Motor

Abstract

The invention relates to an electric machine, and specifically provides a stator core that may define a plurality of core slots in a surface thereof. The core slot may extend between a first end portion and a second end portion of the stator core. The winding may be received in the core slot. The winding may define a channel through at least a portion thereof. A cooling system may be operably coupled with the channel and may be configured to move a cooling fluid through the channel. A turbulator may be positioned within the channel. A turbulator may be located within the flow path of the cooling fluid and may be integrally formed with the winding.

Description

Technical Field

[0001] The present subject matter generally relates to an electric machine having a cooling system fluidly coupled to one or more windings of the electric machine. Background Art

[0002] Electric machines (such as generators, motors, motor / generators, starter / generators, and other electric machines) can be used for a variety of purposes. During operation, the electric machine includes a rotor that can rotate relative to a stator to generate electrical energy and / or can rotate relative to the stator as a result of changing the magnetic field induced in the stator's windings. During operation of the electric machine, heat is generated that can negatively impact the efficiency or output of the electric machine. Therefore, an electric machine that can dissipate this excess heat would be useful. Summary of the Invention

[0003] Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

[0004] In some embodiments of the present disclosure, an electric motor includes a stator core (sometimes also referred to as a stator iron core) having a plurality of core slots defined in a surface thereof. A winding is received in at least one of the plurality of core slots. The winding defines a channel extending through at least a portion thereof. A cooling system is operably coupled to the channel and configured to move a cooling fluid through the channel. A turbulator is positioned within the channel. The turbulator is located within the flow path of the cooling fluid.

[0005] In some embodiments of the present disclosure, the method includes a method of manufacturing an electric machine having a stator core and a rotor, the method including forming a winding for the stator core of the electric machine having a channel at least partially defined therethrough, wherein forming the winding further includes integrally forming one or more turbulators within the channel.

[0006] In some embodiments of the present disclosure, a winding for an electric motor includes an elongated body. The elongated body is configured to be operably coupled to at least one of a stator or a rotor. A channel is defined by the elongated body and extends through at least a portion of the elongated body. A turbulator is positioned within the channel. The turbulator is located within a flow path of a cooling fluid passing through the channel.

[0007] These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims.The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

[0008] Technical Solution 1. A motor comprising: a stator core defining a plurality of core slots in a surface thereof; a winding received in at least one of the plurality of core slots, the winding defining a passageway therethrough at least partially; a cooling system operably coupled to the passage and configured to move a cooling fluid through the passage; and A turbulator is positioned within the passage, wherein the turbulator is located within the flow path of the cooling fluid.

[0009] Technical Solution 2. The motor according to any of the preceding technical solutions, further comprising: A controller is operably coupled to the cooling system and configured to actuate a pump assembly of the cooling system.

[0010] Technical Solution 3. The motor according to any preceding technical solution, wherein the turbulator comprises a first turbulator separated from a first side portion of the channel by a first distance and a second turbulator separated from an opposite second side portion of the channel by a second distance.

[0011] Technical Solution 4. The motor according to any of the preceding technical solutions, wherein the first distance is substantially equal to the second distance.

[0012] Technical Solution 5. The electric machine according to any of the preceding technical solutions, wherein the turbulator is formed integrally with the winding.

[0013] Technical Solution 6. The electric machine according to any of the preceding technical solutions, wherein the turbulator comprises a first turbulator having a first width and a second turbulator having a second width.

[0014] Technical Solution 7. The motor according to any of the preceding technical solutions, wherein the first width is substantially equal to the second width.

[0015] Technical Solution 8. The motor according to any of the preceding technical solutions, wherein the first width is greater than the second width.

[0016] Technical Solution 9. The motor according to any preceding technical solution, wherein the turbulator includes a first section extending from an upper portion of the channel and a second section extending from a bottom portion of the channel, wherein the first section and the second section define a gap therebetween.

[0017] Technical Solution 10. The electric machine according to any of the preceding technical solutions, wherein the first section and the second section are vertically offset from each other.

[0018] Technical Solution 11. The electric machine according to any of the preceding technical solutions, wherein the gap defined between the first section and the second section is asymmetric relative to a centerline of the channel.

[0019] Technical Solution 12. The motor according to any preceding technical solution, wherein the turbulator includes a first section extending from an upper portion of the channel and a second section extending from a bottom portion of the channel, wherein the first section and the second section define a gap therebetween.

[0020] Technical Solution 13. An electric motor according to any of the foregoing technical solutions, wherein the turbulator includes a plurality of turbulators, the plurality of turbulators having a first pair of rows arranged on the linear portion of the winding and separated by a first length substantially along the direction of the cooling fluid flow path, and a second pair of rows arranged on the curved portion of the winding and separated by a second length substantially along the direction of the cooling fluid flow path, wherein the first length and the second length may be substantially equal.

