Wirelessly transferring power within an electric machine with actively rectified rotor windings
A stator defines multiple stator poles with associated stator windings. A rotor defines multiple rotor poles with associated rotor windings configured to be energized substantially by the stator. The rotor defines a rotor field energizable by magnetic fields produced by the stator windings to produce relative force between the rotor and the stator. An active rectifier is conductively coupled to one or more first rotor windings. The active rectifier is configured to control a direction of current flow through the one or more first rotor windings responsive to a signal received wirelessly from the stator by one or more second rotor windings.
1 . An electric machine comprising:
a stator including stator windings configured to be energized to define stator poles;
a rotor including rotor windings configured to be energized to define rotor poles that interact with the stator poles to produce relative force between the rotor and the stator, the rotor configured to be magnetically coupled to the stator to receive a power transfer signal wirelessly from the stator; and
an active rectifier rotationally fixed to the rotor and conductively coupled to one or more first rotor windings of the rotor windings, the active rectifier being configured to:
capture electrical energy from the power transfer signal, and
control current flow through the one or more first rotor windings by directing the electrical energy captured from the power transfer signal to the one or more first rotor windings,
wherein the active rectifier is included in one or more circuit boards mounted on the rotor, and wherein the one or more circuit boards are integrated into a rotor shaft of the rotor.
2 . The electric machine of claim 1 , further comprising an energy storage element coupled to the active rectifier, wherein the active rectifier is further configured to store the electrical energy captured from the power transfer signal in the energy storage element, and wherein the directing of the electrical energy to the one or more first rotor windings includes drawing the electrical energy stored on the energy storage element and directing the electrical energy drawn to the one or more first rotor windings.
3 . The electric machine of claim 1 , wherein the rotor further receives a data signal wirelessly from the stator, the data signal encoding control information for the active rectifier, and the active rectifier is further configured to control the current flow through the one or more first rotor windings responsive to the control information.
4 . The electric machine of claim 1 , wherein
the rotor further includes a rotor control unit configured to estimate an operating state of the stator, based on the power transfer signal, to determine control information; and
the active rectifier is further configured to control the current flow through the one or more first rotor windings responsive to the control information.
5 . The electric machine of claim 1 , wherein the active rectifier includes controllable switches that are configured to be selectively controlled to capture the electrical energy from the power transfer signal and to control the current flow through the one or more first rotor windings.
6 . The electric machine of claim 1 , comprising a controller configured to:
control current through the stator windings to energize the stator windings to define the stator poles and to wirelessly transmit the power transfer signal to the rotor.
7 . The electric machine of claim 1 , wherein the rotor comprises permanent magnets embedded within the rotor.
8 . The electric machine of claim 1 , wherein each rotor winding associated with one of the rotor poles is conductively coupled to a singular corresponding active rectifier.
9 . The electric machine of claim 1 , comprising a rotor control unit configured to:
extract, from the power transfer signal received wirelessly from the stator, a data signal indicative of an operating setpoint for the rotor; and
control switching operations of the active rectifier responsive to the operating setpoint.
10 . The electric machine of claim 1 , comprising a rotor control unit configured to:
estimate, based on the power transfer signal received wirelessly from the stator, an operating state of the stator; and
control switching operations of the active rectifier responsive to the estimated operating state.
11 . The electric machine of claim 1 , wherein n rotor windings of the rotor windings are conductively coupled to one another, and wherein the electric machine further comprises a controller configured to:
apply, to the stator windings, a voltage including n voltage components, each voltage component coupling to a respective one of the n rotor windings by magnetic fields produced by a current corresponding to the voltage component,
wherein the n voltage components are each characterized by a distinct phase, the distinct phases being separated from one another by about 360/n degrees.
12 . The electric machine of claim 11 , wherein the n rotor windings are included in different respective pole pairs of the rotor.
13 . The electric machine of claim 11 , wherein the active rectifier comprises a shared capacitor conductively coupled to each of the n rotor windings, the shared capacitor storing energy while the active rectifier controls the direction of current flow in each of the n rotor windings.
14 . The electric machine of claim 11 , wherein the rotor comprises n additional rotor windings,
wherein each of the n additional rotor windings is included in a pole pair with a corresponding one of the n rotor windings, and
wherein the n rotor windings are conductively coupled to the n additional rotor windings by the active rectifier.
