Configurable BLDC Stator Windings for Torque-Speed Switching
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Solution Overview
Problem
Existing power tools with brushless DC motors are limited to a single stator winding configuration, which restricts their ability to optimize performance across varying operational conditions, such as torque and speed, leading to inefficiencies.
Innovation Solution
A power tool with a brushless DC motor featuring configurable stator windings that can switch between DELTA and WYE configurations, controlled by a controller to adapt to changing conditions, optimizing performance by selectively coupling stator windings in different configurations based on tool conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the motor configuration is fixed in a single setup (DELTA or WYE), then the device complexity is reduced, but the adaptability to different operational conditions deteriorates
Solution Approach 1:
The motor configuration is made dynamic through the introduction of switching circuitry that can change the winding connections between DELTA and WYE configurations based on operational conditions. The controller dynamically selects the appropriate configuration by actuating switches to reconfigure the stator windings, allowing the motor to adapt to varying load and speed requirements rather than being fixed in a single configuration.
Solution Approach 2:
The invention changes the electrical connection parameters of the motor windings by switching between different configuration states. The controller monitors operational parameters and changes the winding connection topology (from DELTA to WYE or vice versa) to optimize motor performance for the current operational condition, effectively changing the electrical parameters to match mechanical demands.
2Productivity
If the motor configuration is dynamically adjusted based on operational conditions, then the productivity is improved, but the device complexity increases
Solution Approach 1:
The controller implements feedback by monitoring operational conditions such as load, speed, and current draw, then using this information to determine the optimal motor configuration. The controller continuously adjusts the switching state based on feedback from the motor's performance parameters, ensuring the motor operates at peak efficiency for the current workload while automatically adapting to changing conditions.
Solution Approach 2:
The motor system is designed with multi-functionality by incorporating switching circuitry that enables a single motor to perform multiple configuration modes (DELTA and WYE). This universal design allows the same motor hardware to adapt to different operational requirements without requiring separate motors for different configurations, improving productivity while managing complexity through integrated control.
3Adaptability or versatility
If switches are added to reconfigure stator windings, then the adaptability is improved, but the device complexity increases
Solution Approach 1:
The switching circuitry is merged with the existing motor control system, integrating the configuration switching functionality into the controller that already manages motor operation. By combining the winding reconfiguration switches with the existing control electronics and using the same controller to manage both motor speed and configuration, the patent reduces the overall device complexity despite adding configuration flexibility.
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
Enhances performance by allowing the motor to leverage the advantages of both DELTA and WYE configurations, achieving higher speed in one mode and greater torque in another, thereby improving operational efficiency and adaptability.
Implementation Method 1
an electric motor including a plurality of stator windings, a plurality of switches for selectively coupling the plurality of stator windings in a first configuration or a second configuration
Data Source
AI summary
A power tool that includes an electric motor. The electric motor includes a plurality of stator windings, a plurality of switches for selectively coupling the plurality of stator windings in a first configuration or a second configuration, and a controller connected to the plurality of switches. The controller is configured to control the plurality of switches to configure the plurality of stator windings in the first configuration, monitor a condition of the power tool, and control the plurality of switches to configure the plurality of stator windings in the second configuration based on the condition of the power tool.