Additive Manufacturing Induction Machine Windings
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Solution Overview
Problem
Existing induction machines face inefficiencies and material limitations, particularly in the use of rare earth materials, and struggle to achieve high efficiency comparable to permanent magnet machines.
Innovation Solution
The method involves laminating a stack of sheet materials with additively manufactured conducting and insulating structures within slots, using laser and electron beam additive manufacturing to create efficient induction machines without rare earth materials, optimizing winding designs for improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional windings of conductive wire are used within a magnetic case, then the induction machine can be constructed with standard manufacturing methods, but the efficiency is limited and cannot reach the level of permanent magnet machines
Solution Approach 1:
The patent replaces traditional mechanical wire winding processes with additive manufacturing technology. Conductive material is deposited layer-by-layer to form windings directly within slots of the magnetic case, eliminating the need for manual or automated wire winding operations. This substitution enables precise control of winding geometry and electrical connectivity while achieving efficiencies comparable to permanent magnet machines through optimized current distribution and reduced parasitic losses.
Solution Approach 2:
The patent changes the manufacturing parameters from traditional wire winding (mechanical assembly) to additive manufacturing (material deposition). This parameter change allows for continuous optimization of winding geometry, slot filling factors, and electrical connectivity, thereby improving efficiency while maintaining manufacturability through digital process control.
2Loss of energy
If permanent magnet machines are used to achieve high efficiency, then the efficiency surpasses traditional induction machines, but rare earth materials are required which have material limitations
Solution Approach 1:
The patent extracts and eliminates the requirement for rare earth permanent magnets from the machine design. By using additively manufactured conductive windings within a magnetic case, the invention achieves high efficiency through optimized electromagnetic design without relying on rare earth materials, thereby resolving the material limitation while maintaining superior efficiency performance.
Solution Approach 2:
The patent replaces expensive rare earth permanent magnets with conventional magnetic materials and additively manufactured conductive structures. This substitution uses readily available, cost-effective materials to achieve comparable or superior efficiency, eliminating dependence on scarce and expensive rare earth resources.
3Manufacturing precision
If additively manufactured conducting and insulating structures are built within slots, then the winding design is optimized for improved performance, but advanced manufacturing technology is required
Solution Approach 1:
The patent merges the functions of conducting structures and insulating structures into a single additive manufacturing process. By depositing conductive and insulating materials sequentially or in combination within the same slots, the invention achieves precise winding geometry and electrical isolation simultaneously, optimizing performance while consolidating manufacturing operations into one integrated process.
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
This approach enables the construction of high-efficiency induction machines that surpass the efficiencies of traditional machines, eliminating the need for rare earth materials while reducing size and weight, and enhancing magnetic field performance.
Implementation Method 1
additive manufacturing devices are used to build up structures of conducting and insulating materials within slots manufactured in at least some of the sheet materials
Implementation Method 2
using laser and electron beam additive manufacturing to create efficient induction machines
Implementation Method 3
A method of laminating a stack of sheet material, wherein the sheet material is cut and unwanted portions are removed, and additive manufacturing devices are used to build up structures
Implementation Method 4
Known induction motors use multiple windings of conductive wire within a magnetic case to form a stator section and apply alternating current to these windings to cause a rotor within the stator section to turn
Data Source
AI summary
A method of making a component comprises producing a layer of sheet material including an aperture over a movable support. An insulating material is deposited in a first portion of the aperture to form an insulating coating with one or more pockets. A conductive material is deposited in the one or more pockets. Heat and pressure are applied to the layer and the movable support is lowered by a thickness of the layer. The steps are repeated to form a laminated stack defining the component. In some embodiments, the laminated stack of sheet materials forms an induction machine.