Self-Powered Rotor Sensing for Electric Machine Temperature Feedback
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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 operational power due to unknown rotor temperatures and the need for safety margins, which can result in overheating and damage.
Innovation Solution
Integration of a sensor element and signal processing unit within the rotor, connected to an induction coil that generates electrical energy from the rotating magnetic field, eliminating the need for external power sources and reducing mechanical wear and limited service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors and signal processing units are integrated into the rotor to enable direct temperature measurement, then measurement precision and reliability are improved, but device complexity increases
Solution Approach 1:
The patent combines multiple functional components (sensors, signal processing units, and induction coils) into a single integrated rotor structure. This merging approach enables direct temperature measurement while maintaining rotational simplicity by consolidating what would otherwise be separate systems into one unified rotating assembly.
Solution Approach 2:
The rotor is designed to perform multiple functions simultaneously: it generates the magnetic field necessary for motor operation, houses the sensors for temperature monitoring, contains the signal processing units for data handling, and incorporates induction coils for self-powering. This multi-functionality reduces the need for additional separate components.
2Use of energy by moving object
If collecting rings or batteries are used to supply power to rotating components, then electrical energy can be provided to sensors, but mechanical wear increases or service life is limited
Solution Approach 1:
The rotor generates its own electrical power through induction coils that utilize the magnetic field already present during normal motor operation. This self-service approach eliminates the need for external power transmission mechanisms like collecting rings or batteries, thereby avoiding mechanical wear and extending service life.
Solution Approach 2:
The patent replaces mechanical power transmission systems (collecting rings, slip rings, or battery connections) with an electromagnetic induction system. The induction coils convert the rotating magnetic field directly into electrical energy, substituting a mechanical wear-prone system with a contactless electromagnetic solution.
3Reliability
If safety margins are applied to maximum rotor temperature, then reliability is improved, but productivity decreases due to limited continuous power
Solution Approach 1:
The integrated sensors continuously monitor the actual rotor temperature and provide real-time feedback to the control system. This feedback enables dynamic adjustment of operating parameters, allowing the motor to operate closer to the true thermal limits without exceeding safe temperatures, thereby eliminating the need for conservative static safety margins.
Solution Approach 2:
The system transitions from static temperature estimation with fixed safety margins to dynamic real-time temperature monitoring and control. The continuous measurement and active management of thermal conditions allow the motor to adapt its power output based on actual thermal state, maximizing productivity while maintaining reliability.
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 allows for accurate temperature measurement and reduced risk of overheating, enabling optimal operation of the electric machine by providing reliable power to sensors and processing units directly on the rotor, enhancing efficiency and longevity.
Implementation Method 1
The at least one induction coil is configured for generating electrical energy from a magnetic field, which is temporally changing during the operation of the electric machine
Data Source
AI summary
A rotor (1) for an electric machine (2) has a rotor body including multiple poles. The rotor (1) further has at least one sensor element (3) for detecting at least one condition variable of the rotor (1), and a signal processing unit (4) connected to the at least one sensor element (3). The signal processing unit (4) is configured to generate measured data from the condition variable of the rotor (1) and to transmit the measured data to a control device (5). Additionally, the rotor (1) has at least one induction coil (7), where each of the at least one induction coil (7) includes at least one electrical conductor (8). The at least one induction coil (7) is arranged at the rotor (1) and is configured to generate electrical energy from a magnetic field that is temporally changing during operation of the electric machine (2).