Description:FIELD OF INVENTION
[0001] Embodiments of the present disclosure relate to a field of automobiles and more particularly to a method and a structural arrangement to manufacture a switched reluctance motor for propelling a vehicle.
BACKGROUND
[0002] An electric vehicle is a vehicle that uses one or more motors for propulsion. The one or more motors draw power from at least one of a battery and a fuel cell. The one or more motors include at least one of a Brushless DC (BLDC) motor and a Permanent Magnet Synchronous (PMS) Motor. The one or more motors include a combination of stator and rotor. The stator includes electromagnetic coils adapted to provide a rotating magnetic field when powered. The rotor is made of permanent magnets adapted to create a static flux. The rotor starts to rotate when the rotating magnetic field provided by the stator interacts with the static flux provided by the rotor.
[0003] The permanent magnets provided in the rotor are manufactured using rare-earth materials to make the one or more motors powerful. Affordability and adoption of the one or more motors are affected since the permanent magnets are expensive and manufactured through a complex process . Apart from that, the speed range of the BLDC motor is limited, making the BLDC motor unsuitable for high-speed applications.
[0004] Hence, there is a need for an improved method and a structural arrangement to manufacture a switched reluctance motor for propelling a vehicle to address the aforementioned issue(s).
OBJECTIVE OF THE INVENTION
[0005] An objective of the invention includes providing a method and a structural arrangement to manufacture a switched reluctance motor for propelling a vehicle.
BRIEF DESCRIPTION
[0006] In accordance with an embodiment of the present disclosure, a method to manufacture a switched reluctance motor for propelling a vehicle is provided. The method includes fabricating a wheel rim by at least one of a technique including rolling of steel and casting of aluminium. The wheel rim includes a ring including a plurality of teeth extending towards a center of the wheel rim. The ring includes a plurality of holes adapted to accommodate a plurality of fasteners to secure two side covers to the wheel rim. The method also includes constructing a rotor by securing a plurality of laminates stacked one upon another by a fastening technique. The plurality of laminates are composed of at least one of a material including silicon steel and a ferro magnetic material. The method further includes integrating the rotor to the wheel rim by a plurality of integration methods to obtain a rotating structure. The method also includes mounting the rotating structure obtained around a stator via one or more bearings to enable rotation of the rotating structure around the stator upon supplying power to the stator, thereby manufacturing the switched reluctance motor to propel the vehicle.
[0007] In accordance with an embodiment of the present disclosure, a structural arrangement to manufacture a switched reluctance motor for propelling a vehicle is provided. The structural arrangement includes a stator adapted to provide a rotating magnetic field upon receiving electric power from a power supply. The structural arrangement also include a rotor mounted around the stator via one or more bearings. The rotor is adapted to rotate corresponding to the rotating magnetic field provided by the stator. The rotor is mounted in an inner periphery of the wheel rim through a plurality of integration methods. The wheel rim is fabricated by at least one of a technique including rolling of steel and casting of aluminium. The wheel rim includes a ring including a plurality of teeth extending towards a center of the wheel rim. The rotor is constructed by a process of securing a plurality of laminates stacked one upon another by a fastening technique. The plurality of laminates are composed of at least one of a material including silicon steel and a ferro magnetic material, thereby forming the structure of the switched reluctance motor to propel the vehicle.
