An optimized induction motor with an improved core design with IE3 and IE4 efficiency class

Abstract

The present disclosure introduces an optimized induction motor with an improved core design with IE3 and IE4 efficiency class. The plurality of changes in the rotor core and stator core of the optimized induction motor comprise the core diameter, the core slot number, the slot dimensions, and other parameters in the rotor and stator core design. By using the special design of the rotor and stator core and optimizing their parameters, finally an optimized induction motor with a high efficiency class in the range of IE3 and IE4 and reducing the consumption of materials has been achieved. This optimized induction motor can be used in various industries and applications.

Description

DescriptionTitle of Invention: n optimized induction motor with an improved core design with IE3 and IE4 efficiency class.Technical Field

[0001] The present disclosure is generally related to equipment in the field of electric motors and generators, specifically to the design of the core building of induction motors and the design of the stator and rotor sheets. The present disclosure application claims priority from PCT application, PCT / IB2022 / 062492, filed on 19 December 2022.Background Art[2] The discussion of optimization in electric machines and induction motors has always been one of the interests of the world's most prestigious companies, and its articles are continuously presented by prestigious journals. Advances in materials used in core construction and providing materials with lower losses have resulted in higher quality engines. Also, in order to increase the efficiency of the motor, one of the methods used in the past years is the use of copper materials and its injection in the rotor of induction motors. Also, another method in providing high-efficiency induction motors is to change the design of the core and provide the core with unique specifications in such a way that the maximum efficiency can be obtained from the motor with the optimal use of the materials or in other words, the least materials used in the electric motor. Therefore, considering the increasing use of induction machines in various industries and the need to increase efficiency for better performance, various plans have been presented to optimize induction machines in various aspects.[3] For example, in the paper with Digital Object Identifier ID 10.15199 / 48.2016.12.46, an induction motor with IE3 efficiency class is presented through evolutionary optimization. In this reference, the outer diameter of the stator is checked by differential optimization. In the present disclosure, an induction motor with core optimization has been investigated and finally an induction motor with IE3 and IE4 efficiency class is introduced. The optimization process of the mentioned reference is different from the present disclosure and also the engine presented in the mentioned reference is not implementable from various aspects. i[4] Also, an induction motor with improved torque density has been introduced in US Patent No. US7741750B1. In this reference, changes have been made in the structure of the rotor and stator of the induction motor and changes in the shape of the core with the aim of improving the torque density of the motor, and finally an induction motor has been obtained for the intended application and with an increase in efficiency. The type of changes and optimization of the present disclosure is different from the mentioned reference, so that in the present disclosure, different parameters of the core of the induction motor have been considered and a precise optimization has been done considering these parameters, and finally an induction motor with a high efficiency class and reduction of consumables in the structure has been achieved. Also, the induction motor introduced in the present disclosure can be used in different industries and in different dimensions.[5] Therefore, in the present disclosure, an electric motor core with the specific design of stator and rotor dimensions has been introduced, and by using this core, an induction motor with a high efficiency class has been presented for use in various industries and applications.Summary of Invention[6] This summary is intended to provide an overview of the subject matter of this patent, and is not intended to identify essential elements or key elements of the subject matter, nor is it intended to be used to determine the scope of the claimed implementations. The proper scope of this patent may be ascertained from the claims set forth below in view of the detailed description below and the drawings.[7] In a general aspect, the present disclosure is directed to an optimized induction motor with the special design of the core building of induction motors and the special design of the stator and rotor sheets to achieve an optimized induction motor with IE3 and IE4 efficiency class. The optimized induction motor may comprise an optimized stator, an optimized rotor, and a motor housing. The optimized stator may use as a fixed part and optimized rotor may use as a rotating part of the induction motor. The optimized stator and the optimized rotor may include a plurality of changes in the stator characteristic and in a rotor characteristic such that the plurality of changes in a stator characteristic may include a stator inner diameter, a stator outer diameter, a stator slot opening width, a stator slotheight, a stator tooth width, a stator sheet width, a stator slot number, and a stator core length, and the plurality of changes in the rotor characteristic may include a rotor tooth width, a rotor diameter, a rotor slot number, a rotor slot height, a rotor shaft diameter, a rotor slot opening width, and a rotor core length.[8] The above general aspect may have one or more of the following features. In one or more exemplary implementation, the stator inner diameter may be in a range of 30-60 mm, the stator outer diameter may be in a range of 60-100 mm, the stator slot opening width may be in a range of 0.5-5 mm, and the stator slot height may be in a range of 5-11 mm. In one or more exemplary implementation, the rotor tooth width may be in a range of 1 -6 mm, the rotor slot number may be in a range of 12- 25 numbers, and the rotor slot height may be in a range of 5-12 mm.Technical Problem[9] Induction motors are the main consumers of electrical energy all over the world, so that about 50% of the total electrical energy produced is consumed by these motors. The design of induction motors has been started since the end of the 19th century with the works of Tesla, Ferrari, and Dobrolovsky, and with the advancement of electromagnetic numerical analysis methods and the advancement of materials, it has been constantly changing and expanding. Nowadays, due to the depletion of fossil fuels, the discussion of energy consumption optimization in electric motors is being seriously pursued, and since induction motors are the main type of motor in the industry, therefore, the optimization of energy consumption in these motors is considered as an important issue and codified standards have been approved for this purpose by relevant associations in countries. The core is the main part of every electric motor where energy conversion and electrical and magnetic processes take place. The core is usually circular and consists of two fixed (stator) and rotating (rotor) parts which a winding set is placed inside the stator slots and connected to the electrical energy source. The rotor can also be in the form of bars injected under AL and Cu pressure rotor or in the form of wounded rotor.

