portion, a portion
of the first transverse housing portion, and a portion of the
second transverse housing portion define the liquid-tight coolant
chamber. In addition, the inner longitudinal housing portion, a
portion of the first transverse housing portion, and a portion of
the second transverse housing portion define the inner,
armature-reception chamber portion.
[0018] Preferably, the brush advance/retard mechanism includes a
roller brush support plate connected to the motor housing assembly.
The roller brush support plate includes plate adjustment slots, and
the roller brush support plate includes peripheral plate teeth.
Plate guide fasteners are received in the plate adjustment slots
and are connected to the motor housing assembly. Roller brush
assemblies are connected to the roller brush support plate, wherein
the roller brush assemblies include the roller brushes and brush
bias springs for biasing the roller brushes against the commutator
contacts.
[0019] A plate drive assembly, supported by the motor housing
assembly, is provided for adjusting the roller brush support plate,
wherein the plate drive assembly includes a brush advance/retard
gear for engaging the peripheral plate teeth.
[0020] Preferably, each stator magnet module includes a plurality
of cylindrical magnets, and a plurality of shunt blocks retaining
the cylindrical magnets.
[0021] With one embodiment of a stator magnet module, the stator
magnet module includes a first row of first directional orientation
carrier-embedded magnets, a second row of first directional
orientation carrier-embedded magnets, a row of third directional
orientation carrier-embedded magnets, and a row of fourth
directional orientation carrier-embedded magnets. A shunt carrier
block is connected between the first row of the first directional
orientation carrier-embedded magnets and the row of fourth
directional orientation carrier-embedded magnets, wherein the first
row of the first directional orientation carrier-embedded magnets
is oriented perpendicular to the row of the fourth directional
orientation carrier-embedded magnets. A shunt carrier block is
connected between the row of the fourth directional orientation
carrier-embedded magnets and the second row of the first
directional orientation carrier-embedded magnets, wherein the row
of the fourth directional orientation carrier-embedded magnets is
oriented perpendicular to the second row of the first directional
orientation carrier-embedded magnets. A shunt carrier block is
connected between the second row of the first directional
orientation carrier-embedded magnets and the row of the third
directional orientation carrier-embedded magnets, wherein the
second row of the first directional orientation carrier-embedded
magnets is oriented perpendicular to the row of the third
directional orientation carrier-embedded magnets. A shunt carrier
block is connected between the row of the third directional
orientation carrier-embedded magnets and the first row of the first
directional orientation carrier-embedded magnets, wherein the row
of the third directional orientation carrier-embedded magnets is
oriented perpendicular to the first row of the first directional
orientation carrier-embedded magnets.
[0022] With another embodiment of a stator magnet module, the
stator magnet module includes a row of second directional
orientation carrier-embedded magnets, a first row of third
directional orientation carrier-embedded magnets, a second row of
third directional orientation carrier-embedded magnets, and a row
of first directional orientation carrier-embedded magnets. A shunt
carrier block is connected between the row of the second
directional orientation carrier-embedded magnets and the first row
of the third directional orientation carrier-embedded magnets,
wherein the row of the second directional orientation
carrier-embedded magnets is perpendicular to the first row of the
third directional orientation carrier-embedded magnets. A shunt
carrier block is connected between the first row of the third
directional orientation carrier-embedded magnets and the row of the
first directional orientation carrier-embedded magnets, wherein the
first row of the third directional orientation carrier-embedded
magnets is perpendicular to the row of the first directional
orientation carrier-embedded magnets. A shunt carrier block is
connected between the row of the first directional orientation
carrier-embedded magnets and the second row of the third
directional orientation carrier-embedded magnets, wherein the row
of the first directional orientation carrier-embedded magnets is
perpendicular to the second row of the third directional
orientation carrier-embedded magnets. A shunt carrier block is
connected between the second row of the third directional
orientation carrier-embedded magnets and the second directional
orientation carrier-embedded magnets, wherein the second row of the
third directional orientation carrier-embedded magnets is
perpendicular to the row of the second directional orientation
carrier-embedded magnets.
