Electric Machine Winding Sector Switching for Performance Range
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Solution Overview
Problem
The complexity in manufacturing electric machines that cover a wide range of operational performances is high due to the need for various mechanical and electrical components to achieve different performance levels.
Innovation Solution
A method involving selectively deactivating and activating subsets of winding sectors in a stator to adjust the operational performance of an electric machine, using a control unit to associate winding sectors with a first or second subset, allowing the same rotor and stator to be used for different performance levels, facilitated by software control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different mechanical and electrical components are used to achieve different performance levels, then the operational performance bandwidth is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent applies universality by designing a single stator structure with multiple winding sectors that can be selectively activated or deactivated. This allows the same stator to serve multiple performance levels (e.g., different maximum torque values) by controlling which winding sectors are active, eliminating the need for multiple specialized stators for different performance requirements.
Solution Approach 2:
The stator is segmented into multiple independent winding sectors (e.g., 12 sectors arranged in three phases with four sectors per phase). Each sector can be independently controlled through switching elements, allowing flexible configuration of the number of active poles. This segmentation enables the system to achieve different operational performances by activating different combinations of sectors without physical reconfiguration.
2Adaptability or versatility
If multiple variants of stators and rotors are produced to cover different operational performances, then the product range is improved, but the production complexity increases
Solution Approach 1:
The invention enables a single stator variant to support multiple product configurations by allowing software-controlled selection of active winding sectors. This universal stator design can be used across different vehicle types (city vehicles, luxury cars, sports cars) by adjusting which sectors are active, eliminating the need to produce multiple stator variants for different performance levels.
Solution Approach 2:
The operational performance is adjusted by changing the parameter of which winding sectors are active rather than changing the physical stator structure. By modifying the control parameters (which sectors receive power), the system can produce different performance levels from the same hardware, simplifying manufacturing while expanding the effective product range.
3Device complexity
If winding sectors are selectively deactivated to adjust operational performance, then the manufacturing complexity is reduced, but the control complexity increases
Solution Approach 1:
The patent replaces mechanical complexity (producing multiple physical stator variants) with electrical/control complexity (selectively activating winding sectors through switching elements). The switching elements are controlled by a control unit that receives performance requirements and automatically configures the active sectors, translating control signals into appropriate winding activation patterns.
Solution Approach 2:
The system dynamically reconfigures which winding sectors are active based on real-time performance requirements. The control unit can adjust the operational performance on-demand by changing which sectors are powered, allowing the electric machine to adapt to different driving conditions, vehicle types, or performance demands without physical reconfiguration.
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 approach reduces manufacturing complexity while maintaining the ability to produce electric machines with a wide range of operational performances, enabling the same components to be used in vehicles with varying performance requirements, and allowing on-demand performance adjustments.
Implementation Method 1
triggering an AC drive signal for a second sub-set of winding sectors such that the rotor is rotated using the winding sectors of the second sub-set
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The disclosure relates to a method for adjusting an operational performance of an electric machine (12). The electric machine (12) comprises a stator (14) and a rotor (16), wherein the stator (14) comprises a set of N phase windings (U, V, W, X, Y). Each of the N phase windings (U, V, W, X, Y) forms p poles around the circumference of the stator (14) and, each pole is formed by at least one winding sector (18). The method comprises deactivating a first sub-set of winding sectors (18), wherein the first sub-set of winding sectors (18) comprises at least one winding sector (18), and triggering an AC drive signal for a second sub-set of winding sectors (18) such that the rotor (16) is rotated using the winding sectors (18) of the second sub-set. Furthermore, the disclosure is directed to a corresponding data processing device (24), a corresponding computer program (32) and a corresponding computer-readable storage medium (30). Moreover, an electric drive system (10) is presented.