AC Motor Winding Pattern for Flat Torque Delivery
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Solution Overview
Problem
Existing electric motor designs fail to provide flat peak torque over a wide range of speeds, which is essential for fuel-efficient and high-speed performance in hybrid and all-electric vehicles.
Innovation Solution
A three-phase electric motor with a winding arrangement where each winding layer occupies every stator slot, featuring concentric and non-overlapping coils with the same number of poles, and alternating winding directions between adjacent poles, ensuring each pole has an even number of coils, allowing for efficient torque delivery across a broad speed range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional winding arrangements are used, then the motor structure is simple, but the torque output is not flat over a wide speed range
Solution Approach 1:
The winding arrangement is segmented into multiple discrete layers, with each layer containing a specific number of coils (e.g., first layer has two coils, second layer has four coils, third layer has six coils). This segmentation allows precise control of magnetic flux distribution to achieve flat torque characteristics across a wide speed range while maintaining manufacturability through standardized layer configurations.
Solution Approach 2:
Different layers are assigned different numbers of coils and specific winding patterns tailored to their position and function. The first layer through third layer each have customized coil configurations that optimize local magnetic field distribution, contributing to overall flat torque output while allowing the structure to remain systematic and manufacturable.
2Power
If the number of coils per pole is increased, then torque flatness is improved, but manufacturing complexity increases
Solution Approach 1:
The coil distribution is segmented across multiple layers with increasing coil counts (2, 4, 6 coils per layer). This segmentation enables achievement of flat torque characteristics through distributed winding patterns while maintaining manufacturing ease by organizing coils into discrete, countable layers that can be systematically assembled.
Solution Approach 2:
The invention changes the parameter of coil count per layer in a systematic progression (2, 4, 6, etc.), which optimizes torque flatness while maintaining manufacturability. This parameter progression creates a predictable winding pattern that facilitates automated fabrication processes.
3Area of stationary object
If overlapping coils are used, then space utilization is improved, but torque ripples and flux harmonic losses increase
Solution Approach 1:
Instead of using overlapping coils as in conventional designs, the invention inverts the approach by using non-overlapping discrete coils arranged in sequential layers. This inversion eliminates torque ripples and flux harmonic losses while maintaining efficient space utilization through systematic layer progression.
4Power
If complex winding patterns are used to achieve flat torque, then torque performance is improved, but automated fabrication becomes difficult
Solution Approach 1:
The winding pattern is segmented into discrete layers with standardized coil configurations. Each layer contains a specific number of coils (2, 4, 6) that can be independently manufactured and assembled, enabling automated fabrication processes while achieving flat torque characteristics through the cumulative effect of layered windings.
Solution Approach 2:
The invention uses systematic parameter changes in coil counts across layers (progressing by increments of 2) to achieve flat torque delivery. This regular parameter progression creates a predictable pattern that is ideal for automated winding machines and assembly processes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The motor design achieves flat torque over a wide range of speeds, maintaining power increase throughout its operating range, reducing flux harmonic losses, torque ripples, and operational noise, while facilitating automated fabrication.
Implementation Method 1
A three-phase electric motor with a winding arrangement where each winding layer occupies every stator slot, featuring concentric and non-overlapping coils with the same number of poles, and alternating winding directions between adjacent poles
Data Source
Figure 1A~1C
Figure 2~3
Figure 4~5
AI summary
A motor winding arrangement that is capable of delivering relatively flat torque over a wide range of speeds, thus achieving increasing power throughout its operating range, is provided. In a multi-phase, e.g., three-phase, motor utilizing the winding arrangement of the invention, each winding layer corresponds to one phase of the motor and occupies every slot of the stator. The poles for each winding layer are comprised of concentric and non-overlapping coils.