[0010] Therefore, development of a cost-effective and low- fossil fuel need core of the induction motors to achieve an optimal performance for the induction motor is required. Moreover, a plurality of changes in the stator characteristic and rotor characteristic is considered as an important issue for designing an optimized core of the induction motors.Solution to Problem

[0011] Therefore, according to mentioned problems, the optimization of the structure of an induction motor core has been discussed in the present disclosure, and by designing the dimensions of the rotor and stator with the aim of achieving high efficiency, finally an induction motor with an optimized core has been introduced, which has high efficiency in the IE4 class and can be used in the industrial engines in different dimensions.Advantageous Effects of Invention

[0012] The optimized induction motor with IE3 and IE4 efficiency class disclosure has the following advantages:1 . High IE3 and IE4 efficiency class;2. Less energy consumption than existing samples;3. Reducing environmental pollution during work and during construction;4. The lower cost of production;5. Reducing the consumption of raw materials in construction;6. Better and more stable output and performance; And7. Increasing energy efficiency.Brief Description of Drawings

[0013] The drawing figures depict one or more implementations in accordance with the present teachings, by way of example only, not by way of limitation. In the figures, like reference numerals refer to the same or similar elements.Fig.1

[0014] [Fig.1 ] illustrates a schematic view of an optimized induction motor, consistent with one or more exemplary embodiments of the present disclosure.Fig.2

[0015] [Fig.2] illustrates a cross-sectional view of an optimized stator core, consistent with one or more exemplary embodiments of the present disclosure.Fig.3

[0016] [Fig.3] illustrates a cross-sectional view of an optimized rotor core, consistent with one or more exemplary embodiments of the present disclosure.

[0017] [Fig.4] illustrates a plurality of curves associated with testing an optimized three- phase 120 watt electric motor, consistent with one or more exemplary embodiments of the present disclosure.Description of Embodiments

[0018] In the following detailed description, numerous specific details are set forth by way of examples in order to provide a thorough understanding of the relevant teachings. However, it should be apparent that the present teachings may be practiced without such details. In other instances, well-known methods, procedures, components, and / or circuitry have been described at a relatively high-level, without detail, in order to avoid unnecessarily obscuring aspects of the present teachings. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present disclosure is defined only by the appended claims.

[0019] The following detailed description is presented to enable a person skilled in the art to make and use the methods and apparatuses disclosed in exemplary embodiments of the present disclosure. For purposes of explanation, specific nomenclature is set forth provide a thorough understanding of the present disclosure. However, it will be apparent to one skilled in the art that these specific details are not required to practice the disclosed exemplary embodiments. Descriptions of specific exemplary embodiments are provided only as representative examples. Various modifications to the exemplary implementations will be readily apparent to one skilled in the art, and the general principles defined herein may be applied to other implementations and applications without departing from the scope of the present disclosure. The present disclosure is not intended to be limited to the implementations shown, but is to be accorded the widest possible scope consistent with the principles and features disclosed herein.

[0020] In the present document, the word "exemplary" is utilized herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments.