[0008] To further clarify the advantages and features of the present disclosure, a more explicit description of the disclosure will follow by reference to specific embodiments thereof, which are illustrated in the appended figures. It is to be appreciated that these figures depict typical embodiments of the disclosure and are therefore not to be considered limiting in scope. The disclosure will be described and explained with additional details with the appended figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The disclosure will be described and explained with additional specificity and detail with the accompanying figures in which:
[0010] FIG. 1 is a flow chart representing the steps involved in a method to manufacture a switched reluctance motor for propelling a vehicle in accordance with an embodiment of the present disclosure;
[0011] FIG. 2 is a schematic representation of a structural arrangement to manufacture a switched reluctance motor for propelling a vehicle in accordance with an embodiment of the present disclosure;
[0012] FIG. 3 is a schematic representation of one embodiment of the structural arrangement of FIG. 2, depicting detailed view of a wheel rim in accordance with an embodiment of the present disclosure;
[0013] FIG. 4 is a schematic representation of another embodiment of the structural arrangement of FIG. 2, depicting detailed view of a rotor constructed using a plurality of laminates in accordance with an embodiment of the present disclosure;
[0014] FIG. 5 is a schematic representation of yet another embodiment of the structural arrangement of FIG. 2, depicting detailed view of the rotor constructed by machining a ferro magnetic block in accordance with an embodiment of the present disclosure;
[0015] FIG. 6 is a schematic representation of yet another embodiment of the structural arrangement of FIG. 2, depicting integrated position the rotor inside the wheel rim by press fitting in accordance with an embodiment of the present disclosure;
[0016] FIG. 7 is a schematic representation of yet another embodiment of the structural arrangement of FIG. 2, depicting integrated position the rotor inside the wheel rim by co-casting in accordance with an embodiment of the present disclosure;
[0017] FIG. 8 is a schematic representation of yet another embodiment of the structural arrangement of FIG. 2, depicting integrated position the rotor inside the wheel rim by welding in accordance with an embodiment of the present disclosure;
[0018] FIG. 9 is a schematic representation of yet another embodiment of the structural arrangement of FIG. 2, depicting integrated position the rotor inside the wheel rim by means of a plurality of split rotor rings in accordance with an embodiment of the present disclosure; and
[0019] FIG. 10 is a schematic representation of yet another embodiment of the structural arrangement of FIG. 2, depicting integrated position the rotor inside the wheel rim through one or more protrusions on the wheel rim and one or more corresponding slots on the wheel rim in accordance with an embodiment of the present disclosure.
[0020] Further, those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein.
DETAILED DESCRIPTION
[0021] To promote an understanding of the principles of the disclosure, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the disclosure as would normally occur to those skilled in the art are to be construed as being within the scope of the present disclosure.
[0022] The terms ``comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more devices or sub-systems or elements or structures or components preceded by "comprises... a'' does not, without more constraints, preclude the existence of other devices, sub-systems, elements, structures, components, additional devices, additional sub-systems, additional elements, additional structures, or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.
[0023] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this disclosure belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.
[0024] In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.
[0025] Embodiments of the present disclosure relate to a method and a structural arrangement to manufacture a switched reluctance motor for propelling a vehicle. The method includes fabricating a wheel rim by at least one of a technique including rolling of steel and casting of aluminium. The wheel rim includes a ring including a plurality of teeth extending towards a center of the wheel rim. The ring includes a plurality of holes adapted to accommodate a plurality of fasteners to secure two side covers to the wheel rim. The method also includes constructing a rotor by securing a plurality of laminates stacked one upon another by a fastening technique. The plurality of laminates are composed of at least one of a material including silicon steel and a ferro magnetic material. The method further includes integrating the rotor to the wheel rim by a plurality of integration methods to obtain a rotating structure. The method also includes mounting the rotating structure obtained around a stator via one or more bearings to enable rotation of the rotating structure around the stator upon supplying power to the stator, thereby manufacturing the switched reluctance motor to propel the vehicle.
[0026] FIG. 1 is a flow chart representing the steps involved in a method (100) to manufacture a switched reluctance motor for propelling a vehicle in accordance with an embodiment of the present disclosure. The method (100) includes fabricating a wheel rim by at least one of a technique including rolling of steel and casting of aluminium in step 110. The wheel rim includes a ring including a plurality of teeth extending towards a center of the wheel rim. The ring includes a plurality of holes adapted to accommodate a plurality of fasteners to secure two side covers to the wheel rim. In one embodiment, at least one hole among the plurality of holes may be adapted to accommodate an air inlet to inflate a wheel associated with the wheel rim. In one embodiment, the ring may be composed of steel.
[0027] The method (100) also includes constructing a rotor by securing a plurality of laminates stacked one upon another by a fastening technique in step 120. The plurality of laminates are composed of at least one of a material including silicon steel and a ferro magnetic material. In one embodiment, constructing the rotor by the process may include constructing the rotor by machining a ferromagnetic block. In one embodiment, constructing the rotor by the predefined process may include constructing the rotor by sintering a ferromagnetic powder. In some embodiments, securing the plurality of laminates one upon another may include securing the plurality of laminates one upon another by the fastening technique comprising at least one of welding, and riveting. In one embodiment, thickness of the plurality of laminates may be between 0.2 milli meters and 2 milli meters. In such an embodiments, the plurality of laminates may be manufactured by at least one of a technique including punching, laser cutting, and wire cutting.
