Electric Drive Scalable Reconfigurable Winding Torque

Solution Overview

Problem

Electric machines in hybrid vehicle systems face constraints in torque capability at high speeds due to operating voltage limits, leading to decreased torque profiles as speed increases, and existing methods for extending speed ranges are limited in scalability and efficiency.

Innovation Solution

A stator phase circuit with series coupled sub-winding circuits and controllable switches allows for configurable winding turn ratios, enabling transitions between operating speed ranges by selectively energizing sub-winding circuits, thereby enhancing torque capability across the entire operating speed range.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If flux weakening is used to extend operating speed range, then speed range is extended, but torque capability decreases at high speeds

Engineering Contradiction:

Improveoperating speed rangeVSAvoidtorque capability

Core Design Contradiction:

SpeedVSForce

Solution Approach 1:

The phase winding circuit is divided into multiple series-coupled sub-winding circuits, each with controllable switches. This segmentation allows selective energization of sub-windings to maintain torque capability across different speed ranges while extending the overall operating speed range of the machine.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The winding configuration is made dynamic through controllable switches that can selectively connect or disconnect sub-winding circuits based on operating speed. This dynamic reconfiguration enables the machine to adapt its torque characteristics to maintain optimal performance across an extended speed range.

Inventive Principle:

Principle #15Dynamics

2Power

If two mode series and parallel connection switching is used, then torque output is optimized for two speed ranges, but scalability to multiple speed ranges is limited

Engineering Contradiction:

Improvetorque outputVSAvoidscalability to multiple speed ranges

Core Design Contradiction:

PowerVSAdaptability or versatility

Solution Approach 1:

The phase winding is segmented into multiple independent sub-winding circuits that can be selectively connected in series or parallel combinations. This segmentation provides a scalable framework where additional sub-windings can be added to create more speed ranges and optimization modes without fundamentally changing the architecture.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each sub-winding circuit is designed with universal controllability through controllable switches, enabling the same basic circuit structure to serve multiple functions across different operating conditions. This multi-functionality allows a single machine design to optimize torque output across many speed ranges rather than being limited to two modes.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If the number of sub-winding circuits is increased to cover more speed ranges, then adaptability increases, but device complexity increases

Engineering Contradiction:

Improvenumber of speed rangesVSAvoidnumber of controllable switches

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The phase winding circuit is divided into multiple series-coupled sub-winding circuits, each with controllable switches. This segmentation allows selective energization of sub-windings to maintain torque capability across different speed ranges while extending the overall operating speed range of the machine.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The winding configuration is made dynamic through controllable switches that can selectively connect or disconnect sub-winding circuits based on operating speed. This dynamic reconfiguration enables the machine to adapt its torque characteristics to maintain optimal performance across an extended speed range.

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 significantly increases torque capability and scalability, allowing the electric machine to maintain optimal torque output across multiple speed ranges, improving the efficiency and performance of hybrid vehicle systems.

Implementation Method 1

each sub-winding circuit includes a respective sub-winding coupled in parallel across a respective first controllable switch

Methodology Applied

Scientific EffectElectrical switching:

Implementation Method 2

A stator phase circuit for an electric machine includes a phase winding circuit including a plurality of series coupled sub-winding circuits

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS8736216B2Electric drive with electronically scalable reconfigurable winding

Publication Date: 2014.05.27 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A stator phase circuit for an electric machine includes a phase winding circuit including a plurality of series coupled sub-winding circuits, each sub-winding circuit includes a respective sub-winding coupled in parallel across a respective first controllable switch.