Electric Power Steering Motor Winding Pattern for Blocking Torque Reduction
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Solution Overview
Problem
The existing electric power steering motor systems face a problem with increased blocking torque due to differences in the number of turns between adjacent coil layers, which hinders motor performance.
Innovation Solution
The motor design includes a stator with a specific winding pattern where only the (a*n+1)th turns form the first layer, and subsequent layers are stacked with a controlled number of turns, using an insulator with winding guides to manage the coil placement, reducing the number of turns in a closed circuit when a short circuit occurs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a parallel winding method is used with multiple coil layers, then the motor can achieve higher power density, but the difference in turn numbers between adjacent layers increases causing increased blocking torque
Solution Approach 1:
The patent changes the winding parameter by ensuring that the first layer of each coil stack consists of turns where (turn_number - 1) is divisible by (2a), where a is the number of coil layers. This parameter control ensures that adjacent layers have minimal turn number differences, reducing blocking torque while maintaining the parallel winding structure for high power density
Solution Approach 2:
The patent applies different winding patterns to different layers locally. Specifically, the first layer of each stack follows a specific turn number pattern ((a*n+1)th turns) while subsequent layers follow different patterns, creating local quality differences that minimize blocking torque at critical interfaces between adjacent layers
2Object-generated harmful factors
If the number of turns in adjacent coil layers is made equal, then blocking torque is reduced, but the manufacturing complexity increases due to precise winding control requirements
Solution Approach 1:
The patent establishes a simple mathematical parameter rule: the first layer consists of turns where (turn_number - 1) is divisible by (2a). This parameter-based approach provides clear manufacturing guidance without requiring complex real-time control, balancing blocking torque reduction with manufacturing simplicity
Solution Approach 2:
The patent determines the winding pattern in advance through the mathematical formula before actual winding begins. The winding guides are pre-configured according to the calculated turn numbers, allowing workers to follow a predetermined pattern rather than making complex real-time adjustments during winding
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
This approach decreases the difference in turn numbers between adjacent coil layers, thereby reducing the blocking torque even when a short circuit forms, enhancing motor performance.
Implementation Method 1
a coil wound around each tooth of the teeth, the coil is wound a plurality of turns around the tooth
Data Source
AI summary
The present invention may provide a motor including a rotating shaft, a rotor coupled to the rotating shaft, and a stator disposed outside the rotor, wherein the stator includes a stator core having a plurality of teeth, and a coil wound around each tooth of the teeth, the coil is wound a plurality of turns around the tooth, and only the coil of (a*n+1)th turns among the plurality of turns forms a first layer closest to the tooth, wherein a is the number of total stacked layers of the coil, and n is zero or a positive integer.