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

VSEngineering 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

Engineering Contradiction:
Improveelectromagnetic thrust forceVSAvoidcoil consumption
Core Design Contradiction:
PowerVSQuantity of substance

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.

Inventive Principle:
Principle #1Segmentation

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.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

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

Engineering Contradiction:
Improveelectromagnetic thrust forceVSAvoidheating quantity
Core Design Contradiction:
PowerVSLoss of energy

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.

Inventive Principle:
Principle #1Segmentation

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.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

3Power

If coils are arranged close to each other in the stator assembly, then the electromagnetic thrust force is enhanced, but operation efficiency decreases

Engineering Contradiction:
Improveelectromagnetic thrust forceVSAvoidoperation efficiency
Core Design Contradiction:
PowerVSProductivity

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.

Inventive Principle:
Principle #1Segmentation

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

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS12407235B2Direct drive system
Publication Date: 2025.09.02 AAC MICROTECH (CHANGZHOU) CO LTD
  • US12407235B2 patent drawing
  • US12407235B2 patent drawing
  • US12407235B2 patent drawing

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.