[0023] With still another embodiment of a stator magnet module, the
stator magnet module includes a first row of second directional
orientation carrier-embedded magnets, a second row of the second
directional orientation carrier-embedded magnets, a row of fourth
directional orientation carrier-embedded magnets, and a row of
third directional orientation carrier-embedded magnets. A shunt
carrier block is connected between the first row of the second
directional orientation carrier-embedded magnets and the row of the
fourth directional orientation carrier-embedded magnets, wherein
the first row of the second directional orientation
carrier-embedded magnets is perpendicular to the row of the fourth
directional orientation carrier-embedded magnets. A shunt carrier
block is connected between the row of the fourth directional
orientation carrier-embedded magnets and the second row of the
second directional orientation carrier-embedded magnets, wherein
the row of the fourth directional orientation carrier-embedded
magnets is perpendicular to the second row of the second
directional orientation carrier-embedded magnets. A shunt carrier
block is connected between the second row of the second directional
orientation carrier-embedded magnets and the row of the third
directional orientation carrier-embedded magnets, wherein the
second row of the second directional orientation carrier-embedded
magnets is perpendicular to the row of the third directional
orientation carrier-embedded magnets. A shunt carrier block is
connected between the row of the third directional orientation
carrier-embedded magnets and the first row of the second
directional orientation carrier-embedded magnets, wherein the row
of the third directional orientation carrier-embedded magnets is
perpendicular to the first row of the second directional
orientation carrier-embedded magnets.
[0024] With yet another embodiment of a stator magnet module, the
stator magnet module includes a row of second directional
orientation carrier-embedded magnets, a first row of fourth
directional orientation carrier-embedded magnets, a second row of
fourth directional orientation carrier-embedded magnets, and a row
of first directional orientation carrier-embedded magnets. A shunt
carrier block is connected between the row of the second
directional orientation carrier-embedded magnets and the first row
of the fourth directional orientation carrier-embedded magnets,
wherein the row of the second directional orientation
carrier-embedded magnets is perpendicular to the first row of the
fourth directional orientation carrier-embedded magnets. A shunt
carrier block is connected between the first row of the fourth
directional orientation carrier-embedded magnets and the row of the
first directional orientation carrier-embedded magnets, wherein the
second row of the fourth directional orientation carrier-embedded
magnets is perpendicular to the row of the first directional
orientation carrier-embedded magnets, A shunt carrier block is
connected between the row of the first directional orientation
carrier-embedded magnets and the second row of the fourth
directional orientation carrier-embedded magnets, wherein the row
of the first directional orientation carrier-embedded magnets is
perpendicular to the second row of the fourth directional
orientation carrier-embedded magnets. A shunt carrier block is
connected between the second row of the fourth directional
orientation carrier-embedded magnets and the row of the second
directional orientation carrier-embedded magnets, wherein the
second row of the fourth directional orientation carrier-embedded
magnets is perpendicular to the row of the second directional
orientation carrier-embedded magnets.
[0025] A tunnel bearing assembly is provided, supporting the
armature, wherein the tunnel bearing assembly includes
wire-reception channels.
[0026] The above brief description sets forth rather broadly the
more important features of the present invention in order that the
detailed description thereof that follows may be better understood,
and in order that the present contributions to the art may be
better appreciated. There are, of course, additional features of
the invention that will be described hereinafter and which will be
for the subject matter of the claims appended hereto.
[0027] In this respect, before explaining a number of preferred
embodiments of the invention in detail, it is understood that the
invention is not limited in its application to the details of the
construction and to the arrangements of the components set forth in
the following description or illustrated in the drawings. The
invention is capable of other embodiments and of being practiced
and carried out in various ways. Also, it is to be understood, that
the phraseology and terminology employed herein are for the purpose
of description and should not be regarded as limiting.
[0028] As such, those skilled in the art will appreciate that the
conception, upon which disclosure is based, may readily be utilized
as a basis for designing other structures, methods, and systems for
carrying out the several purposes of the present invention. It is
important, therefore, that the claims be regarded as including such
equivalent constructions insofar as they do not depart from the
spirit and scope of the present invention.
[0029] It is therefore an object of the present invention to
provide a new and improved liquid cooled DC motor apparatus which
has all of the advantages of the prior art and none of the
disadvantages.
