Dual Stator BLDC Motor for Stationary Holding

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Solution Overview

Problem

Conventional brushless direct current (BLDC) motors face overheating and failure when maintaining a stationary rotor position due to the continuous supply of large electrical current, which is not designed for this purpose.

Innovation Solution

A BLDC motor configuration with a first stator for rotational movement and a second stator with a higher torque constant, more windings, and a control system to selectively supply electrical current to maintain a stationary position of the rotor against external forces, reducing the need for continuous high current supply.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional BLDC motor stator supplies large continuous electrical current to maintain a stationary rotor position, then the rotor position is maintained, but the motor overheats and fails

Engineering Contradiction:

Improvemotor reliabilityVSAvoidstator temperature

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The motor is divided into two separate stators: a first stator configured for rotational movement and a second stator configured for maintaining stationary position. This segmentation allows each stator to be optimized for its specific function, with the second stator having higher torque constant and more windings specifically for stationary holding without compromising the first stator's rotational performance

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second stator is designed with local quality enhancements including higher torque constant and increased number of windings compared to the first stator. This localized optimization enables the second stator to efficiently handle stationary position maintenance with reduced current demand, preventing overheating while maintaining reliability

Inventive Principle:

Principle #3Local quality

2Reliability

If a conventional BLDC motor supplies large continuous electrical current to maintain stationary rotor position, then the rotor remains stationary, but electrical energy consumption increases

Engineering Contradiction:

Improvestationary position stabilityVSAvoidelectrical current demand

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

By segmenting the stator functions into two separate stators, the system can use the second stator's optimized winding configuration and higher torque constant to maintain stationary position with reduced electrical current demand, improving energy efficiency while maintaining position stability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second stator is designed with changed parameters including higher torque constant and increased number of windings. These parameter changes enable more efficient electrical current utilization for stationary position maintenance, reducing overall energy consumption compared to using a conventional single stator design

Inventive Principle:

Principle #35Parameter changes

3Speed

If a conventional BLDC motor stator is designed for rotational movement performance, then rotational performance is optimized, but the stator cannot efficiently maintain stationary position without overheating

Engineering Contradiction:

Improverotational speedVSAvoidstationary position capability

Core Design Contradiction:

SpeedVSAdaptability or versatility

Solution Approach 1:

The motor is segmented into two stators with distinct functions: the first stator maintains rotational movement capability while the second stator provides stationary position maintenance. This segmentation allows both rotational performance and stationary adaptability to be optimized independently without compromise

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The dual stator configuration provides multi-functionality, enabling the motor to efficiently perform both rotational movement and stationary position maintenance. The second stator's enhanced torque constant and winding configuration specifically address stationary holding capability, making the overall system adaptable to both operational modes

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution effectively maintains a stationary rotor position with reduced electrical current demand, preventing overheating and motor failure, while allowing for efficient rotational movement during normal operation.

Implementation Method 1

The stator and the rotor magnetically interact with each other when electric current flows in the windings

Methodology Applied

Scientific EffectElectromagnetic interaction: Electromagnetic Induction

Implementation Method 2

A BLDC motor includes a stator with electromagnetic poles with windings thereon and a rotor with magnets mounted on a surface thereof creating permanent magnetic poles. The stator and the rotor magnetically interact with each other when electric current flows in the windings

Methodology Applied

Scientific EffectMagnetic interaction: Magnetism

Data Source

PatentUS11437898B2Brushless direct current motor with dual stators

Publication Date: 2022.09.06 DANA AUTOMOTIVE SYST GRP LLC

AI summary

A brushless direct current motor including a rotor, a first stator disposed adjacent the rotor, and a second stator disposed adjacent the rotor. The first stator is configured to selectively cause a rotational movement of the rotor during normal operation of the motor, and the second stator is configured to selectively maintain a stationary position of the rotor against a force exerted by an external source.