Two-Phase Motor Rectangular Coil Arrangement Compact Actuator
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Solution Overview
Problem
Existing electric motors for climate control in motor vehicles are large due to the trade-off between torque and compact size, especially when using three-phase motors, and there is a need for a more compact two-phase electric motor with high torque for air-conditioning flap actuators.
Innovation Solution
A two-phase electric motor design featuring four coils arranged in a rectangle with diagonally connected coils and a centrally positioned, diametrically magnetized rotor, along with a stator constructed from multiple metal sheet parts, allowing for a compact and efficient configuration with a high rotor-to-stator diameter ratio.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If three-phase motors are used for climate control actuators, then torque is achieved, but the motor size becomes large due to tight space conditions
Solution Approach 1:
The patent transitions from a conventional three-phase motor configuration to a two-phase motor with four coils arranged in a rectangular pattern around the rotor. This dimensional reconfiguration allows the magnetic fields to interact more efficiently with the rotor, generating high torque in a more compact stator structure. The rectangular coil arrangement creates optimized magnetic flux distribution that delivers sufficient torque while reducing the overall motor volume.
Solution Approach 2:
The patent changes the electrical phase configuration from three-phase to two-phase operation, and adjusts the coil arrangement from conventional distributed winding to a specific rectangular pattern with diagonally connected coils. These parameter changes in the motor's electrical and geometric configuration enable compact dimensions while maintaining the torque output required for climate control actuators.
2Force
If the rotor diameter is increased to improve torque, then torque output increases, but the stator width must also increase which reduces compactness
Solution Approach 1:
The patent employs a rectangular coil arrangement where four coils are positioned at the corners of a rectangle surrounding the rotor, with diagonally opposite coils connected together. This geometric configuration creates efficient magnetic coupling between the stator and rotor, allowing a large rotor diameter to generate high torque without requiring a proportionally large stator width. The rectangular pattern optimizes the magnetic path length and flux distribution.
Solution Approach 2:
The patent uses an asymmetric rectangular coil configuration rather than a symmetric circular arrangement. The diagonally connected coils create unequal magnetic field distribution patterns that are optimized for torque generation in a compact stator width. This asymmetric arrangement allows the magnetic flux to concentrate more effectively on the rotor surface, delivering high torque output without increasing the stator's overall width.
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 design achieves a compact size with a high torque output, enabling a smaller air-conditioning flap actuator while maintaining a large rotor diameter and narrow stator width, thus addressing the size and efficiency constraints of existing motors.
Implementation Method 1
the rotor is arranged centrally between the coils and is diametrically magnetized with two poles
Implementation Method 2
four coils are used to form a two-phase motor, the coils being arranged in a rectangle and the diagonally opposite coils being connected to one another
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
A two-phase electric motor, wherein the electric motor is an electrically commutated permanent magnet electric motor, comprising a coil-bearing stator (1) and a two-pole permanent magnetized rotor (2), wherein the electric motor has a rectangular shape, wherein a first coil (3) and a second coil (4) are arranged on a first side (5) of the rotor (2) and a third coil (6) and a fourth coil (7) are arranged on the second side (8) of the rotor (2), opposite the first side (5), such that the four coils (3, 4, 6, 7) together form a rectangle, wherein the diagonally opposite coils, namely the first coil (3) and the fourth coil (7) on the one hand and the second coil (4) and the third coil (6) on the other hand, are each electrically connected to each other, so that they each form a common phase (A, B).