[0030] It is another object of the present invention to provide a
new and improved liquid cooled DC motor apparatus which may be
easily and efficiently manufactured and marketed.
[0031] It is a further object of the present invention to provide a
new and improved liquid cooled DC motor apparatus which is of
durable and reliable construction.
[0032] An even further object of the present invention is to
provide a new and improved liquid cooled DC motor apparatus which
is susceptible of a low cost of manufacture with regard to both
materials and labor, and which accordingly is then susceptible of
low prices of sale to the consuming public, thereby making such
liquid cooled DC motor apparatus available to the buying
public.
[0033] Still yet a further object of the present invention is to
provide a new and improved DC motor apparatus which is provided
with a liquid cooling system.
[0034] Still another object of the present invention is to provide
a new and improved liquid cooled DC motor apparatus that provides a
stator comprised of a plurality of stator magnet modules.
[0035] Yet another object of the present invention is to provide a
new and improved liquid cooled DC motor apparatus which has an
armature that includes additional armature pole portions.
[0036] Even another object of the present invention is to provide a
new and improved liquid cooled DC motor apparatus that has opposite
armature pole portions having the same winding configurations.
[0037] Still a further object of the present invention is to
provide a new and improved liquid cooled DC motor apparatus which
employs roller brushes.
[0038] Yet another object of the present invention is to provide a
new and improved liquid cooled DC motor apparatus that provides a
tunnel bearing assembly.
[0039] Still another object of the present invention is to provide
a new and improved liquid cooled DC motor apparatus which provides
a brush advance/retard mechanism.
[0040] These together with still other objects of the invention,
along with the various features of novelty which characterize the
invention, are pointed out with particularity in the claims annexed
to and forming a part of this disclosure. For a better
understanding of the invention, its operating advantages and the
specific objects attained by its uses, reference should be had to
the accompanying drawings and descriptive matter in which there are
illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] The invention will be better understood and the above
objects as well as objects other than those set forth above will
become more apparent after a study of the following detailed
description thereof. Such description makes reference to the
annexed drawing wherein:
[0042] FIG. 1 is a schematic view of a PRIOR ART direct current
(DC) powered electric motor.
[0043] FIG. 2 is a side view of a first embodiment of the liquid
cooled DC motor apparatus of the invention.
[0044] FIG. 3 is a front view of the embodiment of the liquid
cooled DC motor apparatus of FIG. 2 taken along line 3-3
thereof.
[0045] FIG. 4 is a rear view of the embodiment of the liquid cooled
DC motor apparatus of FIG. 2 taken along line 4-4 thereof.
[0046] FIG. 5 is a cross-sectional view of the embodiment of the
invention shown in FIG. 4 taken along 5-5 thereof.
[0047] FIG. 5A is an enlarged fragmentary view of the portion
indicated in FIG. 5 by circle 5A.
[0048] FIG. 5B is a schematic assembly view of the fragmentary
portion of FIG. 5A.
[0049] FIG. 6 is a cross-sectional view of the embodiment of the
invention shown in FIG. 5 taken along line 6-6 thereof, wherein the
armature includes two armature winding portions and wherein the
stator includes four stator magnet modules.
[0050] FIG. 7 is a cross-sectional view of a second embodiment of
the invention which includes an armature which includes four
armature winding portions and wherein the stator includes four
stator magnet modules.
[0051] FIG. 8 is a cross-sectional view of a third embodiment of
the invention which includes an armature which includes three
armature winding portions, and wherein the stator includes four
stator magnet modules.
[0052] FIG. 9 is a rear view of a brush advance/retard mechanism
used with the embodiment of the invention shown in FIG. 8, wherein
four roller brush assemblies are shown.
[0053] FIG. 10 illustrates an intense magnetic flux pattern
provided by four stator magnet modules of the invention.
[0054] FIG. 11 is a rear view of a fourth embodiment of the
invention which includes an armature having three armature winding
portions and two roller brush assemblies.
[0055] FIG. 12 is a perspective view of a stator assembly of the
invention which includes two stator magnet modules.
[0056] FIG. 13 is a perspective view showing the stator assembly in
FIG. 12 employed in a DC motor that is powered by a battery.
