Brushless DC Motor Parallel Winding for Constant Power
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Solution Overview
Problem
Conventional electric motors, such as DC motors and AC inverter motors, face limitations in high-speed operation, cost, size, weight, and the inability to provide constant power, especially under load fluctuations, while reluctance motors are inferior in cost, size, and weight and lack constant-power capability.
Innovation Solution
A constant-power brushless DC motor and generator with a stator wound in parallel by phases and poles, using full H-bridges connected to a direct current power source, a rotor with concentrated magnetic flux, and a commutation encoder with photo sensors to control phase excitation, allowing for efficient power generation and reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional DC motors are used, then mechanical contact components (brush and commutator) are present, but these components are eroded and require maintenance
Solution Approach 1:
The patent removes the brush and commutator components from the motor structure, replacing mechanical contact-based commutation with electronic commutation controlled by a microprocessor. This extraction of problematic components eliminates erosion and maintenance requirements while preserving the motor's core functionality.
Solution Approach 2:
The patent replaces the mechanical brush-commutator system with an electronic control system using a microprocessor and power transistors. This substitution eliminates mechanical contact, thereby preventing erosion and reducing maintenance needs while achieving the same commutation function electronically.
2Speed
If power motors are used for high speed rotation, then speed can be increased, but the structure becomes complicated and cost increases
Solution Approach 1:
The patent designs a multi-functional motor structure where the same basic components (stator, rotor, windings) serve multiple purposes. The microprocessor-based control system provides both speed control and commutation functions, eliminating the need for separate complex mechanisms required in conventional high-speed power motors.
Solution Approach 2:
The patent achieves high-speed rotation by changing control parameters through electronic commutation rather than through complex mechanical design changes. The microprocessor adjusts current phase and magnitude dynamically, enabling speed optimization without increasing structural complexity.
3Ease of manufacture
If AC inverter motors or reluctance motors are used, then cost and size are reduced, but constant-power capability is lost
Solution Approach 1:
The patent incorporates feedback control through the microprocessor, which continuously monitors motor operation and adjusts the commutation timing and current magnitude accordingly. This feedback mechanism enables the motor to maintain constant power output across varying speeds and loads, a capability typically associated with more expensive motor types.
Solution Approach 2:
The patent implements dynamic control of motor parameters through electronic commutation, allowing real-time adjustment of current phase and magnitude based on operational conditions. This dynamic control enables constant-power operation across the speed range, overcoming the limitations of fixed-parameter AC and reluctance motors.
4Ease of manufacture
If conventional motor winding methods are used, then manufacturing is simpler, but power generation efficiency under varying loads is reduced
Solution Approach 1:
The patent segments the winding structure into distinct stator and rotor windings with specific spatial arrangements. This segmentation allows each winding set to be optimized for its specific function while maintaining manufacturing simplicity through standardized winding patterns and modular assembly procedures.
Solution Approach 2:
The patent applies different winding configurations to different spatial locations within the motor. The stator and rotor windings are positioned and configured to create optimal magnetic flux distribution, with local winding variations that enhance power generation efficiency under varying load conditions while maintaining overall manufacturing simplicity.
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 solution enables high-power generation with low voltage, reduced production costs, improved efficiency, and stable power output across varying loads without the need for cooling systems, as it avoids inputting current during pole changing areas, resulting in linear torque and efficient operation across all speed ranges.
Implementation Method 1
induced current by the rotation of the rotor is led to the power leading line connected to the power generation winding
Implementation Method 2
photo sensors, in which two photo sensors are positioned at each phase and connected to a half H-bridge of each phase, for turning on/off each half H-bridge
Data Source
AI summary
The present invention relates to a constant-power brushless DC motor and a generator using the same, and in particular, to a constant-power brushless DC motor and a generator using the same, which stably generates power upon load fluctuation. Since the stator is wound in parallel by phases and poles, the motor is realized to generate high power with low voltage and since the stator's winding is performed without interconnection, automatic production is realized to reduce costs and enable mass production. Accordingly, a generator constituted by using the above-described motor supplies high efficient power.