Modular Stator-Inverter Assembly for Scalable Electric Machines
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Solution Overview
Problem
Existing rotary electric machines require custom stator and rotor configurations for specific torque and power capabilities, leading to high manufacturing complexity and costs, as well as limited scalability across different applications.
Innovation Solution
A modular stator-inverter assembly that uses a common stator and traction power inverter module, compatible with various pre-configured rotors, allowing for scalable torque and power capabilities without the need for custom configurations, by optimizing stator design, pole-slot combinations, magnet types, and winding configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If custom stator and rotor configurations are used for specific torque and power capabilities, then the electric machine meets application-specific performance requirements, but manufacturing complexity and costs increase
Solution Approach 1:
The patent applies universality by designing a common stator-inverter assembly that can work with multiple rotor types (permanent magnet rotors, reluctance rotors, induction rotors) to provide different torque and power capabilities. The stator is designed with optimized pole-slot combinations and winding configurations that are compatible with various rotor configurations, allowing a single stator design to serve multiple application-specific needs through rotor selection alone.
Solution Approach 2:
The patent segments the electric machine into modular components: a universal stator-inverter assembly and interchangeable rotor modules. This segmentation allows the complex customization requirements to be handled by selecting different standardized rotor modules rather than customizing the entire machine, thereby reducing manufacturing complexity while maintaining adaptability.
2Adaptability or versatility
If custom stator and rotor configurations are used for specific torque and power capabilities, then the electric machine meets application-specific performance requirements, but costs increase
Solution Approach 1:
The universal stator-inverter assembly serves multiple application-specific configurations, reducing the need for multiple custom stator designs. This universality reduces tooling costs, simplifies supply chain management, and enables economies of scale in stator production, thereby lowering manufacturing costs while maintaining the ability to meet different torque and power requirements through rotor selection.
Solution Approach 2:
The modular architecture allows for easier recovery and reuse of the expensive stator-inverter assembly across different applications. When an application-specific machine needs to be modified or upgraded, only the rotor module needs to be changed while the stator-inverter assembly can be recovered and reused, reducing overall manufacturing costs.
3Manufacturing precision
If custom stator configurations are used for specific applications, then performance requirements are met, but scalability across different applications is limited
Solution Approach 1:
The stator is designed with universal compatibility features including optimized pole-slot combinations and winding configurations that work with multiple rotor types. This universality enables scalability across different applications while maintaining application-specific optimization through the selection of appropriate rotor modules with specific magnetic properties and geometries.
4Device complexity
If a common stator-inverter assembly is used with various rotors, then manufacturing complexity and costs are reduced, but the stator design must be optimized for multiple rotor types
Solution Approach 1:
The stator design incorporates parameter optimizations such as specific pole-slot combinations and winding configurations that create a universal interface compatible with multiple rotor types. By carefully selecting and optimizing these parameters, the stator can work with different rotor configurations without requiring modification, achieving both reduced manufacturing complexity and broad compatibility.
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 cost-effective and simplified manufacturing of electric machines with scalable torque and power capabilities, reducing complexity and enabling use across multiple applications without modifying the stator-inverter assembly, while maintaining optimal performance.
Implementation Method 1
an AC input voltage is applied to the stator windings to generate a rotating stator field
Implementation Method 2
The rotating stator field interacts with the magnetic field of the rotor to produce and sustain tangential forces within a radial stator-rotor airgap
Data Source
AI summary
A modular stator-inverter assembly for an electric machine includes a stator and a traction power inverter module (“TPIM”). The stator includes a stator core having a center axis, an inner diameter (“ID”), an outer diameter (“OD”), and electrical conductors forming stator windings. Stator teeth extending radially toward the center axis from the ID collectively define stator slots occupied by the stator windings. Each adjacent pair of stator teeth defines a respective stator slot. The TPIM delivers a polyphase voltage to the stator windings to generate a predetermined number of stator poles, such that the stator has either two, three, or four of the stator slots per electric phase per stator pole. The stator defines a center cavity and is configured to receive a selected rotor from an inventory of preconfigured machine rotors. The inventory includes multiple synchronous reluctance machine rotors and an induction machine rotor.