[0057] FIG. 14 is a perspective view of the tunnel bearing assembly
according to the invention that includes wire-reception channels
for electric wires that connect with contacts for the roller brush
assemblies.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0058] With reference to the drawings, a new and improved liquid
cooled DC motor apparatus embodying the principles and concepts of
the present invention will be described.
[0059] Turning to FIGS. 2-6, there is shown a first embodiment of
the liquid cooled DC motor apparatus of the invention generally
designated by reference numeral 10. In the first embodiment, liquid
cooled DC motor apparatus 10 includes a motor housing assembly 32
which includes an outer chamber portion and an inner,
armature-reception chamber portion 35. At least one pair of stator
magnet modules are housed within the outer chamber portion, and at
least one pair of shunt members are housed within the outer chamber
portion between the stator magnet modules. The stator magnet
modules include permanent magnets. An armature is housed in the
inner, armature-reception chamber portion 35, wherein the armature
is centrally located with respect to the stator magnet modules,
such that the stator magnet modules are arrayed peripherally around
the armature. The armature includes at least one pair of armature
pole portions 38, and the at least one pair of armature pole
portions 38 are wound with same-directional windings. A commutator
27 is connected to the armature, and the commutator 27 includes at
least one pair of commutator contacts 29. The number of pairs of
commutator contacts 29 is equal to the number pairs of the armature
pole portions 38. A brush advance/retard mechanism is supported by
the motor housing assembly 32, and the brush advance/retard
mechanism includes roller brushes 56 for contacting the commutator
contacts 29.
[0060] The multiple armature pole portions provide maximizing the
efficiency of available electric current. The multiple stator
magnet modules provide for maximum torque. The brush advance/retard
mechanism allows for maximum performance at different motor speeds
and loads. The roller brushes 56 last longer than conventional
sliding brushes.
[0061] Preferably, the DC motor apparatus of the invention includes
a liquid cooling system. More specifically, the motor housing
assembly 32 includes an outer liquid-tight coolant chamber 34 and
the inner, armature-reception chamber portion 35. The stator magnet
modules are housed within the liquid-tight coolant chamber 34, and
the shunt members are housed within the liquid-tight coolant
chamber 34 between the stator magnet modules. In addition,
housing-to-pump conduits 44 are connected to the liquid-tight
coolant chamber 34. A coolant pump 12 is connected to the
housing-to-pump conduits 44. A pump-to-radiator conduit 46 is
connected to the coolant pump 12. A coolant fluid radiator 14 is
connected to the pump-to-radiator conduit 46, and
radiator-to-housing conduits 48 are connected between the coolant
fluid radiator 14 and the liquid-tight coolant chamber 34.
[0062] The liquid cooling system for the stator magnet modules and
the shunt members provides greater operating efficiency for the DC
motor of the invention. More specifically, the liquid cooling
permits the use of high powered motors, such as are useful for
vehicle propulsion. For vehicle propulsion, a battery 11, such as
shown in FIG. 13, is used for powering the DC motor apparatus 10 of
the invention.
[0063] Preferably, the shunt members include at least one
north-pole-to-north-pole, module-to-module shunt member 30 and at
least one south-pole-to-south-pole, module-to-module shunt member
31. The same-directional windings of the armature pole portions can
include right-handed windings, or the same-directional windings can
include left-handed windings. In the drawing figures, an armature
pole portion that has a right-handed winding is labelled RH, and an
armature pole portion that has a left-handed winding is labelled
LH.
[0064] Preferably, the motor housing assembly 32 includes an outer
longitudinal housing portion 50, an inner longitudinal housing
portion 51, a first transverse housing portion 52, and a second
transverse housing portion 54. In this respect, the outer
longitudinal housing portion 50, the inner longitudinal housing
portion 51, a portion of the first transverse housing portion 52,
and a portion of the second transverse housing portion 54 define
the liquid-tight coolant chamber 34. In addition, the inner
longitudinal housing portion 51, a portion of the first transverse
housing portion 52, and a portion of the second transverse housing
portion 54 define the inner, armature-reception chamber portion
35.
