Twisted Coil Structures for Switched Reluctance Motor Efficiency

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Solution Overview

Problem

Switched reluctance motors face inefficiencies at both low speeds with high current and high speeds with lower current due to coil designs that either overheat or lack current-carrying capacity, limiting their ability to power work machines effectively across a range of operating conditions.

Innovation Solution

The use of twisted coil structures in electric motors, where turns of electrically conductive wires on one side are twisted clockwise and turns on the opposite side are twisted counterclockwise, forming an elongate ring shape around stator poles, allowing for efficient current carrying and reduced coil heating across varying operating frequencies.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If coils are designed with high current carrying capacity, then current carrying capacity is improved, but electrical efficiency deteriorates at higher operating frequencies

Engineering Contradiction:
Improvecurrent carrying capacityVSAvoidelectrical efficiency
Core Design Contradiction:
Quantity of substanceVSUse of energy by moving object

Solution Approach 1:

The patent applies parameter changes by twisting the wire strands within the coil windings. This physical transformation of the conductor structure modifies electrical parameters such as reducing skin effect and proximity effect, thereby improving electrical efficiency at higher frequencies while maintaining current carrying capacity. The twisting parameter change allows the same coil to perform effectively across a broader frequency range.

Inventive Principle:
Principle #35Parameter changes

2Quantity of substance

If coils are designed for high current capacity, then current carrying capacity is improved, but coil heating increases

Engineering Contradiction:
Improvecurrent carrying capacityVSAvoidcoil heating
Core Design Contradiction:
Quantity of substanceVSTemperature

Solution Approach 1:

The wire twisting parameter change reduces eddy currents and inter-strand circulation within the coil, which are sources of heat generation. By modifying the physical structure of the conductor through twisting, the patent reduces resistive heating effects while maintaining the ability to carry high current, thus resolving the contradiction between current capacity and thermal management.

Inventive Principle:
Principle #35Parameter changes

3Ease of manufacture

If traditional coil configurations are used, then manufacturing simplicity is maintained, but electrical efficiency deteriorates due to copper losses and eddy currents

Engineering Contradiction:
Improvecoil manufacturing simplicityVSAvoidcopper losses
Core Design Contradiction:
Ease of manufactureVSLoss of energy

Solution Approach 1:

The patent implements wire twisting during the coil manufacturing process, which is a relatively simple parameter change that can be integrated into existing winding equipment. This twisting modification significantly reduces copper losses and eddy currents by altering the current distribution within the coil, thereby improving electrical efficiency without requiring complex manufacturing process changes.

Inventive Principle:
Principle #35Parameter changes

4Power

If coils are optimized for low speed high current operation, then low speed performance is improved, but high speed performance with lower current deteriorates

Engineering Contradiction:
Improvelow speed performanceVSAvoidoperating range performance
Core Design Contradiction:
PowerVSAdaptability or versatility

Solution Approach 1:

The wire twisting parameter change creates a coil structure that performs well across a broad spectrum of operating conditions. The twisted configuration reduces frequency-dependent losses, allowing the motor to maintain high efficiency whether operating at low speeds with high current or at higher speeds with lower current, thus expanding the effective operating range of the motor.

Inventive Principle:
Principle #35Parameter changes

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 electrical efficiency and current-carrying capacity of switched reluctance motors, reducing copper losses, eddy currents, and inter-strand circulation, resulting in improved performance and thermal conductivity by densely packing the coils within the stator slots.

Implementation Method 1

reducing copper losses, eddy currents, and inter-strand circulation

Methodology Applied
Scientific EffectEddy currents: Eddy Currents

Implementation Method 2

Transform Electrical Energy to Mechanical Energy

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS11705768B2Twisted coil structures for an electric motor and systems, components, assemblies, and methods thereof
Publication Date: 2023.07.18 CATERPILLAR INC
  • US11705768B2 patent drawing
  • US11705768B2 patent drawing
  • US11705768B2 patent drawing

AI summary

A coil winding for an electric motor, and systems, components, assemblies, and methods thereof, can comprise turns of a predetermined number of electrically conductive wires on a first side of the coil winding twisted together in a clockwise direction; and turns of the predetermined number of the electrically conductive wires on a second side of the coil winding opposite the first side twisted together in a counterclockwise direction.