Embedded Contactless Shaft Power Transfer for High-Speed Exciters

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Solution Overview

Problem

There are no existing technologies for contactless power transfer mechanisms in separately excited machines.

Innovation Solution

A power transfer system for separately excited machines incorporating a rotating magnetic core, rotating and stationary high index core windings, and a stator referenced magnetic core, with a rotor rectifier mounting plate and rectifiers to convert AC to DC, allowing for passive cooling and decoupled field excitations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If traditional contactless power transfer mechanisms are used in separately excited machines, then power transfer can be achieved, but the axial length must be increased which limits speed operation

Engineering Contradiction:

Improvespeed operationVSAvoidaxial length

Core Design Contradiction:

SpeedVSLength of moving object

Solution Approach 1:

The patent embeds the rotating high index core winding inside the rotating magnetic core, and the stationary high index core winding inside the rotating high index core winding, creating a nested configuration. This nesting allows the power transfer components to be compactly arranged radially rather than axially, reducing axial length while enabling high-speed operation.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent transitions from axial arrangement to radial arrangement of the magnetic cores and windings. By organizing components in the radial dimension (rotating magnetic core, rotating high index core winding, stationary high index core winding, stator referenced magnetic core) rather than axial stacking, the design reduces axial length while maintaining power transfer functionality.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Ease of operation

If rectifiers are mounted on the rotating component for power conversion, then AC to DC conversion is achieved, but heat generation requires active cooling systems

Engineering Contradiction:

Improvepower conversionVSAvoidheat rejection

Core Design Contradiction:

Ease of operationVSTemperature

Solution Approach 1:

The rotor rectifier mounting plate is designed to function simultaneously as a heat sink, allowing the rectifiers to dissipate their own heat through the plate's thermal conduction properties. This self-cooling mechanism eliminates the need for separate active cooling systems while maintaining effective heat rejection from the power conversion components.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The mounting plate serves multiple functions: it mechanically supports the rectifiers, provides electrical connectivity, and acts as a heat sink for thermal management. This multi-functionality integrates power conversion and thermal management into a single component, simplifying the overall system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If brushes are used for power transfer in separately excited machines, then electrical connection is maintained, but frictional losses and wear occur

Engineering Contradiction:

Improveelectrical connectionVSAvoidfrictional losses

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent replaces the mechanical brush-contact system with a contactless power transfer mechanism using embedded high index core windings and magnetic cores. This substitution eliminates physical contact between rotating and stationary components, removing frictional losses and wear while maintaining reliable electrical power transfer through electromagnetic induction.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 the need for axial length increase, enables higher speed operation, optimizes power electronic heat rejection, and mitigates electromagnetic interference while eliminating the need for brushes and reducing frictional losses.

Implementation Method 1

The rotor rectifier mounting plate may include rectifiers to convert AC to DC

Methodology Applied

Scientific EffectRectification: Diode

Implementation Method 2

The power transfer system may be configured to allow cooling fluid to pass therethrough

Methodology Applied

Scientific EffectConvection cooling: Convection

Implementation Method 3

the mounting plate may be configured as a heat sink

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 4

The mounting plate may be operatively attached to the rotating magnetic core via adhesive

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS20250112500A1Novel shaft embedded contactless power transfer for a separately excited machine

Publication Date: 2025.04.03 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A power transfer system may include a rotating magnetic core; a rotating high index core winding within the rotating magnetic core; a stationary high index core winding within the rotating high index core winding; and a stator referenced magnetic core within the stationary high index core winding. The power transfer system may include a rotor rectifier mounting plate, operatively attached to the rotating magnetic core, and/or a first and a second stationary high index core winding; and/or the stationary high index core winding and the stator referenced magnetic core do not rotate and/or the rotor rectifier mounting plate includes rectifiers to convert AC to DC; and/or the rotor rectifier mounting plate is further configured as a heat sink; and/or the rotor rectifier mounting plate is operatively attached to the rotating magnetic core via adhesive; and/or cooling fluid is allowed to pass through the power transfer system.