Claw Pole Motor Stator Segmentation for HVAC Efficiency
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Solution Overview
Problem
Blower motors in HVAC&R systems have low efficiency and oversized structures, leading to increased energy consumption as HVAC&R systems become more efficient, making them a significant contributor to overall energy use.
Innovation Solution
A claw pole motor design featuring a rotor and stator assembly with claw pole teeth and coil windings, where the stator elements are arranged in an intermeshing relationship and the drive unit is sandwiched between interior stator elements, enhancing thermal management and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If traditional split capacitor or induction motors are used in HVAC&R systems, then the motors can provide sufficient power for air movement, but the motors have low efficiency and oversized structure leading to increased energy consumption
Solution Approach 1:
The stator is divided into multiple modular stator elements (first stator element, second stator element, third stator element) that can be assembled together. Each element contains claw pole teeth and coil windings, creating a segmented structure that reduces overall motor size while maintaining efficiency. This segmentation allows for a more compact design compared to traditional induction motors.
Solution Approach 2:
The drive unit is positioned within the hollow interior of the stationary shaft, creating a nested arrangement where the drive unit is contained within the motor structure. This nesting reduces the overall motor size by utilizing internal space, directly addressing the oversized structure problem of traditional motors.
2Loss of energy
If traditional blower motors are used in efficient HVAC&R systems, then the HVAC&R systems achieve high efficiency, but the blower motors become a greater contributor to overall system energy use
Solution Approach 1:
The motor design changes key parameters including the use of claw pole teeth with specific geometric configurations, permanent magnets in the rotor, and optimized coil windings. These parameter changes result in higher motor efficiency, reducing the blower motor's energy consumption from 50-70% of system power to a much lower fraction, directly addressing the energy contribution problem.
3Productivity
If claw pole teeth are arranged in intermeshing relationship with rotated stator elements, then the motor achieves improved efficiency and compact design, but the manufacturing complexity increases
Solution Approach 1:
The stator is segmented into multiple elements that can be manufactured separately and then assembled. This segmentation allows for simpler individual component manufacturing while achieving the complex intermeshing tooth arrangement through modular assembly, reducing overall manufacturing complexity.
Solution Approach 2:
Multiple stator elements are combined through assembly to create the complete stator structure with intermeshing claw pole teeth. This merging of simpler components achieves the complex tooth arrangement without requiring complex manufacturing processes for each individual element.
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 design improves energy efficiency and reduces manufacturing costs, making it suitable for high-efficiency applications in blower systems and other low-power applications.
Implementation Method 1
at least one coil winding positioned between said plurality of stator elements
Implementation Method 2
a rotor rotatable about an axis
Data Source
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AI summary
A claw pole motor is provided including a rotor rotatable about an axis; and a stator assembly. The stator assembly includes a plurality of stator elements having one or more claw pole teeth such that when said plurality of stator elements is assembled, the claw pole teeth extend between a first end and a second end of said stator assembly. At stator assembly additionally includes at least one coil winding positioned between said plurality of stator elements.