[0021] Technical Solution 14. A method for manufacturing a motor having a stator core and a rotor, the method comprising: A winding is formed with respect to the stator core or the rotor of the electric machine having a channel at least partially defined therethrough, wherein forming the winding further includes integrally forming one or more turbulators within the channel.

[0022] Technical Solution 15. The method according to any of the above technical solutions further comprises: operably coupling the winding to one of the stator core or the rotor; and fluidly coupling a cooling system to the passage, wherein fluidly coupling the cooling system to the passage comprises coupling a supply line to one end portion of the winding and coupling a return line to a second end portion of the winding.

[0023] Technical Solution 16. A method according to any of the preceding technical solutions, wherein forming the one or more turbulators in the channel further includes forming at least partially vertically aligned first and second sections of the one or more turbulators, wherein a gap is defined between the first and second sections of the one or more turbulators.

[0024] Technical Solution 17. A winding for a motor, comprising: an elongated body, wherein the elongated body is configured to be operably coupled to at least one of a stator or a rotor; a passage defined by and extending through at least a portion of the elongated body; and A turbulator is positioned within the passage, wherein the turbulator is located within a flow path of a cooling fluid through the passage.

[0025] Technical Solution 18. The winding for an electric machine according to any preceding technical solution, wherein the channel is operably coupled to a cooling system configured to move a cooling fluid through the channel.

[0026] Technical Solution 19. The winding for an electric machine according to any of the preceding technical solutions, wherein the turbulator comprises a first turbulator and an offset second turbulator.

[0027] Technical Solution 20. The winding for a motor according to any of the preceding technical solutions, wherein each of the first and second turbulators comprises a first section extending from a first portion of the channel and a second section extending from a second portion of the channel, the first and second portions being separated by a gap. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] A complete and enabling disclosure of the invention, including the best mode thereof, to one skilled in the art is set forth in the specification which proceeds with reference to the accompanying drawings in which: Figure 1 is a perspective view of a stator core according to various aspects of the present disclosure; Figure 2 is a device having multiple windings according to various aspects of the present disclosure Figure 1 A perspective view of a stator core; Figure 3 is a perspective view of a permanent magnet rotor operably coupled to a stator core according to various aspects of the present disclosure; Figure 4 is a perspective view of a rotor having one or more windings operably coupled to a stator core according to various aspects of the present disclosure; Figure 5 is a perspective view of an electric machine having a rotor positioned within a stator core according to various aspects of the present disclosure; Figure 6 It is taken along line VI-VI Figure 5 A cross-sectional view of a motor; Figure 7 is a schematic diagram of a cooling system operably coupled to one or more windings of an electric machine according to various aspects of the present disclosure; Figure 8A is a perspective view of a portion of one of the windings defining a channel according to various aspects of the present disclosure; Figure 8B It is taken along line VIIIB-VIIIB Figure 8A a cross-sectional view of a portion of a winding; Figures 9A-9D FIGURE 1 is a diagram taken along line IX-IX according to various aspects of the present disclosure. Figure 8AVarious cross-sectional views of a winding illustrating a pair of turbulators separated by various distances; Figures 10A-10D FIGURE 1 is a diagram taken along line XX according to various aspects of the present disclosure. Figure 8A various cross-sectional views of a winding illustrating a pair of turbulators of various widths; Figures 11A-11F FIGURE 1 is a diagram taken along line XI-XI according to various aspects of the present disclosure. Figure 8A Various cross-sectional views of the winding, illustrating turbulators of various heights; Figure 12A and Figure 12B illustrating various cross-sectional views of the winding of FIG. 8 taken along line XII-XII, illustrating a plurality of turbulators located within the winding according to various aspects of the present disclosure; Figures 13A-13C illustrating various cross-sectional views of the winding of FIG. 8 taken along line XIII-XIII illustrating a plurality of turbulators located within the winding according to various aspects of the present disclosure; and Figure 14 is a flow chart of a method for operating an electric machine according to various aspects of the present disclosure. DETAILED DESCRIPTION

[0029] Reference will now be made in detail to the present embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. The same or similar designations in the drawings and the description have been used to refer to the same or similar parts of the invention.

[0030] As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish components from one another and are not intended to indicate the position or importance of individual components.

[0031] The terms "front" and "rear" refer to relative positions within a gas turbine engine or vehicle and to the normal operating posture of the gas turbine engine or vehicle. For example, with respect to a gas turbine engine, the front refers to a position closer to the engine inlet, and the rear refers to a position closer to the engine nozzle or exhaust.

