Stator Sub-Conductor Inverter Layout for High-Current Drives
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Solution Overview
Problem
Existing dynamoelectric machines with conductor bars require high current strength due to low inductance, necessitating low voltage and intricate power electronics, which pose challenges in hardware structure, cooling, and software management, particularly with high currents.
Innovation Solution
The stator winding system is redesigned with sub-conductors or sub-conductor bundles per groove, each connected to a dedicated inverter module, eliminating parallel connections and using low voltages to generate high bar currents, simplifying current transfer and cooling, and reducing failure probability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high current strength is used to achieve the required magnetic field, then the machine can operate with low inductance conductor bars, but this places very high demands on hardware structure, cooling, and ignition pulse control of inverter modules
Solution Approach 1:
The patent divides each conductor bar into multiple sub-conductors (e.g., 3-12 sub-conductors per bar), with each sub-conductor independently controlled by its own inverter module. This segmentation allows the high current to be distributed across multiple parallel paths, reducing the current burden on each individual inverter module and simplifying the hardware structure while maintaining the required total current strength for magnetic field generation.
2Power
If parallel connection of semiconductor structural elements is used to generate high bar currents, then the required current strength is achieved, but this places very high demands on uniform cooling, constant current flow, and low-resistance connection design
Solution Approach 1:
By segmenting the conductor bar into multiple sub-conductors, each with its own inverter module, the patent transforms the parallel connection of semiconductor elements into a modular architecture. This allows independent cooling of each inverter module and sub-conductor, ensuring uniform temperature distribution. The segmentation also enables independent current control for each sub-conductor, maintaining constant current flow and reducing the resistance requirements for individual connections while achieving the required total bar current.
3Power
If switching is delayed in a few structural elements with high currents, then thermal destruction of the board structure occurs, but this requires extremely precise synchronization control
Solution Approach 1:
The patent segments the high current path into multiple independent sub-conductors, each controlled by its own inverter module. This segmentation provides redundancy and flexibility in control: if one sub-conductor experiences switching delays, the others can compensate, and the localized nature of the delay prevents thermal destruction of the entire board structure. The modular architecture simplifies the control system, as each inverter module can be independently controlled without requiring extremely precise synchronization across all elements.
4Use of energy by moving object
If distributed three-phase winding based on cables or wires is used, then the machine can operate with higher inductance, but this results in intricate labor-intensive stator winding
Solution Approach 1:
Instead of using traditional distributed three-phase winding with cables or wires that requires intricate labor-intensive assembly, the patent inverts the approach by using discrete conductor bars with segmented sub-conductors that are individually installed in stator grooves. This inversion simplifies the manufacturing process, as each conductor bar can be independently prepared and installed, eliminating the need for complex winding operations while achieving the required inductance characteristics through the parallel connection of multiple sub-conductors.
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 design achieves a compact, robust, and redundant drive system with simplified cooling and management, avoiding thermal destruction and current asymmetry, while allowing easy replacement and improved cooling of inverter modules.
Implementation Method 1
The magnetic field required to operate the machine is generated by high currents (up to several 1000 A) in the stator bars while using low voltages
Implementation Method 2
The high bar currents are then generated in conventional embodiments by means of a parallel connection of semiconductor structural elements (Si structural elements)
Data Source
AI summary
A drive includes a rotary dynamoelectric machine having a stator and a rotor separated by an air gap. The stator includes a magnetically conductive body with a winding system in air-gap-facing grooves thereof. The winding system includes in each groove a conductor bar divided into sub-conductors or sub-conductor bundles, electrically contacted at a first end of the conductor bar with an inverter module such that a plurality of sub-conductors or a sub-conductor bundle of the conductor bar are attached to the inverter module, or each of the sub-conductors of the conductor bar is attached to an inverter module, so that a plurality of inverter modules are provided per groove. The sub-conductors or sub-conductor bundles are combined at a second end of the conductor bar at another end face of the magnetically conductive body with the sub-conductors or sub-conductor bundles of further conductor bars to form a short-circuit ring.