Transverse Flux Machine Rotor Pole Segmentation for Leakage Reduction
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Solution Overview
Problem
Transverse flux machines face high leakage flux issues, which reduce power factor and torque density due to flux leakage between rotor poles, leading to magnetic saturation and inefficiencies.
Innovation Solution
A transverse flux machine design featuring a stator assembly with E-shaped cores and a rotor assembly comprising radially focused and diffused rotor poles with enlarged core components, along with interpoles, to optimize flux path and reduce leakage, allowing for improved torque density and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If transverse flux machine uses conventional rotor pole configuration, then torque density can be achieved, but flux leakage occurs between rotor poles reducing power factor
Solution Approach 1:
The rotor is segmented into multiple independent poles with discrete magnet arrangements. Each pole can be independently configured with focused or diffused magnet patterns to control flux distribution. This segmentation allows optimization of each pole's flux path while preventing leakage to adjacent poles through proper pole spacing and magnetic shielding.
Solution Approach 2:
Different regions of the rotor poles have different magnetic properties. The patent employs focused magnet arrangements at certain pole regions to concentrate flux where needed, and diffused arrangements at other regions to spread flux and reduce leakage. This local variation in magnetic quality optimizes both torque production and flux containment.
2Power
If flux focusing magnets are used to focus flux in rotor laminations, then torque density improves, but rotor cores show saturation and have many leakage paths
Solution Approach 1:
Instead of uniformly over-focusing flux throughout the rotor core, the patent applies flux focusing selectively at specific locations and to specific degrees. The focused and diffused magnet arrangements create partial focusing that achieves sufficient flux concentration for high torque density while preventing complete saturation of the rotor core by leaving some flux paths intentionally less concentrated.
Solution Approach 2:
The patent varies magnetic parameters such as magnet strength, pole geometry, and air gap dimensions to optimize flux distribution. By adjusting these parameters, the system achieves adequate flux concentration for high torque output while maintaining the rotor core below saturation thresholds, preventing magnetic overload and associated leakage paths.
3Ease of operation
If high number of rotor poles are used to create rotating flux, then flux distribution improves, but flux leakage between poles increases deteriorating machine performance
Solution Approach 1:
The rotor is divided into a high number of discrete, segmented poles, each with independently optimized magnet arrangements. This segmentation enables fine-grained control of flux distribution across the rotor circumference while maintaining clear boundaries between poles that prevent flux leakage. Each pole's focused/diffused configuration is optimized to contain its flux within its designated region.
Solution Approach 2:
The patent introduces magnetic shielding elements and optimized pole spacing as intermediaries between adjacent rotor poles. These intermediary structures act as magnetic barriers that guide flux along intended paths while blocking leakage between poles, enabling the use of high pole counts for improved flux distribution without suffering from inter-pole flux leakage.
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
The design reduces flux leakage, prevents magnetic saturation, and maintains torque density while minimizing magnet weight, achieving enhanced power efficiency and reduced cogging torque.
Implementation Method 1
a rotor assembly positioned adjacent the stator assembly, the rotor assembly comprising a rotor disc, and a rotor ring comprising a plurality of rotor poles interleaved with a plurality of interpoles
Implementation Method 2
the plurality of rotor poles comprise a plurality of focused rotor poles interleaved with a plurality of diffused rotor poles, wherein each plurality of focused rotor poles has either at least one enlarged core component with respect to other core components, or at least two enlarged magnetic components with respect to other magnetic components
Data Source
AI summary
A transverse flux machine includes a stator assembly consisting of a plurality of shaped cores, each having a base with a plurality of legs with a corresponding gap between each leg and each leg having a winding. A rotor assembly is positioned adjacent the stator assembly and includes a rotor disc, and a rotor ring with a plurality of rotor poles interleaved with a plurality of interpoles. The plurality of rotor poles and plurality of interpoles are radially disposed around the rotor disc. The plurality of rotor poles include a plurality of focused rotor poles interleaved with a plurality of diffused rotor poles.