Nine-Phase Induction Motor Starter Alternator Topology

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Solution Overview

Problem

Existing induction motors used as both starters and alternators face increased electronic complexity due to the need to change the number of phases to accommodate different operating modes, leading to inefficiencies in torque and speed transitions.

Innovation Solution

A nine-phase induction motor with windings configured in mesh or star configurations, using contactors to selectively connect windings between current inputs with a 40-degree phase angle difference, and receiving different harmonics of the drive waveform to adjust magnetic poles and torque output electronically.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the number of phases is changed to accommodate different operating modes, then the motor can operate in both starter and alternator modes, but the electronic complexity of the inverter increases significantly

Engineering Contradiction:
Improveoperating mode flexibilityVSAvoidinverter electronic complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies dynamics by making the winding configuration adjustable between mesh and star configurations through contactors. This dynamic reconfiguration allows the motor to adapt between starter and alternator modes without changing the number of phases, thereby maintaining inverter complexity while achieving operational versatility.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent changes physical parameters (winding configuration and connection topology) rather than electrical parameters (number of phases). By switching between mesh and star configurations and adjusting which windings are connected to which current inputs, the motor achieves different operating characteristics without requiring the inverter to generate different numbers of phases.

Inventive Principle:
Principle #35Parameter changes

2Force

If the induction motor operates at lower speeds and higher torque for starting, then the machine can be cranked effectively, but the battery power is significantly drained

Engineering Contradiction:
Improvestarting torqueVSAvoidbattery power consumption
Core Design Contradiction:
ForceVSUse of energy by moving object

Solution Approach 1:

The patent makes the induction motor multi-functional by enabling it to serve both as a starter motor and as an alternator. The same motor windings and structure are used for both high-torque starting and power generation, eliminating the need for separate components and allowing the alternator function to recharge the battery, thereby reducing net power consumption.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system implements self-service by using the induction motor in alternator mode to generate electrical power that recharges the battery. This means the system partially powers itself during operation, reducing the net drain on the battery over time.

Inventive Principle:
Principle #25Self-service

3Power

If the induction motor operates at higher speeds and lower torque in alternator mode, then sufficient electrical power can be generated, but the transition from starter to alternator mode becomes complex

Engineering Contradiction:
Improveelectrical power generationVSAvoidmode transition complexity
Core Design Contradiction:
PowerVSDevice complexity

Solution Approach 1:

The patent uses dynamic switching of winding configurations via contactors to facilitate mode transitions. The contactors selectively connect or disconnect windings in mesh or star configurations, enabling smooth transition between starter and alternator modes without complex electronic control, thereby achieving high-speed power generation with simplified transition mechanics.

Inventive Principle:
Principle #15Dynamics

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 configuration allows for smooth transitions between starting and alternator modes with reduced electronic complexity, enabling higher torque at low speeds and higher speeds with lower torque while maintaining efficient power generation and consumption.

Implementation Method 1

an electrical induction motor configured to receive nine separate current inputs at nine separate terminals from nine output phases of a nine phase inverter

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

Each of the plurality of contactors is configured to be selectively opened or closed in a circuit including the nine windings to selectively connect the nine windings together in one of a mesh configuration or a star configuration

Methodology Applied
Scientific EffectElectrical circuit switching: Conduction (electrical)

Implementation Method 3

The motor is further configured to selectively receive a first one of the harmonics of a drive waveform generated by the nine phase inverter, and a second, different one of the harmonics of the drive waveform generated by the nine phase inverter

Methodology Applied
Scientific EffectHarmonic generation: Electromagnetic Induction

Data Source

PatentUS9416761B2Nine phase induction motor starter/alternator
Publication Date: 2016.08.16 CATERPILLAR INC
  • US9416761B2 patent drawing
  • US9416761B2 patent drawing
  • US9416761B2 patent drawing

AI summary

An electrical induction motor may include nine terminals configured to receive nine current inputs from nine output phases of a nine phase inverter. The motor may include nine windings connected to the nine terminals, and a plurality of contactors, wherein each of the plurality of contactors may be selectively opened or closed in a circuit including the nine windings to selectively connect the windings together in one of a mesh configuration or a star configuration. Each of the windings may be selectively connected between two of the nine current inputs, with a phase angle difference between the two current inputs of 40 degrees. Each of the contactors may be selectively opened or closed to establish a span value for the mesh configuration of two, with two being the number of inverter output phases between a terminal of one of the nine windings and a terminal of another of the nine windings connected to the one of the nine windings. The motor may selectively receive a first one of the harmonics of a drive waveform generated by the nine phase inverter and a second, different one of the harmonics of the drive waveform generated by the nine phase inverter.