Integrated Winding System with Half-Bridge Power Electronics
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Solution Overview
Problem
Conventional electric machines have large dimensions and require separate cooling and additional shielding due to the separation of power electronics and the machine, leading to inefficiencies and electromagnetic compatibility issues.
Innovation Solution
A compact winding system for a rotor and/or stator that integrates power electronics with semiconductor switches, eliminating the need for separate housings and reducing current and voltage requirements, allowing for shared cooling and reduced noise emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If power electronics are housed separately from the machine, then electromagnetic compatibility is improved through shielding, but the overall system dimensions increase and require separate cooling systems
Solution Approach 1:
The patent merges the power electronics (inverter) directly with the motor housing, eliminating the need for separate housings and reducing overall system dimensions. The power electronic components are integrated into the motor's end bell or housing structure, allowing shared cooling and reduced electromagnetic interference through proximity rather than separation.
2Temperature
If power electronics are housed separately from the machine, then cooling can be optimized independently, but the overall system complexity and housing requirements increase
Solution Approach 1:
The patent combines the cooling systems for both the motor and power electronics into a single integrated cooling circuit. The cooling jacket or heat sink serves both components simultaneously, reducing the number of separate cooling systems needed while maintaining effective temperature control for both the motor windings and power electronic devices.
3Device complexity
If conventional windings with few terminals are used, then the machine structure is simplified, but adaptability to different operating conditions is reduced
Solution Approach 1:
The patent segments the winding structure into multiple independent conductor sections with individual half-bridge connections, allowing each section to be controlled independently. This segmentation enables flexible reconfiguration of the winding connections to adapt to different operating conditions, torque requirements, or fault conditions while maintaining a relatively simple overall structure.
Solution Approach 2:
The patent implements dynamic reconfigurability of the winding system through controllable switches (thyristors or IGBTs) in each half-bridge circuit. The winding connections can be dynamically changed during operation to optimize performance for different load conditions, speed ranges, or torque requirements, providing operational flexibility without complex mechanical switching mechanisms.
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 system achieves a compact design, efficient cooling, and improved electromagnetic compatibility, enabling flexible operation and cost-effective manufacturing with reduced noise and enhanced torque generation capabilities.
Implementation Method 1
the half bridges comprise switches, particularly semiconductor power switches, by means of which the respective end of the conductor section can be selectively connected to one of the two annular conductors
Implementation Method 2
a potentially required cooling system for the electric machine can simultaneously cool the power electronics, for example, with cooling air of the motor or the accommodation in a common water cooling jacket
Implementation Method 3
with cooling air of the motor
Data Source
AI summary
A winding system for a stator and/or a rotor of an electric machine is disclosed. The winding system comprises several conductor sections, two annular conductors (+, −) on a first side of the winding system, to which the conductor sections are coupled by means of half bridges, and at least one half bridge on an opposite side of the winding system, to which at least one conductor section is connected.