15 . The electric machine of claim 1 , comprising
a low-pass filter conductively coupled to the active rectifier and to the one or more first rotor windings.
16 . The electric machine of claim 15 , wherein a DC output of the low-pass filter is conductively coupled to a DC output of the active rectifier.
17 . The electric machine of claim 1 , wherein the active rectifier is configured to produce a substantially DC current in a first subset of the rotor windings and a substantially oscillating current in a second, different subset of the rotor windings.
18 . A method of controlling a motor, the method comprising:
receiving, by a rotor, a power transfer signal wirelessly from a stator, the stator including stator windings configured to be energized to define stator poles and the rotor including rotor windings configured to be energized to define rotor poles that interact with the stator poles to produce relative force between the rotor and the stator;
capturing, by an active rectifier rotationally fixed to the rotor, electrical energy from the power transfer signal, wherein the active rectifier is conductively coupled to one or more first rotor windings of the rotor windings;
controlling, by the active rectifier, current flow through the one or more first rotor windings by directing the electrical energy captured from the power transfer signal to the one or more first rotor windings; and
receiving, by the rotor, a data signal wirelessly from the stator windings, the data signal encoding control information for the active rectifier, and a frequency of the data signal is independent of a frequency of a torque control signal sent to the stator windings to produce the relative force.
19 . The method of claim 18 , further comprising:
storing the electrical energy captured from the power transfer signal, by the active rectifier, in an energy storage element, the energy storage element coupled to the active rectifier,
wherein the directing of the electrical energy to the one or more first rotor windings includes drawing the electrical energy stored on the energy storage element and directing the electrical energy that is drawn to the one or more first rotor windings.
20 . The method of claim 18 ,
wherein the controlling, by the active rectifier, of the current flow through the one or more first rotor windings is responsive to the control information.
21 . The method of claim 18 , further comprising:
estimating, by a rotor control unit of the rotor, an operating state of the stator, based on the power transfer signal, to determine control information; and
wherein the controlling, by the active rectifier, of the current flow through the one or more first rotor windings is responsive to the control information.
22 . The method of claim 18 , further comprising:
selectively controlling controllable switches of the active rectifier to capture the electrical energy from the power transfer signal and to control the current flow through the one or more first rotor windings.
23 . The method of claim 18 , further comprising:
controlling by a controller, current through the stator windings to energize the stator windings to define the stator poles and to wirelessly transmit the power transfer signal to the rotor.
24 . The method of claim 23 , wherein, to control the current through the stator windings to energize the stator windings to define the stator poles, the controller sends a torque control signal to the stator windings at a current angle measured relative to a closest one of the rotor poles.
25 . The method of claim 23 , wherein, to control the current through the stator windings to wirelessly transmit the power transfer signal to the rotor, the controller sends the power transfer signal through the stator windings, the power transfer signal being different from the torque control signal.
26 . The method of claim 23 , further comprising:
controlling, by the controller, the current through the stator windings to send the data signal through the stator windings to wirelessly transmit the data signal to the rotor, the data signal being different from the torque control signal and including control information.
27 . The method of claim 24 , further comprising:
adjusting, by the controller, the current angle in response to operating conditions; and
adjusting, by the controller, a current magnitude of the torque control signal in response to the operating conditions,
wherein rotation of the rotor is maintained in synchronicity with magnetic fields of the stator poles produced by the stator windings during operation.
28 . The method of claim 18 , further comprising:
extracting, by a rotor control unit of the rotor, the data signal, the data signal indicative of an operating setpoint for the rotor from the power transfer signal received wirelessly from the stator; and
controlling, by the rotor control unit, switching operations of the active rectifier responsive to the operating setpoint.
29 . The method of claim 28 , wherein the data signal is embedded in the power transfer signal by amplitude modulation or frequency modulation.
30 . The method of claim 18 , further comprising:
estimating, by a rotor control unit of the rotor, an operating state of the stator based on the power transfer signal received wirelessly from the stator; and
controlling, by the rotor control unit, switching operations of the active rectifier responsive to the estimated operating state.
