Integrated Outer-Rotor Motor Layout for Higher Power Density
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Solution Overview
Problem
Existing motor control systems in aerospace and automotive applications are bulky and heavy due to separate motor and control component arrangements, requiring additional space and contributing to weight issues, especially in aircraft, where long cables introduce transmission line effects and reduce power density.
Innovation Solution
An integrated motor and motor drive arrangement with the motor drive components mounted on the inner surface of the stator, allowing for shared cooling and a compact design, where the rotor is positioned radially outside the stator, enabling the use of the stator's inner space for motor drive components and cooling systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If motor components and control circuitry are arranged separately, then each component can be optimized independently, but the overall system becomes large and heavy with reduced power density
Solution Approach 1:
The patent merges the control circuitry with the motor components into a single integrated assembly. The control circuitry is mounted on the motor housing or stator, eliminating the need for separate control units and reducing overall system size. This integration directly addresses the power density issue by consolidating components that were previously distributed separately, while still allowing independent optimization of each subsystem during the design phase.
Solution Approach 2:
The motor housing or stator structure serves multiple functions: it provides mechanical support for the motor components, acts as a mounting platform for the control circuitry, and functions as part of the cooling system. This multi-functionality reduces the number of separate components needed, thereby increasing power density without compromising the ability to optimize each functional element independently.
2Reliability
If separate cooling systems are provided for motor and control circuitry, then each component can be cooled optimally, but the system becomes more complex and heavier
Solution Approach 1:
The patent combines the cooling systems for the motor and control circuitry into a single integrated cooling arrangement. A common coolant flow path or heat sink structure serves both the motor windings and the control electronic components. This integration reduces the complexity of having separate cooling systems while maintaining effective cooling for both components through shared thermal management infrastructure.
Solution Approach 2:
The control circuitry is mounted within or on the motor structure, allowing the cooling system to be nested around both components simultaneously. The coolant channels or heat dissipation structures are positioned to contact both the motor stator and the control circuitry mounting surfaces, creating a nested cooling arrangement that efficiently removes heat from both sources without requiring separate external cooling systems.
3Adaptability or versatility
If long cables are used between motor and motor drive unit, then flexible installation is possible, but transmission line effects increase and weight increases
Solution Approach 1:
By integrating the control circuitry directly with the motor components, the patent eliminates the need for long connecting cables. The power and control connections are made through short internal traces or connectors within the integrated assembly, dramatically reducing cable length and eliminating transmission line effects such as signal reflection, impedance mismatch, and electromagnetic interference that occur with long cables.
4Power
If integrated motor and control system is used, then space and weight are reduced, but manufacturing complexity increases
Solution Approach 1:
The integrated motor and control system is designed as modular segments that can be manufactured separately and then assembled. The control circuitry is mounted on separate boards or modules that attach to the motor housing or stator, allowing independent manufacturing of motor and control components followed by simple assembly. This segmentation reduces manufacturing complexity while maintaining the space and weight benefits of integration.
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 enhances power density, reduces weight, and eliminates the need for separate motor drive units and cables, providing efficient cooling and a compact assembly suitable for space-constrained applications like aircraft propulsion systems.
Implementation Method 1
As the rotor rotates relative to the stator, magnetic fields are created which generate torque on a rotor shaft
Implementation Method 2
magnetic fields are created which generate torque on a rotor shaft to drive a mechanical load
Implementation Method 3
Cooling of the control system is also usually required to avoid damage to, and prolong the life of the components
Data Source
AI summary
An integrated motor and motor drive arrangement includes a motor having a stator, and a rotor, rotatable relative to the stator to drive a load, the rotor being arranged radially outside the stator, and the stator having an inner surface defining a radially inner space, the motor arrangement further comprising: motor drive components mounted to the inner surface of the stator within the radially inner space.