Interchangeable Stator Asymmetric Pole Shoe Electromagnetic Retarder
Solution Overview
Problem
Existing electromagnetic retarders with asymmetric pole shoes require specific designs for gearbox or axle mounting, leading to complex logistical management and additional investment due to non-interchangeable stator designs for guided magnetic circuits.
Innovation Solution
A standardized induction stator design with asymmetric pole shoes on two faces, featuring symmetrical attachment means relative to a median plane, allowing attachment to either a gearbox or axle without modification, using perforated attachment studs or symmetrically distributed attachment holes and lugs for secure fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If asymmetric pole shoes are used to guide the magnetic circuit, then the braking torque and magnetic flux distribution are improved, but the stator design becomes non-interchangeable between gearbox and axle mounting applications
Solution Approach 1:
The patent applies asymmetry by providing asymmetric pole shoes on only one transverse face of the stator (the face intended for mounting to the gearbox or axle), while the opposite face has symmetric or differently configured pole shoes. This allows the magnetic circuit to be properly guided in the direction of rotor rotation for optimal braking torque, while the symmetric features on the opposite face enable interchangeable mounting. The asymmetric pole shoes extend farther in the direction of rotation to optimize magnetic flux distribution in the armature.
Solution Approach 2:
The patent achieves universality by designing the stator with symmetric attachment means (such as symmetrically distributed attachment holes, lugs, or studs) that allow the same stator design to be mounted on either a gearbox or an axle. The symmetric attachment features ensure that the stator can be interchangeably installed in different mounting positions, while the asymmetric pole shoes on one face provide the necessary magnetic circuit guidance for the intended direction of rotation.
2Reliability
If separate stator designs are created for gearbox and axle mounting, then the magnetic circuit is optimized for each application, but manufacturing and logistics complexity increases
Solution Approach 1:
The patent resolves the contradiction between optimization and complexity by using asymmetry selectively - asymmetric pole shoes are provided on only one transverse face of the stator (the face that will be mounted to the gearbox or axle), while the opposite face has symmetric or differently configured pole shoes. This selective asymmetry maintains magnetic circuit optimization for the intended direction of rotation while allowing the same stator design to be used for both gearbox and axle applications.
Solution Approach 2:
The patent achieves universality by designing the stator with symmetric attachment means that allow the same stator design to be mounted on either a gearbox or an axle. This single standardized design replaces the need for separate stator designs for different applications, thereby reducing manufacturing complexity, inventory requirements, and logistics costs while maintaining reliable magnetic circuit guidance through the asymmetric pole shoes on the mounting face.
3Productivity
If asymmetric pole shoes extend farther in the direction of rotation, then magnetic flux distribution and eddy current generation are improved, but the stator structure becomes more complex
Solution Approach 1:
The patent applies asymmetry by providing asymmetric pole shoes on only one transverse face of the stator, where the pole shoes extend farther in the direction of rotor rotation to optimize magnetic flux distribution and eddy current generation. The opposite face has symmetric or differently configured pole shoes with different extension distances. This selective asymmetry achieves improved productivity on the critical mounting face while limiting structural complexity to only where necessary for performance.
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
Enables a single standardized stator design for both gearbox and axle mounting, simplifying manufacturing and sales logistics, reducing investment and operational costs by eliminating the need for distinct stator types.
Implementation Method 1
an electromagnetic retarder comprises at least one stator and at least one rotor... each coil having a cylindrical pole core made of magnetic material that passes through said flange and a winding of electrical wire surrounding said supporting pole core to form a magnetic pole
Implementation Method 2
they ensure a good distribution of the magnetic flux in the armature, and thus an efficient generation of eddy currents
Implementation Method 3
an efficient generation of eddy currents... increase the torques due to creation of eddy currents in the retarders in question
Data Source
AI summary
A stator (1′) for electromagnetic retarders intended for vehicle gearbox and axle installations, includes at least one electromagnetic coils (2) assembly, two identical annular radial flanges (5′, 5″), and an asymmetrical pole shoe (6) on each radial transverse face of the two ends of each of the electromagnetic coils, and attached by a central axial screw (7), perforated attachment studs that are symmetrical relative to a median plane (M) between and parallel to the transverse faces, attached to the electromagnetic coil (2) support (5′, 5″) in order to attach the stator (1′) beside one or the other of the transverse faces to a stator support of the vehicle, using fasteners.