[0065] As shown in FIGS. 2 and 3, the liquid cooling system
operates when the DC motor apparatus 10 of the invention is fully
assembled. The shunt members and the stator magnet modules are
contained in the liquid-tight coolant chamber 34. The coolant pump
12 pumps a liquid coolant, such as a vehicle antifreeze solution,
through the housing-to-pump conduits 44, and past the shunt members
and the stator magnet modules, whereby the liquid coolant picks up
heat from the shunt members and the stator magnet modules. The
heated liquid coolant then flows through the radiator-to-housing
conduits 48 and through the coolant fluid radiator 14 at which heat
exchange with ambient air takes place, and the liquid coolant is
cooled by the ambient air that contacts the coolant fluid radiator
14. Then, the cooled liquid coolant flows through the
pump-to-radiator conduit 46, and the liquid coolant recycles as
long and the coolant pump 12 operates.
[0066] With the DC motor apparatus 10 of the present invention, the
number of sets of stator magnet modules determines the number of
commutator contacts 29 that are needed for each set of armature
pole portions 38. For example, with an armature having one set of
armature pole portions 38, along with one set of stator magnet
modules, there are two commutator contacts 29 for the one set of
armature pole portions 38. As another example, for an armature
having one set of armature pole portions 38, along with two sets of
stator magnet modules, there are four commutator contacts 29 for
the one set of armature pole portions 38.
[0067] Stated somewhat differently, the formula is to add another
whole set of commutator contacts 29 to the original contacts for
each new set of N+S permanent magnets added (that is for each new
set of stator magnet modules added), plus another set of roller
brushes 56. Each new set of N+S permanent magnets added, acts as if
it is an additional motor, so a new set of contacts on the
commutator 27 must be added, plus a new set of roller brushes 56
evenly spaced around the commutator 27. If one starts with a one
set of N+S permanent magnet motor, each set of commutator 27 are
sequentially numbered to coincide with the number of the poles of
the armature, that is called the first set of commutator contacts
29. When the next set of N+S permanent magnets are added, a new
second set of commutator contacts 29 are added to the commutator
27, that are also sequentially numbered, and must be wired
(connected) to the same number position of the first set of
contacts. For a three pole armature, the contacts on the commutator
27 are 1 is connected to 1, 2 is connected to 2, 3 is connected to
3, etc. In addition, a new set of brushes is to be added, so that
they are equally distanced around the commutator 27, and so on.
[0068] With respect to the number of roller brushes 56, the number
of roller brushes 56 is determined by the number of sets of stator
magnet modules. For example, one set of stator magnet modules
requires two roller brushes 56; two sets of stator magnet modules
requires four roller brushes 56; and three sets of stator magnet
modules requires six roller brushes 56.
[0069] Another way to make a DC motor apparatus 10 of the invention
is to use just two roller brushes 56 connected 90 degrees apart. If
another set of permanent magnets were added, the brushes would be
45 degrees apart, and so on. Because the same sequentially numbered
contacts are connected together, an extra set of brushes is not
needed. With the smaller number of brushes and small width of the
surface area of the increased number of commutator contacts 29, the
diameter of the commutator 27 would have to be increased, so that
the surface area of the contacts would be restored, and full
electrical saturation of the pole windings can take place. Even if
the motor were built with the proper number of brushes, the
increased diameter of the commutator 27 would help to saturate the
pole windings at high speed revolutions of the armature.
[0070] The limit of stator magnet modules is determined by the
physical size of the DC motor apparatus 10 and the size of the
stator magnet modules.
[0071] Considering an armature having three armature pole portions
38, there are three commutator contacts 29 for each set of stator
magnet modules. Three commutator contacts 29 have to be added for
each new set of stator magnet modules. That is, there are six
commutator contacts 29 required when there are two sets of stator
magnet modules employed. The general rule is to add another whole
set of commutator contacts 29 to the original commutator contacts
29 for each new set of stator magnet modules that are added.
[0072] For purposes of convenience, the North pole of a magnet is
indicated in the drawings by a plus sign (+), and the South pole of
a magnet is indicated in the drawings by a minus sign (-).
