Electric Motor Bar Winding Connection Plates
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Solution Overview
Problem
Existing multiphase synchronous electrical machines for transport vehicles are bulky and heavy due to the need for additional systems like KERS, which increases weight and dimensions, limiting their application in hybrid vehicles.
Innovation Solution
A compact three-phase synchronous electrical machine design with a rotor and stator pack featuring a winding system that includes connection plates with a main body and arms, optimizing space usage and minimizing volume, while utilizing permanent magnets and a carbon fibre tube for reduced inertia and enhanced reactivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If additional KERS system is installed for kinetic energy recovery, then energy conversion capability is improved, but weight and volume of the vehicle increase
Solution Approach 1:
The patent integrates the kinetic energy recovery system directly into the vehicle's existing electrical machine architecture. The electrical machine serves dual functions as both the primary motor and the KERS generator, eliminating the need for separate dedicated KERS components. This merging approach enables energy recovery capability while avoiding additional weight and volume penalties that would result from completely separate systems.
2Use of energy by moving object
If additional KERS system is installed for kinetic energy recovery, then energy conversion capability is improved, but volume and dimensions of the vehicle increase
Solution Approach 1:
The KERS functionality is merged with the existing electrical machine structure. The stator pack and rotor assembly serve both as the propulsion motor and as the energy recovery generator during braking. This integration allows the system to achieve dual functionality without requiring additional space for separate KERS components, thus avoiding volume increases.
3Volume of moving object
If connection plates with arms extending towards axis are used, then space utilization is improved, but manufacturing complexity increases
Solution Approach 1:
The connection plate is segmented into distinct functional zones: a main body portion that connects to the bars and an arm portion that extends radially inward toward the axis. This segmentation allows each zone to be optimized independently for its specific function while maintaining overall structural integrity. The segmented design facilitates manufacturing by enabling separate formation of the connection plate body and arms, potentially through stamping or casting processes.
Solution Approach 2:
The connection plate serves multiple functions simultaneously: it provides mechanical support for the bars, establishes electrical connections between bars, and the arm portion provides structural reinforcement while enabling compact winding arrangement. This multi-functionality reduces the need for additional separate components, simplifying the overall manufacturing process despite the complex geometry.
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 high power-to-weight efficiency, minimizing volume and weight, and provides effective kinetic energy conversion while maintaining high performance and efficient heat exchange, thus overcoming the limitations of traditional systems.
Implementation Method 1
a multiphase synchronous electrical machine for converting kinetic energy into electrical energy and electrical energy into kinetic energy
Implementation Method 2
a rotor (4) with permanent magnets (22) extending along an axis
Data Source
AI summary
A multiphase synchronous electrical machine for converting kinetic energy into electrical energy and electrical energy into kinetic energy has a rotor, extending along an axis, and a stator, which is provided with a stator pack having slots and with an electrical winding, which extends in part in the slots and in part at two heads arranged on opposite sides of the stator pack and which has bars, housed in the slots and connected to one at the heads, connection plates, each of which has: a main body having at least two seats for housing the bars; and an arm, which is set between the two seats and extends from the main body towards the axis.