31 . The method of claim 18 , wherein n rotor windings of the rotor windings are conductively coupled to one another, and wherein the method further comprising:
applying, to the stator windings, a voltage including n voltage components, each voltage component coupling to a respective one of the n rotor windings by magnetic fields produced by a current corresponding to the voltage component,
wherein the n voltage components are each characterized by a distinct phase, the distinct phases being separated from one another by about 360/n degrees.
32 . The method of claim 18 , comprising
filtering signals, by a low-pass filter, between the active rectifier and the one or more first rotor windings, where the low-pass filter is conductively coupled to the active rectifier and to the one or more first rotor windings.
33 . The method of claim 18 , further comprising:
introducing, by the active rectifier, a zero-sequence into a periodic voltage induced in the one or more first rotor windings by the stator windings.
34 . The method of claim 18 , further comprising:
causing, by the active rectifier, in the one or more first rotor windings, a periodic voltage shifted about 90 degrees compared to a corresponding periodic voltage in the stator windings.
35 . The method of claim 18 , further comprising:
producing, by the active rectifier, a non-zero DC current as the current flow through the one or more first rotor windings.
36 . The method of claim 18 , wherein magnetic fields associated with the stator poles and produced by the stator windings include a D component substantially in-line with a corresponding rotor pole, and a Q component 90° ahead of the corresponding rotor pole within an electrical reference frame, and
wherein the power transfer signal is included in modulations of the D component, in modulations of the Q component, or in modulations of both the D component and the Q component.
37 . The method of claim 18 , wherein magnetic fields associated with the stator poles and produced by the stator windings include a D component substantially in-line with a corresponding rotor pole, a Q component 90° ahead of the corresponding rotor pole within an electrical reference frame, and a z component orthogonal to the D component and the Q component, and
wherein the power transfer signal is included in modulations of the z component.
38 . The method of claim 18 , wherein the power transfer signal provides a wireless transfer of power for energizing the one or more first rotor windings,
wherein the power transfer signal is received wirelessly along a first controllable axis on which the stator and rotor are inductively coupled, and
wherein the data signal is received wirelessly along a second, different controllable axis on which the stator and rotor are coupled.
39 . The method of claim 18 , wherein the power transfer signal provides a wireless transfer of power for energizing the one or more first rotor windings and the rotor further receives the data signal wirelessly from the stator windings, the data signal encoding control information for the active rectifier,
wherein the power transfer signal and the data signal are received wirelessly along a first controllable axis on which the stator and rotor are wirelessly magnetically coupled, the first controllable axis being an axis of a rotational reference frame.
40 . The method of claim 18 , wherein the power transfer signal is received wirelessly by the rotor along a controllable axis on which the stator and rotor are magnetically coupled based on modulated amplitudes of magnetic fields of the stator, modulated frequencies of magnetic fields of the stator, or both.
41 . The method of claim 18 , further comprising:
producing, by the active rectifier, a substantially DC current in a first subset of the rotor windings and a substantially oscillating current in a second, different subset of the rotor windings.
42 . The method of claim 18 , further comprising applying n periodic voltages to the stator windings,
wherein the n periodic voltages are timed to couple respectively, by stator currents associated with the n periodic voltages, to n rotor windings, the n rotor windings conductively coupled to one another, and
wherein the n periodic voltages are each characterized by a distinct phase, the distinct phases being separated from one another by about 360/n degrees.
43 . The method of claim 18 , further, wherein the active rectifier is controlled to apply low-pass filtering to voltages in the one or more first rotor windings.
44 . An electric machine comprising:
a stator including stator windings configured to be energized to define stator poles;
a rotor including rotor windings configured to be energized to define rotor poles that interact with the stator poles to produce relative force between the rotor and the stator, the rotor configured to be magnetically coupled to the stator to receive a power transfer signal wirelessly from the stator, wherein each rotor winding associated with one of the rotor poles is conductively coupled to a singular corresponding active rectifier; and
an active rectifier rotationally fixed to the rotor and conductively coupled to one or more first rotor windings of the rotor windings, the active rectifier being configured to:
capture electrical energy from the power transfer signal, and
control current flow through the one or more first rotor windings by directing the electrical energy captured from the power transfer signal to the one or more first rotor windings.
