Full-Pitch Winding Motor Control for High-Torque Compact Drives
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Solution Overview
Problem
Conventional reluctance motors face issues with low continuous rated torque, low power factor at high torque output, and inefficient utilization of motor components, leading to increased size and weight, particularly in applications requiring large torque like electric vehicle main engines.
Innovation Solution
The motor design incorporates full-pitch windings with unidirectional current supply, allowing for selective excitation of stator magnetic poles with reduced electromagnetic interference, doubling the utilization rate of transistors and reducing copper loss, and incorporating permanent magnets for enhanced efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional reluctance motor design is used, then the motor structure is simple, but the continuous rated torque is low
Solution Approach 1:
The patent combines full-pitch windings with unidirectional current supply to create a hybrid motor structure that merges the simplicity of reluctance motors with the high torque capability of permanent magnet motors. This integration allows the motor to achieve high continuous rated torque while maintaining structural simplicity.
Solution Approach 2:
The motor uses composite construction combining soft magnetic composite materials for the stator and rotor cores with permanent magnets. This composite approach enables the motor to achieve high torque output while maintaining a compact and simple structure.
2Power
If conventional AC motor design is used, then the motor can operate at high speed, but the power factor is low at high torque output
Solution Approach 1:
The patent changes the electrical parameters by using unidirectional current supply instead of alternating current, and by incorporating permanent magnets to establish a fixed magnetic field. This parameter change improves the power factor across the operating range while maintaining high-speed capability.
3Productivity
If conventional winding configuration is used, then the manufacturing is simple, but the utilization rate of transistors is low
Solution Approach 1:
The full-pitch winding configuration allows each transistor to control multiple phases during different operating conditions, doubling the transistor utilization rate. The same winding structure serves both reluctance torque generation and permanent magnet interaction, achieving multi-functionality.
4Force
If conventional motor design is used, then the motor can provide sufficient torque, but the size and weight are large
Solution Approach 1:
The use of soft magnetic composite materials and optimized permanent magnet placement enables the motor to achieve high torque density. The composite structure allows for a more compact design with reduced weight while maintaining sufficient torque output.
Solution Approach 2:
The patent optimizes magnetic flux density parameters and pole configurations to increase torque per unit volume. By changing the magnetic circuit parameters and using permanent magnets, the motor achieves higher specific torque without increasing size or weight.
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 configuration increases continuous and maximum torque, improves power factor, reduces motor size and weight, and enhances efficiency, making it suitable for high-torque applications while minimizing noise and torque ripple.
Implementation Method 1
A-phase concentrated winding 837 and 838 are wound as shown by a broken line. The current of each winding of this motor is a one-way current, and each winding is indicated by a current symbol, indicating the direction in which the current flows. The winding 837 energizes an A-phase current Ia flowing from the front side to the back side of the paper surface
Implementation Method 2
a magnetic flux component pa indicated by an arrow 83E is passed through the stator magnetic pole 832, the rotor magnetic pole 83F, the rotor magnetic pole 83A, and the stator magnetic pole 831 from the lower side to the upper side of the paper surface. The magnetic flux component φa makes a round through the back yoke of the stator
Implementation Method 3
In the state of FIG. 83, CCW torque in the counterclockwise rotation direction is generated in the rotor
Data Source
AI summary
A motor has windings and a control device, which applies appropriately one-way current to each of the windings. Two full-pitch windings, which are located adjacently to both ends of an A-phase stator magnetic pole, and driving transistors are connected in series to each other to supply an A-phase current component, thereby exciting an A-phase magnetic flux component passing through the A-phase stator magnetic pole, resulting in generation of torque. This excitation is also applied to other phases. The respective stator magnetic poles can be excited selectively, and voltages across both ends of the serially connected windings become a voltage for corresponding magnetic flux components which should be provided by the windings, thus providing a more simplified motor structure and higher motor performance. The windings and transistors can be used commonly in two phases, providing an improved usage rate, thus making the motor more compact in size and reducing manufacturing cost.