Vernier External Rotor Machine Flux Modulation
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Solution Overview
Problem
Existing Vernier machines lack improved properties such as higher power factor, torque density, and reduced torque ripple, and often require complex geometries and additional modulator rings.
Innovation Solution
A Vernier external rotor machine with a non-laminated solid iron external rotor directly coupled to a load, featuring anisotropic properties and flux barriers for encoder-free control, and a frequency converter that converts braking energy into thermal energy, eliminating the need for a modulator ring and enabling direct force transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a modulator ring is added to improve magnetic flux modulation, then the power factor and torque density are improved, but the device complexity and geometric complexity increase
Solution Approach 1:
The patent merges the modulator ring function with the stator teeth by integrating the flux modulation capability directly into the stator structure. The stator teeth are designed with specific geometric features that provide the necessary magnetic flux modulation without requiring a separate modulator ring, thereby reducing device complexity while maintaining improved power factor and torque density
Solution Approach 2:
The stator teeth are designed to serve multiple functions simultaneously: they provide magnetic flux modulation, support the winding structure, and define the air gap geometry. This multi-functionality eliminates the need for dedicated modulator rings while achieving the desired performance improvements in power factor and torque density
2Stability of the object's composition
If a modulator ring is added to reduce torque ripple, then the torque ripple is reduced, but the device complexity and manufacturing cost increase
Solution Approach 1:
The flux modulation function previously requiring a separate modulator ring is integrated into the stator teeth design. The stator teeth geometry is optimized to provide the necessary magnetic flux variation that reduces torque ripple, thereby achieving smooth torque delivery without increasing device complexity
Solution Approach 2:
The stator teeth are designed with specific local geometric features (such as tooth width, depth, and positioning) that create the desired magnetic flux distribution pattern. These localized geometric optimizations provide torque ripple reduction while keeping the overall device structure simple and avoiding the need for additional modulator rings
3Loss of energy
If a laminated external rotor is used to reduce eddy current losses, then the energy efficiency is improved, but the manufacturing cost and complexity increase
Solution Approach 1:
The patent extracts and eliminates the need for complex laminated rotor structures by using a solid iron external rotor design. The rotor is made from simple standard pipes that are machined to the required geometry, removing the manufacturing complexity and cost associated with laminated structures while still achieving acceptable energy efficiency through the overall machine design and flux modulation
Solution Approach 2:
The patent changes the material and structural parameters of the external rotor from laminated to solid iron construction. This parameter change simplifies manufacturing by allowing the use of standard pipe materials and conventional machining processes, while the overall machine performance and energy efficiency are maintained through optimized stator design and flux modulation mechanisms
4Measurement precision
If flux barriers are added to form anisotropy for encoder-free control, then the control precision is improved, but the device complexity increases
Solution Approach 1:
The anisotropy is created through localized geometric features on the external rotor surface, such as tooth structures or shaped regions, rather than requiring complex internal flux barriers. These local geometric modifications provide the necessary magnetic anisotropy for encoder-free control while keeping the overall device structure simple and avoiding excessive complexity
Solution Approach 2:
The external rotor is designed with asymmetric geometric features that create magnetic anisotropy. The asymmetric tooth structures or shaped regions on the rotor surface provide distinct magnetic properties in different angular positions, enabling precise rotation angle determination without encoders while maintaining simple device architecture
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 solution achieves higher power factor, torque density, and reduced torque ripple with simpler geometries and direct force transmission, while allowing encoder-free control and efficient energy conversion.
Implementation Method 1
a radiofrequency magnetic alternating field is induced in the external rotor, said radiofrequency magnetic alternating field generating heat in the external rotor
Implementation Method 2
The external rotor is of anisotropic design, that is to say has, for example, (magnetic) properties which are dependent on a rotation angle position of the external rotor
Data Source
AI summary
A Vernier external rotor machine for direct drive of a load is provided. The Vernier external rotor machine includes an external rotor configured to mechanically directly drive to a load.