Cross-coupled composite motor with dual-ring iron core
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Solution Overview
Problem
Conventional motors face challenges in achieving a low-speed, high-torque gearless motor design with improved torque weight ratio, efficient energy reversibility, and resource-free production methods, particularly without using neodymium magnets and copper coils, while enabling mass production.
Innovation Solution
The development of an interconnection-composite-type motor featuring a dual-ring tooth-groove iron core with overlapping coils and a rotor design that utilizes attraction poles and a two-quadrant constant current control circuit for efficient energy management and torque generation, allowing for high torque and reduced weight without rare-earth magnets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional motor structures are used, then the motor can operate reliably, but the torque weight ratio is insufficient and cannot be improved by one digit
Solution Approach 1:
The motor is divided into modular components: stator with tooth-groove iron core, rotor with attraction poles, and separate coil assemblies. This segmentation allows independent optimization of each component for torque generation while reducing overall weight and complexity
Solution Approach 2:
The motor employs composite construction combining tooth-groove iron core with attraction poles, and overlapping coil structures with magnetic cores. This composite approach maximizes torque density per unit weight by optimizing the magnetic circuit and electromagnetic interaction efficiency
2Power
If neodymium magnets and copper coils are used, then high performance is achieved, but resource dependency increases and mass production becomes difficult
Solution Approach 1:
The invention extracts and eliminates the dependency on rare-earth neodymium magnets from the motor structure. Instead, it uses attraction poles with soft magnetic materials and generates magnetic fields through controlled coil excitation, enabling mass production with conventional materials and processes
Solution Approach 2:
The motor uses conventional, inexpensive materials such as soft magnetic steel for tooth-groove iron cores and attraction poles, replacing expensive rare-earth magnets. This allows standard manufacturing processes and facilitates mass production with cost-effective materials
3Loss of energy
If conventional single-direction energy conversion is used, then simple control is maintained, but energy recovery during braking is not efficient
Solution Approach 1:
The control system dynamically switches between motor mode and generator mode based on operational requirements. The same coil and magnetic circuit structures serve dual functions: converting electrical energy to mechanical energy during acceleration, and converting mechanical energy back to electrical energy during braking, maximizing energy efficiency
Solution Approach 2:
The motor-recuperator system recovers kinetic energy during braking by operating in generator mode, converting mechanical energy back to electrical energy that can be stored or reused. This prevents energy waste and improves overall system efficiency, with the control circuit managing energy flow between motor and generator modes
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 solution significantly enhances the torque weight ratio by approximately one digit, enables efficient energy recovery, and facilitates mass production without rare-earth magnets, addressing the limitations of conventional motors.
Implementation Method 1
coils of a predetermined number of overlapping phases overlap each other and are interconnected so that coils' magnetomotive forces are unified in direction in one ring-shaped tooth-groove iron core
Implementation Method 2
attraction poles each having, at both ends, opposed surfaces of the one magnetic pole length in width are opposed on both sides at a same angular position to form a circulation magnetic path
Data Source
AI summary
Provided is a motor system adapted for modern society, which does not use a rare-earth magnet, improves a torque weight ratio by approximately one digit in comparison with the conventional motor, and has transfer efficiency of 90% between electric energy and rotational energy. A stator (1) has a dual-ring tooth-groove iron core, which has magnetic pole surface on both side surfaces and receives coils of basically two-phase structure divided to be multiplexed, with divided coils being interconnected. A rotor (2) is formed to be capable of rotating while holding eight sets of attraction poles having magnetic pole surfaces on both ends, with each set of attraction poles forming four air-gap-facing surfaces by positioning the dual-ring tooth-groove iron core between the attraction poles so that both side surfaces of the dual-ring tooth-groove iron core face the attraction poles via an air gap (6). Magnetic energy accompanying coil switching can be reduced to one part per dozens through the dual effect of reduction owing to coil division and dispersion owing to interconnection. The torque weight ratio can be improved approximately by one digit through synergistic effect of torque increase owing to integration of magnetomotive forces by interconnection, torque increase owing to composite structure of the attraction poles, and weight reduction of the iron core.