[0028] The method (100) further includes integrating the rotor to the wheel rim by a plurality of integration methods to obtain a rotating structure in step 130. In one embodiment, the rotor constructed by machining the ferromagnetic block to the wheel rim fabricated is by at least one of a technique comprising welding, brazing, soldering, and laser bonding. In some embodiments, integrating the rotor to the wheel rim may include integrating the rotor to the wheel rim by press fitting the rotor into the wheel rim. In one embodiment, press fitting of the rotor into the wheel rim may be performed in room temperature. In some embodiments, press fitting of the rotor into the wheel rim may be performed by elevating temperature of at least one of the rotor and the wheel rim. In a specific embodiment, integrating the rotor to the wheel rim may include integrating the rotor to the wheel rim by casting the wheel rim around the rotor constructed. In one embodiment, casting the wheel rim around the rotor may be carried out through a co-casting process. In such an embodiment, the co-casting process may enable casting of aluminum around the ring. In one embodiment, casting the wheel rim around the rotor may include casting the wheel rim around the wheel rim by at least one of a casting technique including gravity die cast, pressure die cast.
[0029] Further, in a specific embodiment, the rotor may be machined to ensure concentricity of the rotor with the wheel rim after the casting. In some embodiments, integrating the rotor to the wheel rim may include integrating the rotor to the wheel rim by a plurality of split rotor rings welded to the rotor constructed. In such an embodiment, the plurality of split rotor rings are adapted to secure the rotor constructed to the wheel rim fabricated by sandwiching the rotor constructed between the plurality of rotor rings. In one embodiment, integrating the rotor to the wheel rim may include integrating the rotor to the wheel rim by introducing one or more protrusions provided on the wheel rim fabricated to one or more corresponding slots provided on the rotor to prevent relative motion between the wheel rim fabricated and the rotor constructed.
[0030] The method (100) also includes mounting the rotating structure obtained around a stator via one or more bearings to enable rotation of the rotating structure around the stator upon supplying power to the stator, thereby manufacturing the switched reluctance motor to propel the vehicle in step 140.
[0031] FIG. 2 is a schematic representation of a structural arrangement (200) to manufacture a switched reluctance motor for propelling a vehicle (not shown in FIG. 2) in accordance with an embodiment of the present disclosure. The structural arrangement (200) includes a stator (210) adapted to provide a rotating magnetic field upon receiving electric power from a power supply. In one embodiment, the power supply may include an alternating current (AC) supply. In one embodiment, the stator (210) may be mounted on a stator hub (270) located on a shaft (280). The structural arrangement (200) also include a rotor (220) mounted around the stator (210) via one or more bearings (230). The rotor (220) is adapted to rotate corresponding to the rotating magnetic field provided by the stator (210). The rotor (220) is mounted in an inside periphery of the wheel rim (240) through a plurality of integration methods. In one embodiment, one or more side covers (290) may be attached to the wheel rim (240) to enclose the rotor (220), the stator (210), the stator hub (270), and the one or more bearings (230).
[0032] FIG. 3 is a schematic representation of one embodiment of the system of FIG. 2, depicting detailed view of the wheel rim (240) in accordance with an embodiment of the present disclosure. The wheel rim (240) is fabricated by at least one of a technique including rolling of steel and casting of aluminium. The wheel rim (240) includes a ring (250) including a plurality of teeth extending towards a center of the wheel rim (240). The ring (250) includes a plurality of holes (300) adapted to accommodate a plurality of fasteners to secure the two side covers (290) of the switched reluctance motor to the wheel rim (240). In one embodiment, at least one hole (310) located on the wheel rim (240) may be adapted to accommodate an air inlet (not shown in FIG. 3) to inflate a wheel (not shown in FIG. 3) associated with the wheel rim (240). In one embodiment, the ring (250) may be composed of steel.