Generally, a magnet has a North pole and a South pole, that is,
generally a magnet has a North magnetic flux and a South magnetic
flux. It is noted with interest, however, that the
north-pole-to-north-pole, module-to-module shunt member 30 has a
pure North magnetic flux, and the south-pole-to-south-pole,
module-to-module shunt member 31 has a pure South magnetic flux.
Moreover, all of the flux fields stay within the motor because of
the pure attraction of the North and South flux fields to each
other, making the flux fields 38 more powerful, as shown in FIG.
10.
[0073] Preferably, the brush advance/retard mechanism includes a
roller brush support plate 20 movably connected to the motor
housing assembly 32. The roller brush support plate 20 includes
plate adjustment slots 22, and the roller brush support plate 20
includes peripheral plate teeth 28. Plate guide fasteners 24 are
received through the plate adjustment slots 22 and are connected to
the motor housing assembly 32 substantially as shown (FIGS. 5A and
5B). Roller brush assemblies 58 are connected to the roller brush
support plate 20, wherein the roller brush assemblies 58 include
the roller brushes 56 and brush bias springs 60 for biasing the
roller brushes 56 against the commutator contacts 29.
[0074] A plate drive assembly 23, supported by the motor housing
assembly 32, is provided for movably adjusting the angular position
of roller brush support plate 20, wherein the plate drive assembly
23 includes a small electric servo motor 25 for driving a brush
advance/retard gear 26 which, in turn, engages the peripheral plate
teeth 28.
[0075] The brush advance/retard mechanism is operated to have a
similar effect as the spark retard and advance mechanism of an
internal combustion engine. With respect to the DC motor apparatus
10 of the invention, such a motor works most efficiently when the
power pulse is delivered to match the conditions. For example, when
the motor starts to pull, the power pulse is delivered at a
different (usually retarded) time. Conversely, when the motor is
operating at a high speed, the power pulse is delivered with
different timing (usually advanced). Generally, the brush
advance/retard mechanism is operated to control the relationship of
the brushes to the permanent magnets.
[0076] More specifically, to adjust the brush advance/retard
mechanism, the brush advance/retard gear 26 is operated to move the
peripheral plate teeth 28, thereby moving the roller brush support
plate 20 around the commutator 27. When the roller brush support
plate 20 is so moved, the plate guide fasteners 24 ride in the
plate adjustment slots 22. Spacer 24a and washer 24b help to
suitably slidably support the brush support plate 20 relative to
housing 32. The operation of the brush advance/retard gear 26 by
servo motor 25 preferably is precisely controlled by a conventional
computerized electronic speed controller the details and operation
of which are well known and outside the scope of the present
invention.
[0077] With respect to cooling features of the DC motor apparatus
10 of the invention, as stated above, the motor housing assembly 32
defines the liquid-tight coolant chamber 34. The housing-to-pump
conduits 44, the coolant pump 12, the pump-to-radiator conduit 46,
the coolant fluid radiator 14, and the radiator-to-housing conduits
48 provide a closed, liquid-tight region in which liquid coolant is
pumped through the liquid-tight coolant chamber 34 to pickup heat
from the motor, pumped through the coolant fluid radiator 14 to
radiate heat and have heat exchanged with the ambient environment,
and pumped back into the liquid-tight coolant chamber 34 after heat
has been removed from the liquid coolant at the coolant fluid
radiator 14.
[0078] Preferably, each stator magnet module includes a plurality
of cylindrical magnets, and a plurality of shunt blocks 40
retaining the cylindrical magnets.
[0079] A particular embodiment of the invention is shown in FIG. 6,
which includes four stator magnet modules and intervening shunt
members, all of which are arrayed as follows.