[0021] In the present disclosure, an optimized core has been introduced by applying changes in the rotor and stator characteristic. Also, by using the optimized core, an optimized induction motor with IE3 and IE4 efficiency class has been obtained.

[0022] In an exemplary embodiment, an optimized induction machine may be an optimized induction motor or an optimized induction generator. In an exemplary embodiment, the optimized induction machine may include an optimized stator and an optimized rotor. In an exemplary embodiment, the optimized stator may be used as a fixed part for the optimized induction machine. In an exemplary embodiment, the optimized rotor may be used as a rotating part for the optimized induction machine. In an exemplary embodiment, the optimized induction machine may be an optimized single-phase induction machine or an optimized three-phase induction machine.

[0023] Fig 1 illustrates a schematic view of an optimized induction motor, consistent with one or more exemplary embodiments of the present disclosure. In an exemplary embodiment, as illustrated in Fig 1 , an optimized induction motor 100 may comprising an optimized stator 101 , an optimized rotor 102, a motor housing 103, a terminal box 104, a motor shaft 105, a motor impeller 106, a start cap 107, an end cap 108 , and an air gap 109.

[0024] In an exemplary embodiment, the motor housing 103 may be incorporated to protect the motor components. In an exemplary embodiment, the motor impeller 106 may be used to cool the optimized induction motor. In an exemplary embodiment, the terminal box 104 may be mounted on an optimized induction motor body to connect at least one pair of power wires. In an exemplary embodiment, the optimized rotor 102 and the optimized stator 101 may be separated by the air gap 109. In an exemplary embodiment, the optimized rotor 102 may be surrounded by the optimized stator 101 . In an exemplary embodiment, the air gap 109 may be designed to achieve a desired magnetic inductance and leakage inductance. In an exemplary embodiment, the design of the air gap 109 may effect on a saturation level and a magnetic flux harmonic which is close to the air gap 109. In an exemplary embodiment, the motor shaft 105 may be connected to the optimized rotor 102. In an exemplary embodiment, the motor shaft 105 may be connected to a downstream device. In an exemplary embodiment, thedownstream device may include an axle, a gearbox, or any desired application device.

[0025] In an exemplary embodiment, the optimized stator 101 may comprise an optimized stator core 200, at least three windings, and at least two bearings. In an exemplary embodiment, the optimized stator 101 may also comprise a fan, a heater, a variable temperature resistor, a sensor, or any desired functional equipment. In an exemplary embodiment, the optimized stator core may be made of steel or any low-loss material in order to reduce losses. In an exemplary embodiment, the optimized stator core may be laminated to reduce losses. In an exemplary embodiment, the losses may include a hysteresis loss, a Foucault loss, or any type of available loss. In an exemplary embodiment, the optimized stator core may be in the form of a plurality of stator core sheets which the plurality of stator core sheets may be formed by stacking several stator sheets. In an exemplary embodiment, the plurality of stator core sheets may be designed as a hollow cylinder. In an exemplary embodiment, each stator sheet of the plurality of stator core sheets may be electrically insulated from a side stator sheet which each stator sheet of the plurality of stator core sheets is designed to achieve an optimal performance of the optimized induction motor. In an exemplary embodiment, at least three stator windings may be embedded within the optimized stator.

[0026] In an exemplary embodiment, the optimized rotor 102 may comprise an optimized rotor core 300, a motor shaft 105, and a plurality of rotor windings. In an exemplary embodiment, the optimized rotor 102 may include a cage rotor, a wounded rotor, or any type of functional rotor.

[0027] Fig.2 illustrates a cross-sectional view of the optimized stator core 200, consistent with one or more exemplary embodiments of the present disclosure. In an exemplary embodiment, as illustrated in Fig 2, the optimized stator core 200 may comprise a stator outer diameter 201 , a stator sheet width 202, a stator tooth width 203, a stator slot opening 204, a stator slot height 205, and a stator inner diameter 206.

[0028] In an exemplary embodiment, the optimized stator core may comprise a plurality of stator teeth, a plurality of stator sheet, a stator outer diameter 201 , a stator inner diameter 206, a plurality of stator slot, and a stator core length. In anexemplary embodiment, a stator slot may be configured between a stator tooth and a side stator tooth. In an exemplary embodiment, the stator winding may be installed next to the stator tooth. In an exemplary embodiment, the stator winding may be made of copper or any other practical material. In an exemplary embodiment, each stator winding may create a pair of stator poles.

