Redundant BLDC Motor Windings for Fault-Tolerant Torque Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric motor designs face inefficiencies and reliability issues due to shared stator windings, which can lead to reduced torque and performance variability, particularly in brushless DC motors.
Innovation Solution
The implementation of two separate and isolated electromagnetic windings in a brushless DC motor, each with specific turn configurations and phases, allows for independent control and enhanced torque generation, improving reliability and efficiency by reducing electrical interference between windings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If shared stator windings are used in electric motors, then device complexity is reduced, but reliability and torque consistency deteriorate due to electrical interference and performance variability
Solution Approach 1:
The patent divides the stator windings into two separate and isolated winding sets (first winding set and second winding set), each with independent coils and phases. This segmentation eliminates electrical interference between windings while maintaining controlled complexity through systematic arrangement of the separate winding sets around the stator perimeter.
2Ease of manufacture
If shared stator windings are used, then manufacturing is simpler, but torque production and performance consistency worsen due to electrical interference
Solution Approach 1:
The stator windings are segmented into two independent winding sets with separate coils and phases, eliminating electrical interference that degrades torque production. Each winding set can be manufactured and tested independently, improving overall torque consistency and performance reliability.
Solution Approach 2:
Different winding sets are assigned to different spatial regions of the stator (e.g., first winding set in one half, second winding set in the other half), allowing each local region to contribute optimally to torque production without interference from adjacent windings, thereby improving overall power output consistency.
3Reliability
If separate electromagnetic windings are implemented, then reliability and torque consistency improve, but device complexity increases
Solution Approach 1:
The patent implements segmentation of windings into two independent sets, which improves reliability by eliminating electrical interference. The complexity is managed through systematic placement of winding sets in different stator regions and using standardized coil configurations within each set.
Solution Approach 2:
Both winding sets are designed with the same fundamental structure and function (producing electromagnetic torque), allowing them to be controlled independently or together. This universality simplifies the overall system architecture despite the increased number of components, as each winding set can serve multiple operational modes.
4Power
If separate electromagnetic windings are implemented, then electrical interference is reduced and performance improves, but manufacturing complexity increases
Solution Approach 1:
The windings are segmented into separate sets that can be manufactured, tested, and assembled independently. This segmentation improves performance by eliminating electrical interference while managing manufacturing complexity through modular construction and standardized coil designs within each winding set.
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 design enhances torque production and reduces electrical interference, resulting in improved motor performance and fault tolerance, enabling precise speed and direction control of the rotor.
Implementation Method 1
the stator coils is to generate magnetic flux that interacts with the permanent magnets of the rotor
Implementation Method 2
a magnetic field is formed that interacts with the magnetic field of the permanent magnet of the rotor in a manner such that torque and subsequent rotation is produced
Data Source
AI summary
An electric motor assembly comprising a rotor, a stator, first and second electromagnetic winding in first and second separate slot sets of a plurality of stator slots operatively configured to be selectively energized to exert a torque on the rotor, the first windings comprising first and second coils in first and second pairs of slots in the first slot set, the first coil comprising a first number of turns and the second coil comprising a second number of turns that is greater than the first number of turns, the second windings comprising third and fourth coils in third and fourth pairs of slots in the second slot set, the third coil comprising a third number of turns and the fourth coil comprising a fourth number of turns that is greater than the third number of turns.