Segmented Stator Saddle Adaptors for Train Bogie Power Generation

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Solution Overview

Problem

Power generator assemblies face challenges in limited space configurations, particularly in train bogies where the stator must be partially or asymmetrically arranged, leading to inefficiencies in magnetic flux and power output due to radial inhomogeneities and potential magnetic flux leakage between generator units.

Innovation Solution

A modular power generator assembly with arc-shaped ferromagnetic saddle adaptors and strategically oriented permanent magnets, including guide and shunt magnets, to optimize magnetic flux and reduce leakage, along with counterweight units for balance and enhanced surface area configurations to increase power output.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the stator is arranged to encompass the rotor completely, then the magnetic circuit is closed and power generation is efficient, but the device cannot be installed in constrained spaces with limited radial space in certain directions

Engineering Contradiction:

Improveadaptability to constrained spacesVSAvoidmagnetic flux leakage

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The stator is segmented into multiple independent stator segments arranged circumferentially around the rotor, each segment capable of independently forming a magnetic circuit with the rotor. This segmentation allows the stator to adapt to constrained radial spaces in certain directions while maintaining functional magnetic circuits in available spaces, thereby resolving the contradiction between adaptability to constrained spaces and preventing magnetic flux leakage.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If the saddle adaptor is made arc-shaped to fit constrained spaces, then the device can be installed in train bogies with limited space, but the magnetic flux becomes inhomogeneous and power output decreases

Engineering Contradiction:

Improveadaptability to train bogie spacesVSAvoidpower output

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

Different stator segments are positioned at different radial locations around the rotor, with each segment optimized for its specific local space constraints. This local quality approach allows the overall device to adapt to the arc-shaped constrained spaces in train bogies while maintaining adequate magnetic flux and power output in each local region, preventing the overall power output from decreasing significantly.

Inventive Principle:

Principle #3Local quality

3Productivity

If multiple generator units are arranged adjacently to increase power output, then the power generation capacity increases, but magnetic flux leakage between adjacent units increases

Engineering Contradiction:

Improvepower generation capacityVSAvoidmagnetic flux leakage between units

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

Magnetic shielding elements or flux barriers are introduced as intermediary structures between adjacent generator units. These intermediaries redirect and contain the magnetic flux within each individual unit, preventing flux leakage into adjacent units. This allows multiple generator units to be arranged adjacently to increase overall power generation capacity while minimizing the harmful magnetic flux leakage between units.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution enhances power generation efficiency by maximizing magnetic flux variation and minimizing leakage, allowing for effective energy harvesting and condition monitoring without external power, suitable for constrained spaces like train axleboxes.

Implementation Method 1

The oscillating magnetic field of the magnetic circuit being periodically opened and closed induces an oscillating voltage in the coil of each generator unit

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

The saddle adaptor is configured to close a magnetic circuit passing via the pole shoes through the coil in at least one first rotational position where the saddle adaptor overlaps with the pole shoes of the generator unit

Methodology Applied

Scientific EffectMagnetic circuit: Magnetic Field

Implementation Method 3

The magnetic flux therefore changes from minimum to maximum when the rotating part rotates from the second rotational position to the first rotational position and vice versa

Methodology Applied

Scientific EffectMagnetic flux variation: Magnetic Field

Data Source

PatentUS10727718B2Power generator assembly comprising a non-rotating part and an electric device included on a rotating part

Publication Date: 2020.07.28 AB SKF SKF PATENT DEPARTMENT

AI summary

A rotating part that includes at least one generator unit having at least one coil, at least one permanent magnet and two pole shoes having pole surfaces facing radially outward is provided, The non-rotating part has an arc-shaped saddle adaptor of ferromagnetic material arranged with a radial distance to the pole surfaces. The saddle adaptor is configured to close a magnetic circuit passing via the pole shoes through the coil in a rotational position where the saddle adaptor overlaps with the pole shoes of the generator unit.