Modular Electric Machine Segments for Stator Assembly
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Solution Overview
Problem
Existing electric machine systems with parallel power converters face issues such as circulating electrical currents, overheating, and lack of modularity due to mechanical and electrical coupling complexities, making it difficult to remove or replace segments without disassembling large portions of the machine.
Innovation Solution
The system includes electrically isolated coils within machine segments, each with unique electrical terminals for removability and mechanical coupling, allowing for easy assembly, disassembly, and replacement of segments to form parts of a stator or rotor, thereby reducing circulating currents and enhancing modularity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple power converters are connected in parallel to achieve higher power or redundancy, then system power capacity and reliability are improved, but circulating electrical currents occur causing overheating and energy loss
Solution Approach 1:
The machine is divided into multiple electrically isolated segments, each connected to separate power converters. The stator contains multiple independent coil sets (e.g., three sets of coils per phase) that are electrically isolated from each other, allowing each segment to be controlled independently by its own power converter, thereby preventing circulating currents between parallel converters.
2Strength
If machine segments are mechanically coupled to form stator or rotor, then structural integrity is improved, but modularity is reduced making it difficult to remove or replace segments
Solution Approach 1:
The machine is divided into discrete, modular segments that can be independently assembled and disassembled. Each segment contains complete electrical windings and can be mechanically coupled to adjacent segments through standardized interfaces, allowing for easy replacement or reconfiguration while maintaining overall structural integrity when assembled.
Solution Approach 2:
The mechanical coupling system allows segments to be dynamically assembled and disassembled. The segments are designed with features that enable them to be securely coupled during operation for structural integrity, but can be easily separated when maintenance or reconfiguration is needed, providing dynamic adaptability between operational and maintenance states.
3Reliability
If electrical connections are made permanent for reliability, then connection stability is improved, but ease of maintenance is reduced making it difficult to disconnect segments
Solution Approach 1:
The electrical system is segmented into independent coil sets with isolated electrical connections. Each segment's electrical connections are designed to be permanently reliable during operation through proper insulation and bonding, yet the segmented architecture allows entire electrical assemblies to be removed as complete units for maintenance, eliminating the need to work with individual permanent connections.
Data Source
AI summary
In some embodiments, a system includes a machine segment that includes multiple coils. Each coil is electrically isolated from the other coils in the machine segment, and each coil is electrically coupled to at least one electrical terminal to provide electrical access to the coil. Each electrical terminal provides electrical access to the coil to which it is electrically coupled such that the coil can be removably electrically coupled to an electrical circuit. The machine segment is also configured to be removably mechanically coupled to a second machine segment to form at least a portion of a stator or a portion of a rotor.