[0029] In an exemplary embodiment, the optimized stator may include a plurality of changes in a stator core characteristic which may include a stator inner diameter, a stator outer diameter, a stator slot opening width, a stator slot height, a stator tooth width, a stator sheet width, a stator slot number, and a stator core length. In an exemplary embodiment, the stator outer diameter may be in a range of 60-100 mm. In an exemplary embodiment, the stator inner diameter may be in a range of 30-60 mm. In an exemplary embodiment, the stator sheet width may be in a range of 0.5-5 mm. In an exemplary embodiment, the stator sheet width may be in a range of 5-1 1 mm. In an exemplary embodiment, the plurality of changes in a stator core characteristic may be made in order to achieve the IE3 and IE4 efficiency class and reduce the consumption of materials.

[0030] Fig.3 illustrates a cross-sectional view of the optimized rotor core 300, consistent with one or more exemplary embodiments of the present disclosure. In an exemplary embodiment, as illustrated in Fig 3, the optimized rotor core 300 may comprise a rotor diameter 301 , a motor shaft diameter 302, a rotor tooth width 303, a rotor slot opening 304, and a rotor slot height 305.

[0031] In an exemplary embodiment, the optimized rotor core may comprise a plurality of rotor teeth, a plurality of rotor sheet, a rotor diameter 301 , a plurality of rotor slot, and a rotor core length. In an exemplary embodiment, a rotor slot may be configured between a rotor tooth and a side rotor tooth. In an exemplary embodiment, the rotor winding may be installed next to the rotor tooth. In an exemplary embodiment, the stator winding may be made of copper or any other practical material. In an exemplary embodiment, each rotor winding may create a pair of rotor poles.

[0032] In an exemplary embodiment, the optimized rotor may include a plurality of changes in a rotor core characteristic which may include a rotor diameter, a rotor axis diameter, a rotor slot opening width, a rotor slot height, a rotor tooth width, astator sheet width, a rotor slot number, and a rotor core length. In an exemplary embodiment, the rotor tooth width may be in a range of 1-6 mm. In an exemplary embodiment, the rotor slot height may be in a range of 5-12 mm. In an exemplary embodiment, the rotor slot number may be in a range of 5-11 numbers. In an exemplary embodiment, the plurality of changes in a rotor core characteristic may be made in order to achieve the IE3 and IE4 efficiency class and reduce the consumption of materials. In an exemplary embodiment, the rotor slot number may be designed to reduce the starting torque and dissipation reactance. In an exemplary embodiment, the rotor tooth width may be designed in order to reduce a size of the rotor slot and reduce the consumption of materials. In an exemplary embodiment, the rotor slot height may be designed in order to reduce losses and increase efficiency.Examples

[0033] EXAMPLE 1 : applying changes on the design of a rotor core and a stator core of an induction motor

[0034] In Example 1 , by applying changes on the design of a rotor core and a stator core and reaching an optimal design, an induction motor with high efficiency is obtained. An example of optimized rotor core design is shown in Fig.2 and an example of optimized stator core design is shown in Fig.3. An optimized stator outer diameter of 100 mm and an optimized stator inner diameter of 60 mm were applied in the design of the stator core, and a 120 W three-phase electric motor sample was built using the optimized core. The engine test was done at the National Standard Research Institute and the results of this test are presented in Fig.4. Fig.4 includes an efficiency curve 401 , an output power curve 402, a power factor curve 403, an output torque curve 404, and a preventive maintenance curve 405 associated with a 120 W three-phase electric motor. According to standard criteria, an electric motor with an efficiency of 65% is placed in the IE4 standard class. The efficiency curve of 401 at the speed of 2785 RPM shows an efficiency of 66.7%, which indicates the efficiency class of the electric motor IE4. According to the test results, the manufactured electric motor has been optimized with a 25% reduction in consumables compared to a standard electric motor sample and an increase of at least two degrees of efficiency.