[0032] The terms "upstream" and "downstream" refer to relative directions relative to the cooling fluid flow path in the fluid pathway. For example, "upstream" refers to the direction from which the cooling fluid flow path originates, and "downstream" refers to the direction to which the cooling fluid flow path originates.

[0033] Unless otherwise specified herein, the terms "coupled," "fixed," "attached to," and the like refer to both direct coupling, fixing, or attachment as well as indirect coupling, fixing, or attachment through one or more intermediate members or features.

[0034] The singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise.

[0035] Approximating language, as used herein throughout the specification and claims, is applicable to modifying any quantitative representation that may permissibly vary without resulting in a change in the basic function to which it is related. Thus, a value modified by a term or terms such as "about," "approximately," "substantially," and "substantially" is not limited to the precise value specified. In at least some instances, approximating language may correspond to the precision of an instrument used to measure the value or the precision of a method or machine used to construct or manufacture a component and / or system. For example, approximating language may refer to being within a 10% limit.

[0036] Here and throughout the specification and claims, range limitations are combined and interchanged, and unless context or language indicates otherwise, such ranges are identified and include all sub-ranges contained therein. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other.

[0037] As used herein, the term "and / or," when used in a list of two or more items, means that any one of the listed items may be employed individually or in any combination of two or more of the listed items may be employed. For example, if a composition or component is described as comprising elements A, B, and / or C, the composition or component may comprise only A; only B; only C; A and B in combination; A and C in combination; B and C in combination; or A, B, and C in combination.

[0038] In general, the present disclosure provides conductive windings that can be operably coupled to the stator and / or rotor of an electric motor, or any other device that incorporates conductive material. During operation, the rotor can be mechanically powered, driven, or rotated about an axis of rotation by a force (such as mechanical energy from an engine). The relative rotational motion of the rotatable rotor relative to the fixed or stationary stator generates electrical power in one or more windings due to the interaction of the motor's magnetic field. The electrical power generated in the one or more windings can be conductively connected to at least one electrical load or power source and further delivered to at least one electrical load or power source. In some aspects, the motor can provide electrical power to a power distribution system or power distribution network. In contrast, when operating as an electric motor, AC power (such as three-phase AC power) can be provided to one or more windings of the stator, which produces rotational motion of the rotor.

[0039] The conductive winding may define a channel therein, and one or more turbulators may be positioned within the channel. The one or more turbulators may be configured as any type of structure extending from the inner surface of the channel. In various examples, the turbulators may have a common or varying width, shape, height, and / or offset relative to one another. The turbulators may include pins, recesses, and various other protruding shapes that improve heat transfer by increasing turbulence. The location, size, and frequency of the turbulators are selected to minimize the increase in the loss coefficient resulting from their presence.

[0040] The cooling system may be operably coupled to the channel and configured to move a cooling fluid through the channel. As the cooling fluid moves through the channel, heat is transferred from the windings to the cooling fluid, and the heat is then at least partially removed from the cooling fluid externally from the windings. Additionally, the cooling fluid may contact one or more turbulators located within the channel, which may create less laminar flow within the channel to increase heat transfer to the cooling fluid and / or increase the surface area of the windings to increase the amount of heat that can be transferred to the cooling fluid. The heated cooling fluid may be cooled by a heat exchanger, which may be located externally from the windings.

[0041] Turbulators are configured to improve the thermal performance of electric machines employing cooling systems. Implementing turbulators within the winding channels increases the heat transfer coefficient (HTC) of the thermal system and, therefore, improves heat removal from the electric machine. By operating according to one or more of the disclosed aspects, the electric machines provided herein can provide more efficient electric machines due to reduced operating temperatures. The electric machines can additionally or alternatively generate more electrical power when operating as a generator and / or use electrical power more efficiently when operating as a motor.

[0042] Referring now to the drawings, wherein like numerals refer to like elements throughout, Figure 1 and Figure 2 Providing a generally cylindrical shape, the stator core 10 may define a plurality of core slots 12 formed in a circumferential inner diameter 14 of the stator core 10. The core slots 12 may extend between a first end portion 16 and a second end portion 18 of the stator core 10.

