Segmented Direct Drive Stator Layout for Lower Coil Heating
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Solution Overview
Problem
Existing direct drive systems face increased coil consumption, material costs, heating, and energy consumption due to close coil arrangements, leading to reduced operation efficiency.
Innovation Solution
A direct drive system with spaced groups of windings and magnetic conductors, where each group of windings is arranged on a second magnetic conductor, and auxiliary teeth are added to reduce thrust fluctuations, allowing for efficient electromagnetic thrust generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If coils are arranged close to each other in the stator assembly, then the electromagnetic thrust force is enhanced, but coil consumption and material costs increase
Solution Approach 1:
The patent divides the stator assembly into multiple independent stator units, each with its own coils and magnetic conductors. This segmentation allows each unit to generate electromagnetic thrust independently, reducing the need for excessive coil material in a single concentrated arrangement while maintaining overall thrust capability through distributed generation.
Solution Approach 2:
The patent transitions from a traditional concentrated coil arrangement to a distributed spatial arrangement where multiple stator units are positioned at different locations around the rotor. This dimensional redistribution of coil placement optimizes the magnetic field distribution and reduces material consumption while maintaining thrust effectiveness.
2Power
If coils are arranged close to each other in the stator assembly, then the electromagnetic thrust force is enhanced, but heating quantity and energy consumption increase
Solution Approach 1:
By segmenting the stator into multiple independent units with spaced coil groups, the patent distributes the electromagnetic work across multiple locations. This reduces current density and resistive heating in any single coil group, thereby reducing overall energy loss and heating quantity while maintaining the required thrust force through cumulative effect of all units.
Solution Approach 2:
The patent converts the potential harm of concentrated coil heating into a benefit by distributing coils across multiple stator units. The spacing between coil groups allows heat dissipation, and the distributed arrangement ensures that no single location experiences excessive heating, thus converting the constraint of heat management into an opportunity for more efficient energy utilization.
3Power
If coils are arranged close to each other in the stator assembly, then the electromagnetic thrust force is enhanced, but operation efficiency decreases
Solution Approach 1:
The patent segments the drive system into multiple independent stator units that can be controlled independently. This allows for optimized current distribution and switching strategies, improving overall system efficiency by activating only the necessary stator units based on operational requirements, thereby maintaining thrust while reducing energy consumption and improving productivity.
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
Reduces coil consumption, material costs, and energy consumption, improving operation efficiency by minimizing heating and enhancing flexibility and versatility.
Implementation Method 1
a magnetic field generated by at least one group of the windings covering at least one of the magnets so as to generate an electromagnetic thrust force with the magnet to drive the slide to move along a sliding direction
Data Source
AI summary
The present disclosure provides direct drive system, belongs to drive systems field. The direct drive system includes: base and slide spaced from the base, the base being provided with stator assembly, slide being provided with rotor assembly; rotor assembly including a first magnetic conductor and a plurality of magnets arranged on the first magnetic conductor; the stator assembly including second magnetic conductors and windings spaced on second magnetic conductors, windings being arranged opposite magnets, and magnetic field generated by windings covering magnets to generate electromagnetic thrust with magnet to drive the slide to move along sliding direction. Windings are spaced, and coils in each group of winding are cooperatively energized to drive rotor assembly with magnets to operate, which effectively reduce consumption of coils, reduce material costs, reduce heating quantity, reduce energy consumption of direct drive system, to improve operation efficiency of direct drive system.


