Laminated Coreless Generator Axial Stacking Power Density
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Solution Overview
Problem
Current small-size generators face challenges with high copper consumption, irreversible demagnetization of permanent magnets at high temperatures, and limited stator size and radiation, while disk type electric machines require material and technological advancements to improve magnetic flux density and power density.
Innovation Solution
The efficient laminated coreless generator design features a stator coil with disk-shaped single coils and a rotor with permanently embedded magnets, arranged in a regular polygon configuration, using an antimagnetic outer fixing bracket and a spindle, with a high surface magnetic intensity and optimized magnet-to-coil ratio, allowing for magnetic field superposition and increased power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a disk type electric machine is used, then the structure is simple and compact with small volume and high torque density, but the magnetic flux density and power density need to be further improved
Solution Approach 1:
The patent transitions from traditional column-type generators to a disk-type configuration, fundamentally changing the spatial arrangement from vertical to horizontal planes. Multiple rotors and stators are stacked axially to create a multi-layer laminated structure, effectively utilizing the third dimension (axial direction) to increase power density without proportionally increasing volume.
Solution Approach 2:
The generator is divided into multiple independent kinetic energy conversion units, each consisting of a rotor-stator pair. These units are stacked axially to form a laminated structure, allowing each segment to contribute independently to the total power output while maintaining a compact overall form factor.
2Loss of energy
If permanent magnets are used in the rotors, then the generator achieves high efficiency, but irreversible demagnetization occurs at high temperature
Solution Approach 1:
The patent specifies precise parameter ranges for the permanent magnets including surface magnetism intensity (at least 3700 Gs), geometric ratios (d/h = 2-2.65 for round cylinders, 2.13-2.66 for sector-shaped cylinders), and volume ratios (20-50% of generator body). These optimized parameters ensure high magnetic field strength for efficiency while maintaining thermal stability to prevent demagnetization.
3Volume of moving object
If the stator size is limited, then the generator is compact, but the stator assembly is difficult to radiate heat
Solution Approach 1:
The patent employs a disk-type stator configuration with axial stacking of multiple layers, creating large surface area relative to volume. The antimagnetic outer fixing bracket and axial arrangement provide extended thermal pathways for heat radiation without significantly increasing the overall footprint, effectively solving the heat dissipation challenge in compact designs.
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 design significantly enhances power density and efficiency, with output power improved by at least twice compared to single-layer structures, achieving up to 85% efficiency and power density exceeding existing generators, while reducing weight and volume.
Implementation Method 1
the stator coil is provided with a coil holder, the coil holder is provided with a plurality of disk-shaped single coils, the rotor is composed of a rotor frame and a permanent magnet fixedly embedded into the rotor frame
Implementation Method 2
single coils on a side wall cut magnetic force lines, the generators consume a large amount of copper
Implementation Method 3
The outer fixing bracket is made of an antimagnetic material, and only the rotor in a magnetism-guided loop is a magnetizer
Data Source
AI summary
A generator is provided with stator coils fixed with an outer fixing bracket and rotors driven by a spindle, and the rotors are fixed with the spindle, and both of stator coils and a rotor frame are of disk shapes with the spindle passing through centers therein; one rotor and an adjacent stator coil constitute one kinetic energy conversion unit, a plurality of kinetic energy conversion units are axially aligned through the spindle and successively mounted in a consistent direction to form a laminated generator body; permanent magnets configured in even number and having consistent shapes on a single rotor frame are distributed in a form of regular polygon around an axis, the shape of a single coil is the same as that of the magnet.