Modular Transverse Flux Stator Assembly
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Solution Overview
Problem
Existing transverse flux electrical machines face challenges in assembly complexity and cost, with a need for a modular design that simplifies production and enhances mechanical torque per unit weight.
Innovation Solution
A modular transverse flux electrical machine (TFEM) comprising axially assembled phase modules with a 120° phase shift, secured by opposed support portions, featuring a stator with soft iron cores and a rotor with permanent magnets, allowing for easy assembly and increased torque efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a traditional transverse flux electrical machine is designed with circular stator and rotor components, then the machine achieves high mechanical torque per weight unit, but the assembly complexity and production cost increase significantly
Solution Approach 1:
The stator is divided into multiple identical modular units, each comprising U-shaped soft iron cores with embedded toroid coils. These modular units can be independently manufactured and then assembled by stacking, significantly reducing assembly complexity while maintaining the transverse flux configuration that delivers high torque per weight unit
2Shape
If a traditional transverse flux electrical machine uses circular stator and rotor with U-shaped cores, then the machine achieves proper magnetic flux directionality, but the production cost increases
Solution Approach 1:
The machine is segmented into standardized modular units that can be mass-produced using conventional manufacturing techniques. Each module maintains the U-shaped core geometry necessary for transverse flux, but the modular approach enables economies of scale and simplified production processes, reducing overall manufacturing cost
Solution Approach 2:
The modular design creates universal building blocks that can be configured for different power ratings and applications by varying the number of stacked modules. This universality reduces tooling costs and enables standardized production processes across multiple product variants
3Force
If the stator comprises horseshoe shaped soft iron cores oriented perpendicular to rotation axis, then high torque per weight is achieved, but the assembly process becomes more difficult
Solution Approach 1:
The stator is segmented into discrete modular units that can be independently assembled and then stacked together. Each module contains the horseshoe-shaped U-cores in the required perpendicular orientation for high torque, but the segmentation allows for simpler handling and assembly compared to constructing a large monolithic structure
Solution Approach 2:
The assembly approach transitions from in-plane assembly to axial stacking. Modules are assembled individually and then stacked along the axial dimension to form the complete stator, converting a complex two-dimensional assembly problem into a simpler one-dimensional stacking operation
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 simplifies assembly, reduces production costs, and achieves a high mechanical torque per unit weight by ensuring proper phase alignment and magnetic flux directionality, enhancing overall machine performance.
Implementation Method 1
the rotor comprises a plurality of identical permanent magnet parts, which are disposed so as to create an alternated magnetic flux in the direction of the air gap. This magnetic flux goes through the air gap with a radial orientation and penetrates the soft iron cores of the stator, which directs this magnetic flux around the electrical conductors.
Implementation Method 2
electrical conductors, defining a toroid coil, which is coiled in a direction that is parallel to the direction of rotation of the machine
Implementation Method 3
The perpendicular orientation of the magnetic flux in the cores of the stator, with respect to the rotation direction, gives to transverse flux electrical machines a high ratio of mechanical torque per weight unit of the electrical machine.
Data Source
AI summary
A modular stator portion adapted to be used in a transverse flux electrical machine (TFEM) includes a plurality of phase modules adapted to be axially secured together with a plurality of securing members. The phase modules of at least en embodiment thereof are substantially identical and interchangeable. Each pair of axially adjacent phase modules are adapted to be angularly located in respect with each other to set a phase shift. A phase module and a kit of phase modules sized and designed to assemble a modular stator are also encompassed by the present application.