Toroidal-Field Motor Coil Assembly for Higher Torque With Less Copper
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Solution Overview
Problem
Conventional electric motors face challenges in increasing speed and torque without increasing the quantity of copper in coil assemblies, and in efficiently cooling and stabilizing the rotor and stator within a housing.
Innovation Solution
The system employs a rotor with magnetic elements arranged radially within a body, coupled with a stator featuring coil assemblies with outer and inner hook elements that generate a toroidal magnetic field, and a housing that supports the stator and rotor to maintain magnetic flux balance and stability, allowing for increased speed and torque while minimizing copper usage and enabling efficient cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the quantity of copper in coil assemblies is increased to increase speed and torque, then power output is improved, but material cost and device complexity increase
Solution Approach 1:
The motor is divided into modular components: a stator with multiple independent coil assemblies, a rotor with segmented magnetic elements, and a housing with integrated cooling channels. This segmentation allows optimization of each component's copper usage while maintaining overall power output through coordinated operation of multiple segments.
Solution Approach 2:
The patent transitions from conventional radial magnetic fields to a toroidal magnetic field configuration. This dimensional change in magnetic flux path creates more efficient coupling between stator and rotor, improving power density and reducing the copper quantity needed for equivalent power output.
2Temperature
If conventional cooling methods are used, then cooling function is provided, but device complexity and space requirements increase
Solution Approach 1:
The cooling system is merged with the housing structure. Cooling channels are integrated directly into the housing walls, eliminating the need for separate cooling components. This combines the structural support function with the thermal management function, reducing device complexity while maintaining effective cooling.
3Stability of the object's composition
If rotor and stator are not properly stabilized, then assembly is simplified, but magnetic flux balance and operational stability deteriorate
Solution Approach 1:
The housing serves multiple functions simultaneously: it provides structural support for the stator and rotor, establishes precise magnetic gaps for flux balance, and contains integrated cooling channels. This multi-functionality stabilizes the magnetic assembly without adding separate stabilization components, avoiding increased device complexity.
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 enhances the electric motor's speed and torque output while reducing material costs and improving cooling efficiency, stabilizing the rotor and stator within the housing.
Implementation Method 1
A controller is configured to drive current through the set of coil assemblies to generate a toroidal magnetic field configured to envelop the rotor and couple the set of magnetic elements of the rotor, thereby rotating the rotor embedded within the set of coil assemblies
Data Source
AI summary
One variation of a system for an electric motor includes a rotor including magnetic elements within a body. The system also includes a stator including coil assemblies arranged about the rotor. Each coil assembly includes an outer hook element and an inner hook element. The outer hook element extends across a first axial face and an outer radial surface of the rotor. The inner hook element: extends across a second axial face of the rotor; extends partially across the inner radial surface of the rotor; and is coupled to the outer hook element to define a throat configured to locate the rotor within the coil assembly. The system includes a shaft coupled to the inner radial surface of the rotor. Furthermore, the system includes a controller configured to drive current through the coil assemblies to generate a toroidal magnetic field configured to couple the magnetic elements to rotate the rotor.