Multi-Rotor BLDC Motor With Clutch-Isolated Dynamic Range
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Solution Overview
Problem
Brushless direct current (BLDC) motors have limited dynamic range, requiring either increased voltage, which reduces efficiency, or the use of transmissions that add complexity and losses, especially in space-constrained applications like underwater systems.
Innovation Solution
A high dynamic range electric motor system comprising multiple rotor-stator pairs with a clutch mechanism that isolates each pair from the shaft, allowing for optimal power delivery and torque transfer, eliminating the need for transmissions and maximizing efficiency, power, space, and weight utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the supplied voltage is dramatically increased to increase the dynamic range of a single BLDC motor, then the dynamic range is improved, but the motor efficiency decreases and the power source is depleted faster
Solution Approach 1:
The patent divides a single motor system into multiple independent rotor-stator pairs (first pair, second pair, third pair), each capable of operating independently. This segmentation allows the system to achieve extended dynamic range by activating different pairs for different operating conditions without increasing voltage, thereby maintaining motor efficiency while improving adaptability.
2Adaptability or versatility
If a transmission is included to increase the dynamic range of a single BLDC motor, then the dynamic range is improved, but the complexity of the motor system increases and mechanical losses occur
Solution Approach 1:
The patent segments the motor into multiple rotor-stator pairs with independent torque capabilities, eliminating the need for a transmission system. Each pair can be independently controlled to provide the required torque and speed characteristics, achieving extended dynamic range without adding mechanical complexity or transmission losses.
Solution Approach 2:
Multiple rotor-stator pairs are designed to perform different functions across different operating ranges. The first pair operates at high speeds with low torque, the second pair at medium speeds with medium torque, and the third pair at low speeds with high torque. This multi-functionality allows a single motor system to replace what would traditionally require a motor plus transmission combination.
3Adaptability or versatility
If a transmission is included to increase the dynamic range, then the dynamic range is improved, but mechanical and frictional losses are inherent in the gear interactions
Solution Approach 1:
The patent replaces the mechanical transmission system with an electrical control system that independently activates different rotor-stator pairs based on operating conditions. This substitution eliminates mechanical gear interactions, frictional losses, and associated energy waste while maintaining the ability to achieve extended dynamic range through electronic control of multiple motor pairs.
4Power
If multiple motors are applied to rotate a single shaft to improve power, then the power is improved, but the complexity and losses similar to transmission systems occur
Solution Approach 1:
The patent merges multiple rotor-stator pairs into a single integrated motor structure that shares a common stator and control system. This unified design allows multiple torque sources to work together on a single shaft without requiring separate motor housings, mounting systems, or independent control electronics, thereby reducing overall complexity while maintaining improved power output capability.
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 system achieves a significantly larger dynamic range without increased voltage or transmission losses, ensuring efficient operation across a broader range of speeds and torques, particularly beneficial in space-limited environments.
Implementation Method 1
electrical motors operate by producing a magnetic field and winding currents to generate a rotational force
Implementation Method 2
The rotor is set to turn about the motor's stator, generating torque, a rotational force
Implementation Method 3
A clutch is configured to isolate at least one of the first and second pairs away from the shaft, establishing an at least a first isolated pair, and preventing torque transfer between the at least one isolated pair and the shaft
Data Source
AI summary
An efficient, large dynamic range electric motor system and method of operating same, including a frame, at least a first rotor-stator pair, together having a first dynamic range, and a second rotor-stator pair, having a second dynamic range, with the first and second pairs mounted within the frame for rotation about a common central axis of an output shaft, mounted for rotation about the first axis and configured to transfer torque from the first and second pairs. A clutch is configured to isolate at least one of the first and second pairs away from the output shaft, thereby establishing an at least one isolated pair, and preventing torque transfer between the at least one isolated pair and the output shaft. A controller is connected to the first and second pairs and is configured to control power delivery to the first and second pairs.