45 . An electric machine comprising:
a stator including stator windings configured to be energized to define stator poles;
a rotor including rotor windings configured to be energized to define rotor poles that interact with the stator poles to produce relative force between the rotor and the stator, the rotor configured to be magnetically coupled to the stator to receive a power transfer signal wirelessly from the stator;
an active rectifier rotationally fixed to the rotor and conductively coupled to one or more first rotor windings of the rotor windings, the active rectifier being configured to:
capture electrical energy from the power transfer signal, and
control current flow through the one or more first rotor windings by directing the electrical energy captured from the power transfer signal to the one or more first rotor windings; and
a rotor control unit configured to:
extract, from the power transfer signal received wirelessly from the stator, a data signal indicative of an operating setpoint for the rotor; and
control switching operations of the active rectifier responsive to the operating setpoint.
46 . An electric machine comprising:
a stator including stator windings configured to be energized to define stator poles;
a rotor including rotor windings configured to be energized to define rotor poles that interact with the stator poles to produce relative force between the rotor and the stator, the rotor configured to be magnetically coupled to the stator to receive a power transfer signal wirelessly from the stator;
an active rectifier rotationally fixed to the rotor and conductively coupled to one or more first rotor windings of the rotor windings, the active rectifier being configured to:
capture electrical energy from the power transfer signal, and
control current flow through the one or more first rotor windings by directing the electrical energy captured from the power transfer signal to the one or more first rotor windings; and
a rotor control unit configured to:
estimate, based on the power transfer signal received wirelessly from the stator, an operating state of the stator; and
control switching operations of the active rectifier responsive to the estimated operating state.
47 . An electric machine comprising:
a stator including stator windings configured to be energized to define stator poles;
a rotor including rotor windings configured to be energized to define rotor poles that interact with the stator poles to produce relative force between the rotor and the stator, the rotor configured to be magnetically coupled to the stator to receive a power transfer signal wirelessly from the stator;
an active rectifier rotationally fixed to the rotor and conductively coupled to one or more first rotor windings of the rotor windings, the active rectifier being configured to:
capture electrical energy from the power transfer signal, and
control current flow through the one or more first rotor windings by directing the electrical energy captured from the power transfer signal to the one or more first rotor windings; and
a low-pass filter conductively coupled to the active rectifier and to the one or more first rotor windings.
48 . An electric machine comprising:
a stator including stator windings configured to be energized to define stator poles;
a rotor including rotor windings configured to be energized to define rotor poles that interact with the stator poles to produce relative force between the rotor and the stator, the rotor configured to be magnetically coupled to the stator to receive a power transfer signal wirelessly from the stator; and
an active rectifier rotationally fixed to the rotor and conductively coupled to one or more first rotor windings of the rotor windings, the active rectifier being configured to:
capture electrical energy from the power transfer signal, and
control current flow through the one or more first rotor windings by directing the electrical energy captured from the power transfer signal to the one or more first rotor windings,
wherein the active rectifier is configured to produce a substantially DC current in a first subset of the rotor windings and a substantially oscillating current in a second, different subset of the rotor windings.
49 . A method of controlling a motor, the method comprising:
receiving, by a rotor, a power transfer signal wirelessly from a stator, the stator including stator windings configured to be energized to define stator poles and the rotor including rotor windings configured to be energized to define rotor poles that interact with the stator poles to produce relative force between the rotor and the stator;
capturing, by an active rectifier rotationally fixed to the rotor, electrical energy from the power transfer signal, wherein the active rectifier is conductively coupled to one or more first rotor windings of the rotor windings;
controlling, by the active rectifier, current flow through the one or more first rotor windings by directing the electrical energy captured from the power transfer signal to the one or more first rotor windings;
extracting, by a rotor control unit of the rotor, a data signal indicative of an operating setpoint for the rotor from the power transfer signal received wirelessly from the stator; and
controlling, by the rotor control unit, switching operations of the active rectifier responsive to the operating setpoint.
50 . A method of controlling a motor, the method comprising:
receiving, by a rotor, a power transfer signal wirelessly from a stator, the stator including stator windings configured to be energized to define stator poles and the rotor including rotor windings configured to be energized to define rotor poles that interact with the stator poles to produce relative force between the rotor and the stator;
capturing, by an active rectifier rotationally fixed to the rotor, electrical energy from the power transfer signal, wherein the active rectifier is conductively coupled to one or more first rotor windings of the rotor windings;
controlling, by the active rectifier, current flow through the one or more first rotor windings by directing the electrical energy captured from the power transfer signal to the one or more first rotor windings; and
filtering signals, by a low-pass filter, between the active rectifier and the one or more first rotor windings, where the low-pass filter is conductively coupled to the active rectifier and to the one or more first rotor windings.
