Toroidal Coil Carrier Geometry for Low-Loss Electric Drives
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Solution Overview
Problem
Conventional electric drives face challenges in maximizing magnetic flux amplitude and minimizing current heat losses due to suboptimal winding geometries, particularly in stator structures with rectangular tooth configurations.
Innovation Solution
The implementation of a toroidal coil carrier with elliptical or circular cross-sectional areas, combined with a lamella structure, to support winding coils, which are wound in sections, optimizing the winding geometry and enhancing the stator's ability to accommodate magnetic flux while reducing heat losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If rectangular tooth structures with conventional winding geometries are used, then the stator geometry is simple to manufacture, but current heat losses increase and magnetic flux amplitude decreases
Solution Approach 1:
The patent applies curvature by using a toroidal coil carrier instead of conventional rectangular tooth structures. The toroidal geometry with circular or elliptical cross-section minimizes the winding wire length while maintaining effective magnetic flux linkage, thereby reducing current heat losses. The curved surface allows optimal coil placement and reduces the enclosing wire length compared to rectangular geometries.
Solution Approach 2:
The patent changes the geometric parameters of the stator structure from rectangular to toroidal with specific cross-sectional dimensions. The cross-sectional area of the toroidal coil carrier is optimized to provide the largest surface area with the smallest possible circumference, minimizing winding wire length while maximizing magnetic flux accommodation capability.
2Force
If rectangular tooth structures with conventional winding geometries are used, then the stator structure is compact, but magnetic flux amplitude decreases
Solution Approach 1:
The toroidal shape with circular or elliptical cross-section provides optimal magnetic flux distribution and maximizes the magnetic flux amplitude. The curved geometry allows better alignment with the magnetic field lines generated by the rotor, improving the coupling between stator and rotor magnetic fields compared to rectangular tooth structures.
Solution Approach 2:
The patent transitions from a conventional 2D planar stator structure to a 3D toroidal structure. This dimensional change allows the stator to accommodate magnetic flux more effectively by providing volume in the radial direction, enabling better magnetic flux linkage without increasing the overall footprint significantly.
3Loss of energy
If toroidal coil carrier with optimized winding geometry is used, then current heat losses are minimized, but manufacturing complexity increases
Solution Approach 1:
The toroidal coil carrier is divided into multiple sections or segments around the torus, with coils wound only in specific sections rather than continuously around the entire torus. This segmentation simplifies the manufacturing process by allowing modular assembly and reducing the complexity of winding operations while maintaining the energy-efficient toroidal geometry.
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 configuration minimizes current heat losses and maximizes magnetic flux by utilizing a toroidal coil carrier with a lamella structure, allowing for efficient cooling and accommodating main magnetic flux, thereby improving the performance of electric drives.
Implementation Method 1
the current heat losses in the winding wire, which is wound in a circle around the toroidal coil carrier, are also minimized. This is because the amount of current heat loss is a function of the length of the winding wire
Implementation Method 2
Current-carrying conductor coils generate magnetic fields whose mutual forces of attraction and repulsion are converted into movement
Implementation Method 3
Current-carrying conductor coils generate magnetic fields whose mutual forces of attraction and repulsion are converted into movement
Implementation Method 4
the lamellae extend in the direction of the axis of rotation of the toroidal coil carrier over a greater length than the toroidal coil carrier. This provides a large stator that can accommodate the main magnetic flux from the rotor
Data Source
AI summary
An electric drive comprises a stator and a rotor and a plurality of coils of a winding. The stator a toroidal coil carrier, the cross-sectional area of the toroidal coil carrier having the shape of an ellipse, in particular a circle. The coils of the winding are wound around sections of the toroidal coil carrier.