Rotor End-Face Induction Coil for Self-Powered Temperature Sensing
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Solution Overview
Problem
Existing electric machines face challenges in supplying sensors associated with the rotor with sufficient electrical energy, leading to limited continuous power due to unknown rotor temperature, which can result in overheating and damage.
Innovation Solution
Incorporating a sensor element and signal processing unit connected to an induction coil on the rotor's end face, which generates electrical energy from the rotating magnetic front stray field, allowing for self-sustenance and reducing the need for external power sources like batteries or collecting rings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors and signal processing units are installed on the rotor to enable real-time temperature monitoring, then measurement precision and reliability are improved, but device complexity and difficulty of installation increase due to the need for external power sources
Solution Approach 1:
The sensor system on the rotor is powered by the magnetic field it monitors. The induction coil generates electrical energy directly from the rotating magnetic field, enabling the sensor and signal processing unit to be self-sufficient without external power sources like batteries or collecting rings
Solution Approach 2:
The induction coil acts as an intermediary that converts the magnetic field (which already exists for motor operation) into electrical energy to power the sensor system. This mediator enables power transfer without mechanical contact or external power sources
2Reliability
If a safety margin is applied to the maximum rotor temperature, then reliability is improved by preventing overheating, but productivity decreases due to limited continuous power output
Solution Approach 1:
The sensor continuously monitors the actual rotor temperature and feeds this information back to the control device. The control device adjusts the power output based on real-time temperature data, allowing operation right up to the maximum temperature limit without requiring a conservative safety margin
Solution Approach 2:
The system performs periodic temperature measurements and control adjustments, allowing dynamic optimization of power output while maintaining safety. The continuous monitoring enables the system to operate at maximum capacity with real-time safety management
3Reliability
If traditional power supply methods like collecting rings or batteries are used for rotor sensors, then power supply reliability is improved, but ease of operation deteriorates due to complex installation and maintenance requirements
Solution Approach 1:
The induction coil generates electrical energy autonomously from the rotating magnetic field, eliminating the need for batteries that require replacement or collecting rings that require precise alignment and maintenance. The system powers itself through its normal operation
Solution Approach 2:
The power supply function is extracted from external components (batteries, collecting rings) and integrated directly into the rotor structure through the induction coil, which generates power internally from the existing magnetic field
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 solution enables accurate temperature measurement and reduces the risk of overheating by providing a reliable power source for sensors and signal processing units, allowing for improved operation and easier installation of the rotor.
Implementation Method 1
at least one induction coil, which includes at least one electrical conductor and is arranged at least indirectly on an end face of the rotor and is configured for generating electrical energy from a magnetic front stray field, which is rotating in relation to the rotor or temporally changing during the operation of the electric machine
Data Source
AI summary
A rotor (1) for an electric machine (2) includes at least one sensor element (3) configured for detecting at least one condition variable of the rotor (1), a signal processing unit (4) connected to the at least one sensor element (3) and configured for generating measured data from the detected condition variable of the rotor (1) and transmitting the measured data to a control device (5), and at least one induction coil (7) that includes at least one electrical conductor (8), is arranged at least indirectly on an end face of the rotor (1), and is configured for generating electrical energy from a magnetic front stray field (12) rotating in relation to the rotor (1) during the operation of the electric machine (2).