[0033] FIG. 4 is a schematic representation of another embodiment of the system of FIG. 2, depicting detailed view of the rotor (220) constructed using a plurality of laminates (260) in accordance with an embodiment of the present disclosure. The rotor (220) is constructed by a process of securing a plurality of laminates (260) stacked one upon another by a fastening technique. The plurality of laminates (260) are composed of at least one of a material including silicon steel and a ferro magnetic material, thereby forming the structural arrangement (200) of the switched reluctance motor to propel the vehicle. In some embodiments, securing the plurality of laminates (260) one upon another may include securing the plurality of laminates (260) one upon another by welding. In a specific embodiments, the plurality of laminates (260) may be secured by a rivet (320). In one embodiment, thickness of the plurality of laminates (260) may be between 0.2 milli meters and 2 milli meters. In such an embodiments, the plurality of laminates (260) may be manufactured by at least one of a technique including punching and laser cutting.
[0034] FIG. 5 is a schematic representation of yet another embodiment of the system of FIG. 2, depicting detailed view of the rotor (220) constructed by machining a ferro magnetic block in accordance with an embodiment of the present disclosure. In one embodiment, constructing the rotor (220) by the process may include constructing the rotor (220) by machining a ferromagnetic block. In one embodiment, constructing the rotor (220) by the predefined process may include constructing the rotor (220) by sintering a ferromagnetic powder.
[0035] FIG. 6 is a schematic representation of yet another embodiment of the system of FIG. 2, depicting integrated position the rotor (220) inside the wheel rim (240) by press fitting in accordance with an embodiment of the present disclosure. In some embodiments, integrating the rotor (220) to the wheel rim (240) may include integrating the rotor (220) to the wheel rim (240) by press fitting the rotor (220) into the wheel rim (240). In one embodiment, press fitting of the rotor (220) into the wheel rim (240) may be performed in room temperature. In some embodiments, press fitting of the rotor (220) into the wheel rim (240) may be performed by elevating temperature of at least one of the rotor (220) and the wheel rim (240).
[0036] FIG. 7 is a schematic representation of yet another embodiment of the system of FIG. 2, depicting integrated position the rotor (220) inside the wheel rim (240) by co-casting in accordance with an embodiment of the present disclosure. In a specific embodiment, integrating the rotor (220) to the wheel rim (240) may include integrating the rotor (220) to the wheel rim (240) by casting the wheel rim (240) around the rotor (220) constructed. In one embodiment, casting the wheel rim (240) around the rotor (220) may include casting the wheel rim (240) around the wheel rim (240) by at least one of a casting technique including gravity die cast, pressure die cast. In a specific embodiment, the rotor (220) may be machined after the casting process to ensure concentricity of the rotor (220) with the wheel rim (240) after the casting.
[0037] FIG. 8 is a schematic representation of yet another embodiment of the system of FIG. 2, depicting integrated position the rotor (220) inside the wheel rim (240) by welding in accordance with an embodiment of the present disclosure. In one embodiment, the rotor (220) constructed by machining the ferromagnetic block to the wheel rim (240) by at least one of a technique including welding, brazing, soldering, and laser bonding. One or more weld joints (330) formed by the welding are shown in FIG. 8.
[0038] FIG. 9 is a schematic representation of yet another embodiment of the system of FIG. 2, depicting integrated position the rotor (220) inside the wheel rim (240) by means of a plurality of split rotor rings (340) in accordance with an embodiment of the present disclosure. In some embodiments, integrating the rotor (220) to the wheel rim (240) may include integrating the rotor (220) to the wheel rim (240) by a plurality of split rotor rings (340) welded to the rotor (220). In such an embodiment, the plurality of split rotor rings (340) are adapted to secure the rotor (220) to the wheel rim (240) by sandwiching the rotor (220) between the plurality of split rotor rings (340).
[0039] FIG. 10 is a schematic representation of yet another embodiment of the system of FIG. 2, depicting integrated position the rotor (220) inside the wheel rim (240) through one or more protrusions (350) on the wheel rim (240) and one or more corresponding slots (360) on the wheel rim (240) in accordance with an embodiment of the present disclosure. In one embodiment, integrating the rotor (220) to the wheel rim (240) may include integrating the rotor (220) to the wheel rim (240) by introducing one or more protrusions (350) provided on the wheel rim (240) fabricated to one or more corresponding slots (360) provided on the rotor (220) to prevent relative motion between the wheel rim (240) fabricated and the rotor (220) constructed.
