Permanent-Magnet Synchronous Machine Dual Winding Redundancy
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Solution Overview
Problem
Existing motor vehicle systems with higher rated voltages lack redundancy, leading to potential faults and reduced availability due to the lack of mechanical separation of coil windings and identical controller designs for different voltage levels.
Innovation Solution
A permanent-magnet synchronous machine with a stator comprising two electrically insulated stator windings of different conductor cross-sections and turn counts, connected in star and delta configurations respectively, to accommodate different operating voltages and provide improved redundancy and fault tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the stator winding is sub-divided into separate windings for different on-board networks, then redundancy and functional security are improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The stator winding is segmented into two electrically independent windings (first stator winding and second stator winding) that can be separately connected to different on-board networks. This segmentation enables redundancy where each winding can operate independently if the other fails, directly improving functional security while maintaining a manageable structural complexity through systematic design.
Solution Approach 2:
The synchronous machine is designed with multi-functionality to operate with different on-board network voltages (e.g., 12V and 48V). The machine can selectively connect to either the first or second on-board network depending on availability, providing universal compatibility across different voltage standards and enhancing system reliability without requiring separate machines for each voltage level.
2Adaptability or versatility
If separate windings are provided for different voltage levels, then adaptability to different on-board networks is improved, but the manufacturing precision requirements increase
Solution Approach 1:
Different portions of the stator winding have different local qualities optimized for their specific voltage requirements. The first stator winding is configured with conductor cross-section and turn count suitable for the first on-board network voltage, while the second stator winding has different parameters optimized for the second on-board network voltage. This local optimization enables adaptability to different voltage levels while managing manufacturing precision through targeted design rather than uniform specifications throughout.
3Volume of moving object
If windings are overwound or interwound to save space, then the volume of the machine is reduced, but the risk of short-circuits and faults increases
Solution Approach 1:
The stator winding is segmented into two electrically independent windings with separate routing and insulation. This segmentation prevents short-circuits between windings for different voltage levels while maintaining compact arrangement. The electrical independence of each winding ensures that a fault in one winding does not propagate to the other, preserving reliability despite space constraints.
Solution Approach 2:
Electrical insulation acts as an intermediary between the first and second stator windings, preventing direct contact and potential short-circuits. This insulation layer enables the windings to be arranged in close proximity for space efficiency while maintaining electrical separation to prevent faults and ensure reliable operation of each winding independently.
4Ease of manufacture
If identical output stages are used for both half-motors, then ease of manufacture is improved, but the ability to handle different voltage levels and fault scenarios is reduced
Solution Approach 1:
The synchronous machine incorporates multi-functionality by designing the output stages and control system to handle different voltage levels and operational scenarios. The machine can operate with either the first or second on-board network, and the control system can adapt to different voltage conditions, providing versatility while maintaining reasonable manufacturing simplicity through standardized components where applicable.
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 solution enables operation of the synchronous machine using either on-board network in case of failure, ensuring improved functional security and reduced localized saturation, while allowing for adaptable performance to different voltage levels.
Implementation Method 1
A permanent-magnet synchronous machine (1) comprises a rotor (2) and a stator (3) for holding at least a first stator winding (4a) and a second stator winding (4b)... the first stator winding (4a) is provided for motor operation with a first operating voltage... and the second stator winding (4b) is provided for motor operation at a second operating voltage
Data Source
AI summary
A permanent-magnet synchronous machine comprises a rotor and a stator for holding at least one first stator winding and a second stator winding which is electrically insulated from said first stator winding. The second stator winding has a smaller conductor cross section and a larger number of turns than the first stator winding, wherein a first operating voltage is provided for motor operation of the first stator winding and a second operating voltage is provided for motor operation of the second stator winding. The second operating voltage has a higher rated voltage than a rated voltage of the first operating voltage.