Electric Winding Exchanger Assembly for Torque-Speed Extension
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Solution Overview
Problem
Multi-phase electric motor-controller-battery systems face limitations in maximum torque and speed due to controller and battery current constraints, necessitating a solution to exceed these boundaries without increasing motor volume, controller current, or battery voltage.
Innovation Solution
An integrated assembly of an electric winding exchanger system and a multiphase electric motor, featuring a back electromotive force (EMF) boosting circuit with switches and bus bars, and sensors, which adjusts the motor's winding configuration to enhance torque and speed performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multi-phase motor-controller-battery systems are used, then torque and speed controllability is improved, but maximum torque and speed boundaries are limited by controller and battery current ratings
Solution Approach 1:
The patent applies dynamics by making the winding configuration adjustable and reconfigurable in real-time. The motor windings can be dynamically switched between different connection patterns (series, parallel, series-parallel) to adapt to varying torque and speed demands, allowing the system to exceed conventional power boundaries without changing controller or battery ratings.
Solution Approach 2:
The invention changes the electrical parameters of the motor by reconfiguring the winding connections. By altering the series/parallel arrangement of windings, the effective resistance, inductance, and back-EMF characteristics are changed, enabling the motor to operate beyond its rated torque and speed limits while keeping controller and battery parameters constant.
2Power
If motor volume is increased to exceed torque and speed boundaries, then power output is improved, but device volume increases
Solution Approach 1:
Instead of increasing motor volume, the patent changes the electrical operating parameters through winding reconfiguration. The same physical motor can deliver variable torque and speed characteristics by switching winding connections, effectively extracting more power capability from the existing motor volume.
Solution Approach 2:
The motor winding system is designed to perform multiple functions through different connection configurations. The same windings can be arranged in series for high torque, parallel for high speed, or series-parallel for intermediate conditions, making the motor universally adaptable to different power demands without requiring multiple motors or increasing volume.
3Power
If controller current rating is increased to exceed torque boundaries, then maximum torque is improved, but controller complexity and cost increase
Solution Approach 1:
Rather than designing a controller with continuously variable high current capability, the system uses discrete switching of winding configurations. The controller maintains fixed current ratings but dynamically reconfigures the motor windings to achieve higher effective torque output, reducing the need for oversized or complex controller design.
4Speed
If battery voltage is increased to exceed speed boundaries, then maximum speed is improved, but system voltage requirements and safety constraints increase
Solution Approach 1:
The patent changes the motor's back-EMF characteristics through winding reconfiguration to enable higher speeds without increasing battery voltage. By altering the winding connections, the effective voltage constant is changed, allowing the motor to achieve higher rotational speeds while maintaining compatibility with existing battery voltage levels and safety standards.
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
Enables increased torque and speed performance beyond conventional limits without increasing motor control unit, battery current, or battery voltage, through dynamic reconfiguration of the motor's winding patterns.
Implementation Method 1
the electric winding exchanger system may include a back electromotive force (EMF) boosting circuit
Data Source
AI summary
An integrated assembly of an electric winding exchanger system and a multiphase electric motor comprises a housing, the multiphase electric motor, and the electric winding exchanger system. Further, the housing comprises a first housing portion, a second housing portion, and a partition. Further, the first housing portion comprises a first interior space and the second housing portion comprises a second interior space. Further, the first housing portion houses the multiphase electric motor and the second housing portion houses the electric winding exchanger system. Further, the electric winding exchanger system comprises a back electromotive force (EMF) boosting circuit comprising switches and bus bars. Further, the partition comprises openings. Further, leads of coils of the multiphase electric motor enters the second interior space through a first opening of the openings for connecting terminals of the leads to the bus bars.