Modular PMaSynRM Winding Design for Fault Tolerance
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Solution Overview
Problem
Conventional PMaSynRMs with distributed winding suffer from poor fault-tolerant performance, leading to potential safety threats due to phase-to-phase magnetic circuit coupling and vulnerability to open or shorted circuits, which can cause electrical torque drop and severe vibration.
Innovation Solution
A modular winding design is introduced, featuring a modular stator with non-magnetic conductors and asymmetric rotor, where each module has independent three-phase windings and flux barriers with varying angles, allowing for physical, magnetic, and thermal isolation between modules, and enabling decoupling of flux lines to enhance fault tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional three-phase PMaSynRM with distributed winding is used, then the motor structure is simple, but the fault-tolerant performance is poor due to phase-to-phase magnetic circuit coupling
Solution Approach 1:
The stator is divided into multiple independent modules, each with its own three-phase winding set. The modules are physically isolated by non-magnetic conductors, creating independent magnetic circuits. This segmentation allows one module to fail without affecting others, significantly improving fault-tolerant performance while maintaining reasonable structural complexity through modular design
Solution Approach 2:
Non-magnetic conductors are introduced as intermediary elements between adjacent stator modules. These conductors prevent magnetic flux from coupling between modules, effectively isolating the magnetic circuits. This intermediary structure enables independent operation of each module while maintaining overall motor functionality even when other modules fail
2Reliability
If conventional distributed winding is used, then the manufacturing process is simple, but the motor is vulnerable to open or shorted circuits causing severe vibration and torque drop
Solution Approach 1:
The winding system is segmented into multiple independent three-phase sets, each confined to a specific stator module. This segmentation ensures that open or shorted circuit faults are localized to individual modules rather than affecting the entire motor. The modular winding design maintains manufacturing feasibility through standardized repeating units
Solution Approach 2:
Each stator module has its own dedicated three-phase winding with unique local characteristics. The windings are designed with specific local quality features including localized magnetic conductors and tailored flux barrier configurations. This local quality approach enables independent fault isolation while maintaining overall system functionality
3Reliability
If modular design with non-magnetic conductors is implemented, then magnetic isolation between modules is achieved, but the device complexity increases
Solution Approach 1:
The stator is segmented into discrete modules separated by non-magnetic conductors. This segmentation creates distinct magnetic circuits within each module while the non-magnetic conductors provide physical and magnetic isolation. The modular structure achieves effective magnetic isolation but increases structural complexity through the addition of dividing elements
Solution Approach 2:
Non-magnetic conductors serve as intermediary elements that physically divide and magnetically isolate adjacent stator modules. These conductors are positioned at specific locations to prevent flux leakage between modules. The intermediary structure provides necessary magnetic isolation but adds complexity to the overall stator construction
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 modular design achieves high independence between modules, ensuring safe operation under fault conditions by allowing faulty windings to be removed, reducing torque ripple, and improving fault tolerance through independent module control, while also simplifying assembly and reducing costs.
Implementation Method 1
Each module is formed by two non-magnetic conductors (4) distributed along the circumference... achieving physical isolation, magnetic isolation and thermal isolation between each set of windings
Implementation Method 2
PMaSynRM is a special IPMS motor and its permanent magnet is used to improve the power factor
Implementation Method 3
The permanent magnets (6) are inserted in the flux barriers and the N poles and the S poles of the permanent magnets adjacent in the circumferential direction are alternately arranged
Implementation Method 4
The rotor includes rotor iron core (2-1), flux barriers (2) and permanent magnets (6). Flux barrier angles are different in each pole
Implementation Method 5
The modular stator (1) includes stator iron core (1-1), armature windings (3)... each module has independent three-phase windings
Data Source
AI summary
The present invention relates to a fault-tolerant modular permanent magnet assisted synchronous reluctance motor (PMaSynRM) and provides a modular winding connection method. The modular winding connection is to change the positions of inlet and outlet coils based on the slot electrical potential star vectogram. Then, each module has a separate set of winding and the left and right relative distribution will be adopted on the winding connection. The invention has the advantages of modularization in structure, high independence between the modules, effectively avoiding overlapping of magnetic lines between the modules, and improving fault tolerance and reliability of the motor. The invention has the advantages of modularization in structure, high independence between the modules, magnetic decoupling between the modules, and improvement of fault tolerance and reliability of the motor.