Electric Motor Sub-Coil Winding for Higher Power Density
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Solution Overview
Problem
Conventional electric motors face limitations in power density due to the opposing direction of electric current flow, which restricts torque and speed, and increasing power supply voltage requires additional complex and expensive booster components, leading to inefficiencies.
Innovation Solution
A novel winding arrangement that subdivides phase turns into sub-coils, allowing for lower voltage, resistance, and inductance, enabling independent control of sub-coils and using silicon switches for improved efficiency and redundancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the power supply voltage is increased to overcome current flow limitations and improve torque and speed, then the power density increases, but additional complex and expensive booster components are required
Solution Approach 1:
The patent divides the phase winding into multiple sub-coils (e.g., three sub-coils per phase) that can be independently controlled. This segmentation allows the motor to operate in different modes (motoring, generating, braking) without requiring external voltage boosting, as each sub-coil can be switched independently to achieve the desired electrical characteristics and power output.
2Power
If the power supply voltage is increased using a booster converter, then the power density increases, but energy losses increase due to electrical resistance and accumulation in the booster
Solution Approach 1:
The motor system performs its own voltage and power management through the independent control of sub-coils. The motor can operate in generating mode to recover energy during deceleration, and in braking mode to dissipate excess energy, eliminating the need for external booster converters that would introduce energy losses through resistance and accumulation.
3Shape
If the number of turns in phase winding is increased to generate higher voltage, then the voltage output increases, but the speed and current capability are limited
Solution Approach 1:
By dividing the phase winding into multiple sub-coils with fewer turns each, the motor achieves the desired voltage output through series connection during motoring mode while maintaining the capability for higher speed operation. The segmented structure allows flexible switching between different connection configurations to optimize for either voltage or speed requirements.
Solution Approach 2:
The patent implements dynamic switching between different operational modes (motoring, generating, braking) and different sub-coil configurations. This dynamic control allows the motor to adapt its electrical characteristics in real-time, achieving both high voltage output when needed and high speed capability when required, rather than being constrained by a fixed winding configuration.
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 new motor design enhances power density, reduces size and cost, and maintains efficiency by eliminating the need for external power conditioning components, while ensuring operation even with partial component failures.
Implementation Method 1
the voltage generated by a motor is proportional to the numbers of turns in a phase winding
Data Source
AI summary
An electric motor and winding method that improves its characteristics of torque and speed. An improved electric motor that provides higher power density and safety features by a novel winding architecture. Since the new winding architecture does not affect the measures, design or materials of the electric motor there is no need for any special manufacturing process or extra cost. Therefore the improved electric motors are smaller, lighter and cheaper than the same power size conventional electric motors as in other prior arts. The improved electric motor provides redundancy features against failure.