Axial Conductor Motor with Integrated End-Drive Electronics
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Solution Overview
Problem
The automation of winding and assembly processes for three-phase induction motors is complex and costly, limiting manufacturing efficiency and motor performance, and existing motors require complex external power electronics for variable speed and torque control.
Innovation Solution
An electronically commutated axial conductor motor with a stator core featuring holes for linear conductors and electronic control circuitry at the ends, allowing for direct digital control of conductors for commutation, enabling automated assembly and precise torque and speed control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional winding methods are used for three-phase induction motors, then motor performance is maintained, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent divides the stator core into modular segments with standardized hole patterns, allowing conductors to be inserted individually rather than requiring complex continuous winding operations. This segmentation enables automated insertion processes while simplifying the overall manufacturing workflow.
Solution Approach 2:
The patent replaces the traditional mechanical winding process with a direct insertion method where linear conductors are placed into pre-drilled holes. This substitution eliminates the need for complex winding machines and manual lacing operations, enabling simpler automated assembly.
2Adaptability or versatility
If fixed quantity and size windings are used, then motor structure is simplified, but adaptability to different applications decreases
Solution Approach 1:
The patent implements dynamic configurability by allowing different numbers and arrangements of conductors to be inserted into the stator holes depending on the application requirements. The electronic control system can dynamically adjust commutation patterns to accommodate various motor configurations within the same physical platform.
Solution Approach 2:
The patent creates a universal motor platform where the same stator design with standardized holes can accommodate different conductor configurations for various applications. The integrated electronic control system provides multi-functionality by handling different commutation modes and motor configurations through software rather than requiring different hardware designs.
3Productivity
If manual labor is used for lacing and inserting windings, then manufacturing flexibility is maintained, but productivity decreases
Solution Approach 1:
The patent replaces manual lacing and insertion operations with automated linear insertion mechanisms. Conductors are fed through pre-drilled holes using simple automated positioning and insertion devices, eliminating the need for manual threading, tying, and securing operations that characterize traditional winding processes.
Solution Approach 2:
The patent performs preliminary actions by pre-drilling holes in the stator core before conductor insertion. This preparatory step creates ready-to-receive positions for conductors, enabling rapid automated insertion without requiring complex real-time positioning or manual guidance during the assembly process.
4Ease of operation
If external power electronics are used for variable speed control, then motor control flexibility is improved, but system complexity and cost increase
Solution Approach 1:
The patent merges the power electronics control system with the motor structure itself by integrating commutation circuitry and control electronics directly into the motor housing. This consolidation eliminates separate external power electronics packages and reduces the overall system complexity while maintaining full variable speed and torque control capabilities.
Solution Approach 2:
The patent implements self-service control where the motor's own structure and integrated electronics handle the commutation and control functions that would traditionally require external power electronics. The motor essentially controls itself through integrated sensing and actuation, eliminating the need for separate control systems.
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 achieves efficient, automated assembly and variable speed/torque control with reduced costs, offering a universal replacement for standard induction motors and enabling regenerative capabilities, while maintaining performance comparable to traditional motors.
Implementation Method 1
The conductors are electrically coupled to bidirectional solid-state or semiconductor switches, or a plurality of solid-state switches combined in a bidirectional bridge configuration, formed of transistors (IGBT, FET or similar) installed or fabricated directly onto the end member integrated circuit board. The switch circuits provide commutation to and from a negative and positive DC bus on the end drive member
Data Source
AI summary
An electronic motor with a stator core having a plurality of holes for receiving a plurality of conductors, each conductor comprising a substantially linear body portion extending within the holes of the stator core, and a stator drive member adjacent each end of the stator core, the stator end member adjacent at least one end of the stator core including electronic control circuitry electrically coupled to at least some of the conductors.Also, a method of manufacturing an electronic motor by providing a stator with a plurality of holes having conductors within at least some of the plurality of holes, said conductors each having a substantially linear body portion extending through the stator core, and placing a drive member on each end of the stator core, at least one of the drive members provided with electronic circuitry, where the conductors are electrically coupled to the circuitry in the drive member.