Motor Stator Windings for Regenerative Braking Resistor
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Solution Overview
Problem
Conventional electromechanical actuators require large, off-the-shelf brake resistors to dissipate energy during deceleration or braking, leading to size and thermal management issues in motor controllers.
Innovation Solution
Incorporating second sets of electrical windings on the stator to function as brake resistor coils, connected to the motor controller, which dissipate energy during regenerative modes, reducing the size of the motor controller and improving thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an external brake resistor is used to dissipate energy during regenerative braking, then the braking function is achieved, but the size of the motor controller increases significantly
Solution Approach 1:
The patent merges the brake resistor function with the motor stator windings. The stator windings serve dual purposes: motor operation during propulsion and brake resistor during regenerative braking. This eliminates the need for a separate external brake resistor, thereby reducing the motor controller size while maintaining the braking function.
Solution Approach 2:
The stator windings are designed to perform multiple functions: they act as motor windings during normal operation and as brake resistor windings during regenerative braking. This multi-functionality removes the need for dedicated brake resistor components, reducing overall system size.
2Power
If a large off-the-shelf brake resistor is used, then maximum energy dissipation capability is ensured, but thermal management becomes more difficult
Solution Approach 1:
By combining the brake resistor function with the motor stator, the heat dissipation capacity is integrated into the motor's existing thermal management infrastructure. The motor housing and cooling systems can handle the thermal load, eliminating the need for separate thermal management for an external resistor.
Solution Approach 2:
The motor structure itself provides the thermal management capability for the brake resistor function. The motor housing, cooling channels, and thermal pathways that serve the motor windings also serve the brake resistor windings, allowing the system to self-manage heat without additional components.
3Ease of manufacture
If off-the-shelf brake resistors are used, then availability is ensured, but the resistance cannot be optimized for specific motor requirements
Solution Approach 1:
The brake resistor windings are locally integrated into the motor stator structure, allowing the resistance characteristics to be specifically optimized for each motor design. The winding configuration, wire gauge, and turns can be tailored to match the specific motor parameters, providing optimal braking performance for each application.
Solution Approach 2:
The resistance parameters can be customized during motor manufacturing by adjusting winding parameters such as number of turns, wire cross-section, and winding configuration. This allows the brake resistor characteristics to be precisely matched to the motor's electrical and mechanical parameters, achieving optimal energy dissipation and thermal management.
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 approach reduces the size of the motor controller, optimizes braking resistance for specific stators, and enhances thermal management by dissipating energy within the motor's larger thermal mass, eliminating the need for external resistors.
Implementation Method 1
one or more second sets of electrical windings on the stator that are configured to dissipate the energy produced by the motor in the regenerative mode as heat
Implementation Method 2
the energy produced by the motor during deceleration or under braking
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
There is provided an electric motor comprising a rotor, a stator and a motor controller. The stator comprises a substantially cylindrical body, a plurality of teeth extending from the substantially cylindrical body in a radial direction, one or more first sets of electrical windings that are wound around said teeth and configured to drive the rotor, and one or more second sets of electrical windings electrically separate from the first set of electrical windings. The second set of electrical windings on the stator are electrically connected to the motor controller such that energy produced by the electric motor during a regenerative mode of operation in use is diverted to the second set of electrical windings on the stator for dissipating the energy produced in the regenerative mode.