[0080] In FIG. 6, the farthest left stator magnet module includes a
first row of first directional orientation carrier-embedded magnets
36, a second row of first directional orientation carrier-embedded
magnets 36, a row of third directional orientation carrier-embedded
magnets 42, and a row of fourth directional orientation
carrier-embedded magnets 43. A shunt carrier block 40 is connected
between the first row of the first directional orientation
carrier-embedded magnets 36 and the row of fourth directional
orientation carrier-embedded magnets 43, wherein the first row of
the first directional orientation carrier-embedded magnets 36 is
oriented perpendicular to the row of the fourth directional
orientation carrier-embedded magnets 43. A shunt carrier block 40
is connected between the row of the fourth directional orientation
carrier-embedded magnets 43 and the second row of the first
directional orientation carrier-embedded magnets 36, wherein the
row of the fourth directional orientation carrier-embedded magnets
43 is oriented perpendicular to the second row of the first
directional orientation carrier-embedded magnets 36. A shunt
carrier block 40 is connected between the second row of the first
directional orientation carrier-embedded magnets 36 and the row of
the third directional orientation carrier-embedded magnets 42,
wherein the second row of the first directional orientation
carrier-embedded magnets 36 is oriented perpendicular to the row of
the third directional orientation carrier-embedded magnets 42. A
shunt carrier block 40 is connected between the row of the third
directional orientation carrier-embedded magnets 42 and the first
row of the first directional orientation carrier-embedded magnets
36, wherein the row of the third directional orientation
carrier-embedded magnets 42 is oriented perpendicular to the first
row of the first directional orientation carrier-embedded magnets
36.
[0081] In FIG. 6, the topmost stator magnet module includes a row
of second directional orientation carrier-embedded magnets 37, a
first row of third directional orientation carrier-embedded magnets
42, a second row of third directional orientation carrier-embedded
magnets 42, and a row of first directional orientation
carrier-embedded magnets 36. A shunt carrier block 40 is connected
between the row of the second directional orientation
carrier-embedded magnets 37 and the first row of the third
directional orientation carrier-embedded magnets 42, wherein the
row of the second directional orientation carrier-embedded magnets
37 is perpendicular to the first row of the third directional
orientation carrier-embedded magnets 42. A shunt carrier block 40
is connected between the first row of the third directional
orientation carrier-embedded magnets 42 and the row of the first
directional orientation carrier-embedded magnets 36, wherein the
first row of the third directional orientation carrier-embedded
magnets 42 is perpendicular to the row of the first directional
orientation carrier-embedded magnets 36. A shunt carrier block 40
is connected between the row of the first directional orientation
carrier-embedded magnets 36 and the second row of the third
directional orientation carrier-embedded magnets 42, wherein the
row of the first directional orientation carrier-embedded magnets
36 is perpendicular to the second row of the third directional
orientation carrier-embedded magnets 42. A shunt carrier block 40
is connected between the second row of the third directional
orientation carrier-embedded magnets 42 and the second directional
orientation carrier-embedded magnets 37, wherein the second row of
the third directional orientation carrier-embedded magnets 42 is
perpendicular to the row of the second directional orientation
carrier-embedded magnets 37.
[0082] In FIG. 6, the farthest right stator magnet module includes
first row of second directional orientation carrier-embedded
magnets 37, a second row of the second directional orientation
carrier-embedded magnets 37, a row of fourth directional
orientation carrier-embedded magnets 43, and a row of third
directional orientation carrier-embedded magnets 42. A shunt
carrier block 40 is connected between the first row of the second
directional orientation carrier-embedded magnets 37 and the row of
the fourth directional orientation carrier-embedded magnets 43,
wherein the first row of the second directional orientation
carrier-embedded magnets 37 is perpendicular to the row of the
fourth directional orientation carrier-embedded magnets 43. A shunt
carrier block 40 is connected between the row of the fourth
directional orientation carrier-embedded magnets 43 and the second
row of the second directional orientation carrier-embedded magnets
37, wherein the row of the fourth directional orientation
carrier-embedded magnets 43 is perpendicular to the second row of
the second directional orientation carrier-embedded magnets 37. A
shunt carrier block 40 is connected between the second row of the
second directional orientation carrier-embedded magnets 37 and the
row of the third directional orientation carrier-embedded magnets
42, wherein the second row of the second directional orientation
carrier-embedded magnets 37 is perpendicular to the row of the
third directional orientation carrier-embedded magnets 42. A shunt
carrier block 40 is connected between the row of the third
directional orientation carrier-embedded magnets 42 and the first
row of the second directional orientation carrier-embedded magnets
37, wherein the row of the third directional orientation
carrier-embedded magnets 42 is perpendicular to the first row of
the second directional orientation carrier-embedded magnets 37.
