Modular Switched Reluctance Motor Layout for Lower Unaligned Induction
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Solution Overview
Problem
Existing synchronous reluctance motors face challenges in torque production and power conversion efficiency due to unaligned induction, complex winding strategies, and inadequate cooling, particularly in axial-flux and radial-flux motors, which necessitate a more efficient and simpler design that reduces unaligned induction and enhances cooling.
Innovation Solution
A hybrid axial-flux and radial-flux switched reluctance motor design with modular rotor-stator assemblies and forced air-cooling systems, featuring minimal ferromagnetic material between stator poles and circumferential windings, along with vacuum cavities to minimize unaligned induction and enhance cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional axial-flux or radial-flux synchronous reluctance motors are used, then magnetic flux can be generated, but unaligned induction occurs reducing torque production and power conversion efficiency
Solution Approach 1:
The motor is divided into modular rotor-stator assemblies with discrete magnetic circuits for each phase, allowing independent optimization of each segment's magnetic path to minimize unaligned induction while maintaining torque production
Solution Approach 2:
Ferromagnetic material is removed from regions between stator poles where it would create unwanted magnetic flux paths during unaligned positions, eliminating the source of unaligned induction losses
2Power
If complex winding strategies are employed to improve torque, then torque production increases, but device complexity and manufacturing difficulty increase
Solution Approach 1:
Ferromagnetic material is strategically placed only in specific locations where it is needed for magnetic flux conduction, with minimal material between stator poles, optimizing magnetic circuit efficiency without requiring complex windings
Solution Approach 2:
The motor utilizes changes in magnetic reluctance as the rotor rotates, exploiting the natural variation in magnetic circuit impedance to generate torque through simple windings rather than complex configurations
3Temperature
If adequate cooling systems are added to improve heat dissipation, then temperature control improves, but device complexity and manufacturing cost increase
Solution Approach 1:
The motor structure itself provides cooling pathways through its modular rotor-stator assembly design, allowing air to flow naturally through internal channels and dissipate heat without requiring separate complex cooling systems
Solution Approach 2:
The motor incorporates ferromagnetic material with controlled porosity or structured geometry that facilitates air flow and heat dissipation while maintaining magnetic circuit integrity
4Loss of energy
If minimal ferromagnetic material is used between stator poles, then unaligned induction is reduced, but magnetic flux conduction path may be compromised
Solution Approach 1:
Ferromagnetic material is placed precisely where needed to conduct magnetic flux during aligned positions, with strategic gaps or reduced material in regions that would create unaligned induction, achieving both goals through localized optimization
Solution Approach 2:
The magnetic circuit is designed to dynamically adapt its effective path as the rotor rotates, providing strong flux conduction when aligned and minimal coupling when unaligned, exploiting the rotational position to optimize 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
The design achieves a 35% increase in torque and power conversion efficiency, with improved saliency ratio and responsiveness, while simplifying assembly and maintenance, and reducing manufacturing costs.
Implementation Method 1
a machine that transforms electric power into mechanical power (and vice versa) via the exclusive principle of magnetic reluctance
Implementation Method 2
The novel motor architecture enables a powerful and effective air-based cooling of the internal components, encompassing the electric windings plus rotor and stator
Implementation Method 3
the electrical winding is coiled in a circular manner circumferential around the said axis of rotation
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
The invention relates to a switched reluctance motor that includes two identical modules interconnected in parallel, each composed of a rotor assembly and two joined halves of a stator assembly. The two rotor assemblies are mounted and locked onto the same shaft such that when one is aligned with the stator, the other is unaligned. More particularly, the rotor assemblies are composed of a non-ferromagnetic shaft-mounted and rotational-locked disc, with slotted ferromagnetic blades forming the rotor poles. Two pairs of windings, located at either side of said rotor assembly, are enclosed within each stator's half and are coiled circumferentially around the engine axis, to facilitate assembly and maintenance. Each module has the same number of stator and rotor poles. Thus, the stator's cross section at the rotor midsection (during alignment) forms two vertically-mirrored O-shaped magnetic loops, where the flux exists the rotor vertically to the stator at the tip, travels around the windings on either side, down radially via the stator's poles, and enters axially back into the rotor blade. Electrically, each motor module is activated in an alternating way. Forced-air cooling is driven through the motor via rotating wings embodied into the rotor blades, and also via shaft mounted side fans. Two covers connect on either side of the two linked modules representing all together the static part of the motor, while bearings provide rotational interface between said covers and the shaft plus rotor assemblies. The vehicle and/or load-bearing machine's transmission axle slides inside, and is geared to, the shaft via inner teeth. The stator design minimizes coil exposure to ferromagnetic material during unalignment, effectively reducing unaligned induction. In another embodiment of the novel motor, the rotor gaps in between blades are filled with vacuum blades that, due to their absence of magnetic permeability, break completely the unaligned magnetic circuit, thus drastically enhancing this unaligned induction effect. The collective end outcome is a boost in torque production and power conversion capacity, including a readily available internal air-cooling ability.