51 . A method of controlling a motor, the method comprising:
receiving, by a rotor, a power transfer signal wirelessly from a stator, the stator including stator windings configured to be energized to define stator poles and the rotor including rotor windings configured to be energized to define rotor poles that interact with the stator poles to produce relative force between the rotor and the stator;
capturing, by an active rectifier rotationally fixed to the rotor, electrical energy from the power transfer signal, wherein the active rectifier is conductively coupled to one or more first rotor windings of the rotor windings;
controlling, by the active rectifier, current flow through the one or more first rotor windings by directing the electrical energy captured from the power transfer signal to the one or more first rotor windings; and
introducing, by the active rectifier, a zero-sequence into a periodic voltage induced in the one or more first rotor windings by the stator windings.
52 . A method of controlling a motor, the method comprising:
receiving, by a rotor, a power transfer signal wirelessly from a stator, the stator including stator windings configured to be energized to define stator poles and the rotor including rotor windings configured to be energized to define rotor poles that interact with the stator poles to produce relative force between the rotor and the stator;
capturing, by an active rectifier rotationally fixed to the rotor, electrical energy from the power transfer signal, wherein the active rectifier is conductively coupled to one or more first rotor windings of the rotor windings;
controlling, by the active rectifier, current flow through the one or more first rotor windings by directing the electrical energy captured from the power transfer signal to the one or more first rotor windings; and
causing, by the active rectifier, in the one or more first rotor windings, a periodic voltage shifted about 90 degrees compared to a corresponding periodic voltage in the stator windings.
53 . A method of controlling a motor, the method comprising:
receiving, by a rotor, a power transfer signal wirelessly from a stator, the stator including stator windings configured to be energized to define stator poles and the rotor including rotor windings configured to be energized to define rotor poles that interact with the stator poles to produce relative force between the rotor and the stator;
capturing, by an active rectifier rotationally fixed to the rotor, electrical energy from the power transfer signal, wherein the active rectifier is conductively coupled to one or more first rotor windings of the rotor windings; and
controlling, by the active rectifier, current flow through the one or more first rotor windings by directing the electrical energy captured from the power transfer signal to the one or more first rotor windings,
wherein the power transfer signal is received wirelessly by the rotor along a controllable axis on which the stator and rotor are magnetically coupled based on modulated amplitudes of magnetic fields of the stator, modulated frequencies of magnetic fields of the stator, or both.
54 . A method of controlling a motor, the method comprising:
receiving, by a rotor, a power transfer signal wirelessly from a stator, the stator including stator windings configured to be energized to define stator poles and the rotor including rotor windings configured to be energized to define rotor poles that interact with the stator poles to produce relative force between the rotor and the stator;
capturing, by an active rectifier rotationally fixed to the rotor, electrical energy from the power transfer signal, wherein the active rectifier is conductively coupled to one or more first rotor windings of the rotor windings;
controlling, by the active rectifier, current flow through the one or more first rotor windings by directing the electrical energy captured from the power transfer signal to the one or more first rotor windings; and
producing, by the active rectifier, a substantially DC current in a first subset of the rotor windings and a substantially oscillating current in a second, different subset of the rotor windings.
55 . A method of controlling a motor, the method comprising:
receiving, by a rotor, a power transfer signal wirelessly from a stator, the stator including stator windings configured to be energized to define stator poles and the rotor including rotor windings configured to be energized to define rotor poles that interact with the stator poles to produce relative force between the rotor and the stator;
capturing, by an active rectifier rotationally fixed to the rotor, electrical energy from the power transfer signal, wherein the active rectifier is conductively coupled to one or more first rotor windings of the rotor windings; and
controlling, by the active rectifier, current flow through the one or more first rotor windings by directing the electrical energy captured from the power transfer signal to the one or more first rotor windings,
wherein the active rectifier is controlled to apply low-pass filtering to voltages in the one or more first rotor windings.