Electric Motor Winding Overhang Shielding for EMC
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Solution Overview
Problem
Electric machines in motor vehicles generate electromagnetic interference due to high-voltage supply and drive currents, which interfere with radio reception and compromise electromagnetic compatibility (EMC), and existing solutions fail to reduce these disturbances without affecting efficiency.
Innovation Solution
An electrically conductive shielding element is connected to the frame potential connection of the electric machine, partially arranged between the winding overhang and the rotor or drive shaft, to electrically and electromagnetically shield the winding overhang, using materials like aluminum or copper with sufficient conductivity to prevent disturbance transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high-voltage supply and drive currents are used for the electric machine, then the power and drive capability are improved, but electromagnetic interference radiation increases and compromises EMC
Solution Approach 1:
A shielding element made of electrically conductive material is introduced as an intermediary between the winding overhang and the surrounding environment. This shielding element is connected to the frame potential connection and acts as a mediator to redirect electromagnetic interference away from sensitive components, thereby maintaining both high power capability and EMC compliance
Solution Approach 2:
The shielding element utilizes the electromagnetic interference energy and redirects it to the frame potential connection, converting the harmful radiation into a controlled electrical path that dissipates energy safely without compromising the high-voltage power delivery capability of the electric machine
2Object-generated harmful factors
If shielding measures are added to reduce electromagnetic interference, then EMC is improved, but device complexity increases
Solution Approach 1:
Instead of implementing comprehensive shielding throughout the entire electric machine, the invention applies shielding selectively and locally only to the winding overhang area where electromagnetic interference is generated. This localized approach reduces device complexity while maintaining effective EMC protection
Solution Approach 2:
The shielding element is implemented as a thin, flexible conductive structure that can be easily integrated into the existing electric machine design. This thin-film approach provides effective electromagnetic shielding without adding significant structural complexity or volume to the device
3Object-generated harmful factors
If shielding elements are added to reduce electromagnetic interference, then EMC is improved, but manufacturing cost increases
Solution Approach 1:
The shielding element is designed as a thin, flexible conductive component that can be manufactured using cost-effective processes and materials. This approach provides necessary EMC protection while minimizing the impact on manufacturing cost
Solution Approach 2:
The invention optimizes the parameters of the shielding element, such as material selection, thickness, and conductivity, to achieve the minimum necessary shielding effectiveness. By carefully selecting parameters, the solution meets EMC requirements while minimizing material costs and manufacturing complexity
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 shielding effectively reduces electromagnetic interference below predetermined thresholds, preventing disturbance radiation and maintaining the efficiency of the electric machine, particularly in hybrid and battery electric vehicles.
Implementation Method 1
an electrically conductive shielding element arranged on the at least one winding overhang and configured to electrically and/or electromagnetically shield the winding overhang against an environment
Implementation Method 2
For generating the rotary field, individual electric coils of a coil device are alternately impinged with an electric current
Implementation Method 3
having a soft magnetic flux-guiding device for guiding the rotary field
Data Source
AI summary
An electric machine for a motor vehicle, includes a rotor, and a stator. The stator has a coil device for generating a magnetic rotary field for driving the rotor. the coil device has a soft magnetic flux-guiding device for guiding the rotary field, wherein the coil device is only partially arranged in the flux-guiding device, wherein at least one winding overhang of the coil device extends out of the flux guiding device into an environment of the stator. The electric also includes and an electrically conductive shielding element arranged on the at least one winding overhang and configured to electrically and/or electromagnetically shield the winding overhang against an environment, wherein the shielding element is connected to a frame potential connection of the electric machine.