Segmented Transverse Flux Motor for Scalable Torque Output
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Solution Overview
Problem
Existing electric motors, particularly transverse flux motors, face challenges in efficiently generating high torque and power output while maintaining a compact design and modular scalability.
Innovation Solution
The design incorporates a stator and rotor configuration with multiple phases, each comprising flux rings and a coil, where stator phases are stacked to form a stator segment, and rotor phases are stacked to form a rotor segment, allowing for modular assembly and increased torque and power output through phased electromagnetic interactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If traditional stator and rotor designs are used, then the motor structure is simple, but the torque and power output are limited
Solution Approach 1:
The stator is divided into multiple independent stator phases, each with its own coil and flux rings, allowing modular assembly. The rotor is segmented into multiple rotor phases with permanent magnet arrays, enabling scalable configuration. This segmentation allows the motor to achieve higher torque and power output by adding more phases without requiring a complete redesign of the entire motor structure.
Solution Approach 2:
The patent introduces a transverse flux configuration where flux rings are positioned radially around the motor axis, creating a three-dimensional electromagnetic field structure. This dimensional change from traditional planar winding arrangements enables more efficient use of space and allows for higher power density in a compact form factor.
2Power
If more phases are added to increase power output, then the torque and power increase, but the number of parts and assembly complexity increase
Solution Approach 1:
Each stator phase is designed as a modular unit that can be independently manufactured and then assembled. The rotor phases are similarly segmented. This allows power output to be increased by simply adding more identical modular units rather than redesigning the entire system, thereby increasing power without proportionally increasing assembly complexity.
Solution Approach 2:
The patent designs all stator phases to be identical in structure and function, and all rotor phases to be identical. This universality means that once a phase design is optimized, it can be replicated indefinitely to scale the motor's power output without needing to develop new components, reducing overall design and manufacturing complexity.
3Adaptability or versatility
If modular phase assemblies are used, then scalability is improved, but the interface and mating requirements become more complex
Solution Approach 1:
The motor is divided into discrete phase assemblies with standardized interfaces. Each assembly can be independently manufactured, tested, and assembled. The segmentation creates natural mating surfaces and alignment features that simplify the interface design between modules, making the system highly scalable while controlling interface complexity through standardization.
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 enables higher torque and power output with reduced part count, facilitating scalable motor designs by allowing additional segments to be added or removed, thus optimizing manufacturing efficiency and cost-effectiveness.
Implementation Method 1
a coil disposed axially between the first flux ring and the second flux ring
Implementation Method 2
the rotor includes a rotor hub and a permanent magnet array supported by the rotor hub
Data Source
AI summary
An electric motor includes a rotor and a stator formed by a plurality of stator phases. The stator phases include coils that extend fully about the motor axis of the motor. The stator phases further includes flux rings disposed on opposite axial sides of the coil and that are joined by axial returns. The stator phases electromagnetically drive rotation of the rotor on the motor axis. Stator segments are formed by one or more stator phases grouped together. Rotor segments are formed by one or more rotor phases grouped together. Motor segments are formed by one or more stator segments and one or more associated rotor segments. Motor segments are stacked along a shaft to form the electric motor.