[0083] In FIG. 6, the bottom most stator magnet module includes a
row of second directional orientation carrier-embedded magnets 37,
a first row of fourth directional orientation carrier-embedded
magnets 43, a second row of fourth directional orientation
carrier-embedded magnets 43, and a row of first directional
orientation carrier-embedded magnets 36. A shunt carrier block 40
is connected between the row of the second directional orientation
carrier-embedded magnets 37 and the first row of the fourth
directional orientation carrier-embedded magnets 43, wherein the
row of the second directional orientation carrier-embedded magnets
37 is perpendicular to the first row of the fourth directional
orientation carrier-embedded magnets 43. A shunt carrier block 40
is connected between the first row of the fourth directional
orientation carrier-embedded magnets 43 and the row of the first
directional orientation carrier-embedded magnets 36, wherein the
second row of the fourth directional orientation carrier-embedded
magnets 43 is perpendicular to the row of the first directional
orientation carrier-embedded magnets 36, A shunt carrier block 40
is connected between the row of the first directional orientation
carrier-embedded magnets 36 and the second row of the fourth
directional orientation carrier-embedded magnets 43, wherein the
row of the first directional orientation carrier-embedded magnets
36 is perpendicular to the second row of the fourth directional
orientation carrier-embedded magnets 43. A shunt carrier block 40
is connected between the second row of the fourth directional
orientation carrier-embedded magnets 43 and the row of the second
directional orientation carrier-embedded magnets 37, wherein the
second row of the fourth directional orientation carrier-embedded
magnets 43 is perpendicular to the row of the second directional
orientation carrier-embedded magnets 37.
[0084] As shown in FIG. 14, a tunnel bearing assembly 16 is
provided, supporting the armature, wherein the tunnel bearing
assembly 16 includes wire-reception channels 18. The tunnel bearing
assembly puts the bearings close to the armature for better
stability and load supporting.
[0085] The components of the liquid cooled DC motor apparatus of
the invention can be made from inexpensive and durable metal,
ceramic, and plastic materials.
[0086] As to the manner of usage and operation of the instant
invention, the same is apparent from the above disclosure, and
accordingly, no further discussion relative to the manner of usage
and operation need be provided.
[0087] It is apparent from the above that the present invention
accomplishes all of the objects set forth by providing a new and
improved DC motor apparatus that is low in cost, relatively simple
in design and operation, and which is provided with a liquid
cooling system. With the invention, a liquid cooled DC motor
apparatus provides a stator comprised of a plurality of stator
magnet modules. With the invention, a liquid cooled DC motor
apparatus is provided which has an armature that includes
additional armature pole portions. With the invention, a liquid
cooled DC motor apparatus is provided which has opposite armature
pole portions having the same winding configurations. With the
invention, a liquid cooled DC motor apparatus is provided which
employs roller brushes. With the invention, a liquid cooled DC
motor apparatus provides a tunnel bearing assembly. With the
invention, a liquid cooled DC motor apparatus provides a brush
advance/retard mechanism.
[0088] Thus, while the present invention has been shown in the
drawings and fully described above with particularity and detail in
connection with what is presently deemed to be the most practical
and preferred embodiment(s) of the invention, it will be apparent
to those of ordinary skill in the art that many modifications
thereof may be made without departing from the principles and
concepts set forth herein, including, but not limited to,
variations in size, materials, shape, form, function and manner of
operation, assembly and use.
[0089] Hence, the proper scope of the present invention should be
determined only by the broadest interpretation of the appended
claims so as to encompass all such modifications as well as all
relationships equivalent to those illustrated in the drawings and
described in the specification.
[0090] Finally, it will be appreciated that the purpose of the
annexed Abstract is to enable the U.S. Patent and Trademark Office
and the public generally, and especially the scientists, engineers
and practitioners in the art who are not familiar with patent or
legal terms or phraseology, to determine quickly from a cursory
inspection the nature and essence of the technical disclosure of
the application. Accordingly, the Abstract is neither intended to
define the invention or the application, which only is measured by
the claims, nor is it intended to be limiting as to the scope of
the invention in any way.
* * * * *