Two-Phase Motor Coil Layout for Higher Space Utilization
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Solution Overview
Problem
Conventional motors with a 4-slot coil stator and 8-pole rotor have a low space utilization rate, leading to inefficient motor performance due to the mechanical arrangement and control methods, which results in suboptimal efficiency and increased vibration.
Innovation Solution
The motor design incorporates a rotor with staggered poles and a stator with coils wound in an axial configuration, utilizing Hall elements and logic units to generate control signals with a 90-degree phase difference, optimizing the placement and driving of coil sets to enhance space utilization and reduce torque ripple.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional 4-slot coil stator with 8-pole rotor is used, then the motor structure is simple and easy to manufacture, but the space utilization rate of the stator coil is only 50%, leading to low motor efficiency
Solution Approach 1:
The patent divides the stator coil into multiple independent coil groups (first coil group, second coil group, third coil group, fourth coil group) with different winding directions and positions. This segmentation allows each coil group to be optimized independently for space utilization while maintaining manufacturing simplicity through modular assembly
Solution Approach 2:
Different coil groups are assigned different winding directions (clockwise and counter-clockwise) and positioned at specific angular intervals (every 45 degrees). This local differentiation optimizes the magnetic field distribution and space utilization rate in different regions of the stator, achieving over 50% overall space utilization
2Ease of operation
If coils are arranged with 45-degree mechanical angle separation, then the structure is conventional and easy to implement, but the space utilization rate is limited to 50%
Solution Approach 1:
The patent implements a nested arrangement where coil groups are positioned within specific angular sectors of the stator. The first and third coil groups are nested in one half of the stator while the second and fourth coil groups are nested in the other half, allowing dense packing that achieves over 50% space utilization rate
Solution Approach 2:
The patent transitions from a single-plane coil arrangement to a multi-dimensional configuration by specifying precise angular positions (0°, 45°, 90°, 135°, etc.) and winding directions for each coil group. This dimensional specification optimizes space utilization by effectively using the three-dimensional space within the stator structure
3Device complexity
If independent coils are connected in series for two-phase driving, then the control is simple, but the torque ripple is high causing increased vibration
Solution Approach 1:
The patent implements periodic switching control where different coil groups are activated in a specific sequence according to the rotor position detected by Hall elements. The control unit switches between coil groups periodically as the rotor rotates, maintaining simple two-phase driving while reducing torque ripple through optimized switching timing
Solution Approach 2:
The patent incorporates Hall elements that detect rotor position and provide feedback to the control unit. Based on this feedback, the control unit dynamically selects which coil groups to activate, enabling simple adaptive control that minimizes torque ripple and vibration while maintaining ease of operation
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 increases the space utilization rate of the stator coils by 16.67% to 50%, significantly improving motor efficiency and reducing vibration, compared to conventional designs.
Implementation Method 1
Two Hall elements are configured to sense the change of the magnetic field generated by the passage of the permanent magnet
Implementation Method 2
Through the interaction between the coils and the magnetic element, a magnetic field is generated between the stator and the rotor, thereby making the rotor to rotate
Data Source
AI summary
A motor is provided and driven by two phase. The first and second control signals have a phase difference of 90 degrees and are configured to control the first and second driving units, respectively, and the first and second control signals drive the first and second coil sets, respectively. Each of the first and second poles of the permanent magnet occupies a mechanical angle of 360/2n degrees of the permanent magnet, respectively, and n is 1 or 3. The four sets of the coils of the stator are equally located on the stator, each set of the coil occupies a mechanical angle of 360/2m degrees of the stator, any two sets of the coils adjacent to each other are separated by a mechanical angle of 90−(360/2m) degrees, and m is 3 or 2, wherein m corresponds to 2 when n is 1, m corresponds to 3 when n is 3.