[0040] Various embodiments of the method and the structural arrangement to manufacture a switched reluctance motor for propelling a vehicle described above enable various advantages. By constructing the rotor without the permanent magnets, construction cost of the switched reluctance motor is considerably reduced, thereby enhancing the affordability of the same. Also, the switched reluctance motor constructed is capable of providing superior torque and speed characteristics, thereby making the switched reluctance motor suitable for high speed applications. Machining of the rotor after the casting is ensuring concentricity of the rotor with the wheel rim thereby enhancing the performance of the switched reluctance motor when used as a hub motor.
[0041] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the disclosure and are not intended to be restrictive thereof. While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended.
[0042] The figures and the forgoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, the order of processes described herein may be changed and is not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all the acts need to be necessarily performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples.
, Claims:1. A method (100) of manufacturing a switched reluctance motor to propel a vehicle comprising:
characterized in that:
fabricating a wheel rim by at least one of a technique comprising rolling of steel and casting of aluminium, wherein the wheel rim comprises a ring comprising a plurality of teeth extend towards a center of the wheel rim,
wherein the ring comprises a plurality of holes adapted to accommodate a plurality of fasteners to secure two side covers to the wheel rim; (110)
constructing a rotor by securing a plurality of laminates stacked one upon another by a fastening technique, wherein the plurality of laminates are composed of at least one of a material comprising silicon steel and a ferro magnetic material; (120)
integrating the rotor to the wheel rim by a plurality of integration methods to obtain a rotating structure; (130) and
mounting the rotating structure obtained around a stator via one or more bearings to enable rotation of the rotating structure around the stator upon supplying power to the stator, thereby manufacturing the switched reluctance motor to propel the vehicle. (140)
2. The method (100) as claimed in claim 1, wherein constructing the rotor comprises constructing the rotor by machining a ferromagnetic block.
3. The method (100) as claimed in claim 2, wherein the rotor constructed by machining the ferromagnetic block is integrated to the wheel rim by at least one of a technique comprising welding, brazing, soldering, and laser bonding.
4. The method (100) as claimed in claim 1, wherein constructing the rotor comprises constructing the rotor by sintering a ferromagnetic powder.
5. The method (100) as claimed in claim 1, wherein securing the plurality of laminates one upon another comprises securing the plurality of laminates one upon another by the fastening technique comprising at least one of welding, and riveting.
6. The method (100) as claimed in claim 1, wherein integrating the rotor to the wheel rim comprises integrating the rotor to the wheel rim by press fitting the rotor into the wheel rim.
7. The method (100) as claimed in claim 1, wherein integrating the rotor to the wheel rim comprises integrating the rotor to the wheel rim by casting the wheel rim around the rotor constructed.
8. The method (100) as claimed in claim 1, wherein integrating the rotor to the wheel rim comprises integrating the rotor to the wheel rim by a plurality of split rotor rings welded to the rotor constructed, wherein the plurality of split rotor rings are adapted to secure the rotor constructed to the wheel rim by sandwiching the rotor constructed between the plurality of rotor rings.
9. The method (100) as claimed in claim 1, wherein integrating the rotor to the wheel rim comprises integrating the rotor to the wheel rim by introducing one or more protrusions provided on the wheel rim to one or more corresponding slots provided on the rotor to prevent relative motion between the wheel rim and the rotor.
10. A structural arrangement (200) of a switched reluctance motor to propel a vehicle comprising:
a stator (210) adapted to provide a rotating magnetic field upon receiving electric power from a power supply;
characterized in that:
a rotor (220) mounted around the stator (210) via one or more bearings (230), wherein the rotor (220) is adapted to rotate corresponding to the rotating magnetic field provided by the stator (210), wherein the rotor (220) is mounted in an inner periphery of the wheel rim (240) through a plurality of integration methods,
wherein the wheel rim (240) is fabricated by at least one of a technique comprising rolling of steel and casting of aluminium, wherein the wheel rim (240) comprises a ring (250) comprising a plurality of teeth extending towards a center of the wheel rim (240),
wherein the rotor (220) is constructed by a process of securing a plurality of laminates (260) stacked one upon another by a fastening technique, wherein the plurality of laminates (260) are composed of at least one of a material comprising silicon steel and a ferro magnetic material, thereby forming the structural arrangement (200) of the switched reluctance motor to propel the vehicle.
Dated this 28th day of June 2023

Signature

Jinsu Abraham
Patent Agent (IN/PA-3267)
Agent for the Applicant