[0035] While particular aspects of the present subject matter described herein have been shown and described, it will be apparent to those skilled in the art that, based upon the teachings herein, changes and modifications may be made without departing from this subject matter described herein and its broader aspects and, therefore, the appended claims are to encompass within their scope all such changes and modifications as are within the true spirit and scope of this subject matter described herein. Furthermore, it is to be understood that the invention is solely defined by the appended claims. It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and / or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations or two

[0036] It will be understood that the terms and expressions used herein have the ordinary meaning as is accorded to such terms and expressions with respect to their corresponding respective areas of inquiry and study except where specific meanings have otherwise been set forth herein. Relational terms such as first, second, and third and the like may be used solely to distinguish one entity or action from another without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” “include,” “including,” or any other variation thereof, are intended to cover a nonexclusive inclusion, such that a process, method, article, apparatus, or device thatcomprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, apparatus, or device. An element proceeded by “a” or “an” does not, without further constraints, preclude the existence of additional identical elements in the process, method, article, or device that comprises the element. Moreover, “may” and other permissive terms are used herein for describing optional features of various embodiments. These terms likewise describe selectable or configurable features generally, unless the context dictates otherwise.Industrial Applicability

[0037] The optimized induction motor in the present disclosure is practical for use in various industries, both domestic and industrial, in small, medium, and large sizes. Also, this motor can be used in various types of energy-consuming applications, such as types of permanently on-ventilation fans, or water pumps of electric motors.

Claims

Claims

1. [ An optimized induction motor with IE3 and IE4 efficiency class comprising: an optimized stator, wherein the optimized stator used as a fixed part of the induction motor, wherein the optimized stator including a plurality of changes in a stator core characteristic including a stator inner diameter; an optimized rotor, wherein the optimized rotor used as a rotating part of the induction motor, wherein the optimized rotor including a plurality of changes in a rotor core characteristic including a rotor tooth width; and a motor housing, wherein a motor housing used as a protector of the optimized stator and the optimized rotor.

2. The induction motor according to claim 1 , wherein the stator inner diameter is in a range of 30-60 mm.

3. The induction motor according to claim 1 , wherein rotor tooth width is in a range of 1 -6 mm.

4. The induction motor according to claim 1 , wherein the plurality of changes in a stator core characteristic further including a stator outer diameter, a stator slot opening width, a stator slot height, a stator tooth width, a stator sheet width, a stator slot number, and a stator core length.

5. The induction motor according to claim 1 and 4, wherein the plurality of changes in a rotor core characteristic further including a rotor diameter, a rotor slot number, a rotor slot height, a rotor shaft diameter, a rotor slot opening width, and a rotor core length, wherein the plurality of changes in a stator characteristic and the plurality of changes in a rotor characteristic are made in order to achieve the IE3 and IE4 efficiency class and reduce the consumption of materials.

6. An optimized induction motor with an improved core design with IE3 and IE4 efficiency class comprising: an optimized stator, wherein the optimized stator used as a fixed part of the induction motor, wherein the optimized stator including a plurality of changes in a stator core characteristic including a stator inner diameter, a stator outer diameter, a stator slot opening width, and a stator slot height; an optimized rotor, wherein the optimized rotor used as a rotating part ofthe induction motor, wherein the optimized rotor including a plurality of changes in a rotor core characteristic including a rotor tooth width, a rotor slot number, and a rotor slot height; and a motor housing, wherein a motor housing used as a protector of the optimized stator and the optimized rotor.

7. The induction motor according to claim 6, wherein the stator inner diameter is in a range of 30-60 mm.

8. The induction motor according to claim 6, wherein the stator outer diameter is in a range of 60-100 mm.

9. The induction motor according to claim 6, wherein the stator slot opening width is in a range of 0.5-5 mm.

10. The induction motor according to claim 6, wherein the stator slot height is in a range of 5-1 1 mm.[Claim 1 1 ] The induction motor according to claim 6, wherein the rotor tooth width is in a range of 1 -6 mm.

12. The induction motor according to claim 6, wherein the rotor slot number is in a range of 12-25 numbers.

13. The induction motor according to claim 6, wherein the rotor slot height is in a range of 5-12 mm.

14. The induction motor according to claim 6, wherein the plurality of changes in a stator core characteristic further including a stator slot opening width, a stator sheet width, a stator slot number, and a stator core length.

15. The induction motor according to claim 6 and 14, wherein the plurality of changes in a rotor core characteristic further including a rotor diameter, a rotor shaft diameter, a rotor slot opening width, and a rotor core length, wherein the plurality of changes in a stator characteristic and the plurality of changes in a rotor characteristic are made in order to achieve the IE3 and IE4 efficiency class and reduce the consumption of materials. ]

Images