Segmented Inverters in a Cooling Jacket for Fault-Tolerant Machines
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Solution Overview
Problem
Existing electrical machines face challenges in maintaining temperature control and redundancy in the event of inverter failure, leading to potential system shutdown and complex maintenance.
Innovation Solution
The implementation of segmented inverters within a cooling jacket, each connected independently to stator windings, allows for temperature regulation and continued operation even with inverter failures, enhancing redundancy and simplifying maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single centralized inverter is used to control all stator windings, then the device complexity is reduced, but the reliability decreases because the entire system shuts down when the inverter fails
Solution Approach 1:
The patent divides the single centralized inverter into multiple independent segmented inverters, each controlling a specific subset of stator windings. This segmentation allows the system to maintain partial operation when one inverter fails, thereby improving reliability while managing complexity through modular design
2Reliability
If multiple inverters are used to control different stator windings, then the redundancy and reliability improve, but the device complexity increases
Solution Approach 1:
The patent segments the inverter system into multiple independent units, each handling a portion of the total load. This allows redundancy without requiring a complete duplicate of the entire inverter system, thus managing complexity while improving reliability
Solution Approach 2:
Each segmented inverter is designed to be functionally equivalent and capable of operating independently to control its assigned stator windings. This universality allows any inverter to potentially take over additional loads if needed, providing redundancy without proportionally increasing overall system complexity
3Loss of energy
If inverters are placed close to stator windings, then AC cable losses are reduced, but temperature control becomes more challenging
Solution Approach 1:
The patent combines the inverter housing with the cooling jacket structure, integrating the cooling function directly into the inverter assembly. This merging allows efficient heat dissipation while maintaining the spatial proximity needed to minimize AC cable losses
4Temperature
If a cooling jacket is integrated with the inverter housing, then temperature control improves, but the device complexity increases
Solution Approach 1:
The cooling jacket is integrated directly into the inverter housing structure, combining two functions (cooling and structural enclosure) into a single unified component. This reduces the need for separate cooling system assemblies, thereby improving temperature control while actually reducing overall device complexity
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 system effectively maintains temperature within a predetermined threshold and ensures continuous operation by isolating inverters, reducing AC cable losses, and facilitating easy maintenance.
Implementation Method 1
a cooling jacket defining a plurality of recess cavities, the cooling jacket configured to maintain the temperature of the electrical machine below a pre-determined threshold
Implementation Method 2
a cooling jacket defining a plurality of recess cavities, the cooling jacket configured to maintain the temperature of the electrical machine below a pre-determined threshold
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
An electrical machine includes a cooling jacket defining a plurality of recess cavities, the cooling jacket configured to maintain the temperature of the electrical machine below a pre-determined threshold. The electrical machine also includes a plurality of segmented inverters, each of the plurality of segmented inverters received within one of the plurality of recess cavities of the cooling jacket. The electrical machine also includes plurality of stator windings electrically coupling the plurality of the segmented inverters to an alternating current (AC) terminal. The electrical machine also includes a direct current (DC) power connection ring. The power connection ring includes a positive DC power connection electrically coupling the segmented inverter with a positive DC power source and a negative DC power connection electrically coupling the segmented inverter with a negative DC power source.