Continuous Winding for Electric Motors Reducing Space Harmonics
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Distributed winding configurations in linear electric motors face inefficiencies due to space harmonics, force ripple, and core losses, which limit their scalability and practicality, especially in medium voltage applications.
Innovation Solution
A continuous winding configuration is developed where coils are arranged in blocks with offset portions, interlocked and molded together to form a magnetically continuous stator, reducing space harmonics and core losses, and allowing for efficient alignment and connection of blocks to minimize magnetic gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If distributed winding configuration is used, then sinusoidal motor magnetic field profile is achieved, but space harmonics and force ripple increase
Solution Approach 1:
The stator is divided into multiple modular blocks, each containing distributed windings. By segmenting the overall winding into discrete blocks with overlapping end regions, the patent maintains the sinusoidal MMF profile benefits of distributed windings while enabling practical construction and reducing space harmonics through optimized block interfaces
Solution Approach 2:
Adjacent blocks are nested together with overlapping end regions that interlock to form a continuous winding pattern. This nesting approach allows the distributed windings in each block to contribute to the sinusoidal MMF while the overlapping regions minimize magnetic gaps and reduce space harmonics at block boundaries
2Power
If air is removed from between coils and core, then medium voltage application is enabled, but manufacturing complexity increases
Solution Approach 1:
The patent removes air from between coils and core during the manufacturing process before final assembly, enabling medium voltage operation. By performing this air removal action preliminarily during block fabrication rather than during final assembly, the patent enables MV capability while managing manufacturing complexity through standardized block processing
Solution Approach 2:
The patent uses resin or bonding material as an intermediary substance to fill and seal the gaps between coils and core in each block. This intermediary material eliminates air pockets that would prevent medium voltage operation while providing a manageable manufacturing process that can be applied consistently across multiple blocks
3Productivity
If blocks are connected to form continuous winding, then scalability is improved, but magnetic gaps between blocks increase
Solution Approach 1:
The continuous winding is segmented into discrete blocks for manufacturing and assembly purposes. This segmentation enables scalability by allowing blocks to be produced independently and assembled in sequence, while the modular design facilitates easy scaling to different motor sizes and power ratings
Solution Approach 2:
Adjacent blocks are nested together with overlapping end regions that contain windings from both blocks. This nesting configuration creates interlocking connections that minimize magnetic gaps at block interfaces, reducing core losses and improving efficiency while maintaining the scalability benefits of modular construction
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 continuous winding configuration reduces space harmonics, lowers core losses, and minimizes eddy currents, resulting in a more efficient and scalable linear motor design suitable for high-speed transportation systems.
Implementation Method 1
a core formed by a resin applied to the first coil and each additional coil to substantially bind the first coil and the at least one additional coil
Implementation Method 2
A linear motor is an electric motor that has had its stator and rotor 'unrolled' so that instead of producing torque, it produces a linear force along its length
Data Source
AI summary
A magnetically continuous winding includes a first coil and at least one additional coil substantially fixed in place in at least one direction with respect to a position of the first coil. A core formed by a resin is applied to the first coil and the at least one additional coil to substantially bind the first coil and the at least one additional coil.