Conical Rotor-Stator Structures for Axial Flux Machines
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Solution Overview
Problem
Conventional axial motor and generator structures experience inefficiencies such as eddy current losses and hysteresis losses due to heat transfer issues and material constraints, particularly in outer rotor configurations where stators and windings are located within a smaller diameter region, hindering effective heat dissipation and resource utilization.
Innovation Solution
The implementation of rotor-stator structures with conically-shaped magnetic regions and field pole members that optimize flux interaction by adjusting the angle and surface area of magnetic materials and magnetically permeable structures, allowing for enhanced flux concentration and reduced material usage, thereby minimizing losses and improving torque generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional axial motor structures are used with stators located within a smaller diameter region, then the device can be compact, but heat dissipation is hindered and losses increase
Solution Approach 1:
The patent inverts the conventional radial motor configuration by placing the stator on the outside and the rotor on the inside, creating an outer rotor structure. This inversion allows the stator to be positioned in a larger diameter region where heat dissipation is more effective, while maintaining compact overall device dimensions through the unconventional arrangement.
Solution Approach 2:
The patent transitions from traditional radial flux paths to axial flux paths, changing the dimensional orientation of magnetic field interaction. This dimensional change allows for optimized heat dissipation pathways and improved spatial utilization, enabling compact design without compromising thermal management.
2Reliability
If conventional axial motor structures are used, then the structure is functional, but hysteresis losses increase due to excessive magnetic material
Solution Approach 1:
The patent changes the geometric parameters of magnetic regions by introducing conically-shaped magnetic structures with optimized surface areas and angles. This parameter optimization reduces the volume of magnetic material required while maintaining functional performance, thereby reducing hysteresis losses associated with excessive material.
Solution Approach 2:
The patent employs composite magnetic structures combining different magnetic materials with optimized properties in specific regions. This allows for reduced overall material usage while maintaining functionality, and the composite structure enables more efficient flux paths that minimize hysteresis effects.
3Quantity of substance
If conically-shaped magnetic regions are implemented, then flux concentration is enhanced and material usage is reduced, but structural complexity increases
Solution Approach 1:
The patent divides the magnetic structure into segmented conical regions with specific geometric parameters. This segmentation allows for optimized flux concentration in each region while using standard manufacturing techniques for conical shapes, balancing material efficiency with manufacturability and avoiding excessive structural complexity.
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
This configuration enhances torque generation, reduces material consumption, and improves heat dissipation by optimizing flux paths and surface areas, leading to more efficient and compact motor designs suitable for high-speed applications.
Implementation Method 1
a magnetically permeable structure configured to convey flux between the pole face and the rotor assembly
Implementation Method 2
a boost magnetic material disposed adjacent to the magnetically permeable material and configured to enhance an amount of flux passing through the magnetically permeable material
Implementation Method 3
conically-shaped magnetic regions and field pole members that optimize flux interaction by adjusting the angle and surface area of magnetic materials
Data Source
AI summary
Various embodiments relate generally to electrodynamic machines and the like, and more particularly, to rotor assemblies and rotor-stator structures for electrodynamic machines, including, but not limited to, outer rotor assemblies. In some embodiments, a stator assembly including field pole members arranged about an axis of rotation and including pole faces at the ends of the field pole members, subsets of the pole faces being disposed within a boundaries of conically-shaped spaces having apexes disposed on the axis of rotation. The rotor assemblies include interior regions in which the subsets of the pole faces are disposed, the interior regions having surfaces external to the boundaries of the conically-shaped spaces. The rotor assemblies also include subsets of magnets interleaved circumferentially with the subsets of magnetically permeable structures and boost magnets disposed adjacent the subsets of magnetically permeable structures. Further, rotor assemblies include flux conductor shields disposed adjacent the boost magnets.