[0043] In various embodiments, the core slots 12 are generally equally spaced about the circumferential inner diameter 14 of the stator core 10, unequally spaced about the circumferential inner diameter 14 of the stator core 10, and / or a combination thereof. The core slots 12 define a radial depth 20 between the end portions 16, 18 of the core slots 12. The core slots 12 are adapted to receive one or more windings 24. In some embodiments, each winding 24 may have a plurality of segments that may include one or more end ring segments 28 and one or more slot segments 26 received in the core slots 12. The core slots 12 may have a plurality of segments that may include one or more end ring segments 28 and one or more slot segments 26 received in the core slots 12 without departing from the teachings provided herein. Figure 1 The rectangular cross-sectional shape seen in FIG. 1 and / or any other shape.

[0044] refer to Figure 3-6 , rotor 30 may include a rotor core 32 and one or more windings 24 and / or magnets 34 supported by rotor core 32. Rotor 30 may also support and / or be operably coupled to a rotatable shaft 40. In various embodiments, rotor 30 may be, but is not limited to, a "claw pole" rotor, a permanent magnet non-claw pole rotor, a permanent magnet claw pole rotor, a salient field wound rotor, or an induction type rotor.

[0045] Further references Figure 3-6 In some embodiments, an electric machine 38 is formed when the stator 22 is operably coupled to the rotor 30. During operation, the rotor 30 can be mechanically powered, driven, or rotated about an axis of rotation by a force (such as mechanical energy from an engine). The relative rotational motion of the rotatable rotor 30 relative to the fixed or stationary stator 22 generates electrical power in one or more windings 24 due to the interaction of the motor's magnetic field. The electrical power generated in the one or more windings 24 can be conductively connected to and further delivered to at least one electrical load or power source. In some aspects, the electric machine 38 can provide electrical power to a power distribution system or power distribution network. In contrast, when operating as an electric motor, alternating current (AC) power (such as three-phase AC power) can be provided to one or more windings 24 of the stator 22, which produces rotational movement of the rotor 30. Additionally, the types of electric machines 38 provided herein can be AC synchronous machines, AC induction machines, switched reluctance machines, or any other feasible types of electric machines.

[0046] refer to Figure 7-8B To maintain the temperature of the electric machine 38 within a desired operating temperature range while in operation, the electric machine 38 may include a cooling system 42. In some embodiments, one or more of the windings 24 of the electric machine 38 may include an elongated body 86 defining cooling channels 44 extending therethrough, the cooling channels 44 being in fluid communication with the cooling system 42. In some embodiments, each winding 24 may be independently coupled to the cooling system 42, and / or a first winding 24 may be fluidly coupled to a second winding 24 and coupled in series to the cooling system 42.

[0047] In some embodiments, the cooling system 42 may provide cooling fluid in the form of lubricating oil, a consumable liquid (such as water), a gas, supercritical steam, and / or any other suitable cooling fluid to the windings 24 of the stator 22 and / or rotor 30. In various embodiments, the cooling fluid may have a high specific heat capacity to transfer heat from the windings 24 to the heat exchanger 56 via the cooling fluid flow path FP, may have a low dynamic viscosity to reduce the amount of power required to move the cooling fluid through the cooling system 42 and the passages 44, may have a high flash / boiling temperature to allow for high operating temperatures, and / or may have a high dielectric strength to withstand potential temperature differences across the windings 24 that may generate corona discharges that may dent or corrode the windings 24. In various embodiments, the cooling fluid may be electrically insulating to prevent electrical shorting through the cooling fluid that results in axial circulating currents (due to potential differences axially across the windings 24) that increase losses, and / or may have a high corrosion resistance to prevent corrosion over time of portions of the electric machine 38 contacted by the cooling fluid.

[0048] In various embodiments (such as Figure 7 ), the cooling system 42 may include a cooling system supply line 46 and a return line 48 in communication with one or more of the windings 24. The cooling system supply line 46 and the return line 48 carry a cooling fluid 50 to and from the passages 44 of each winding 24. It will be appreciated that the cooling system supply line 46 and the return line 48 may be formed in a variety of configurations suitable for the purpose.

[0049] A pump assembly 52 (and / or compressor assembly) is positioned between the cooling system supply line 46 and the return line 48, opposite the one or more windings 24. The pump assembly 52 may be responsible for moving the cooling fluid 50 through the passage 44. In some embodiments, the pump assembly 52 may be configured to maintain the flow rate of the cooling fluid 50 below a maximum desired flow rate, which may reduce and / or prevent erosion of one or more turbulators 54 or any other features that may be located within the passage 44.

[0050] In some examples, the cooling system 42 can include a heat exchanger 56 in communication with both the cooling system supply line 46 and the return line 48. In some examples, the heat exchanger 56 can be positioned between the windings 24 and the pump assembly 52. In some examples, the heat exchanger 56 can be configured to transfer thermal energy from the cooling fluid 50 to the atmosphere, which can reduce the temperature of the cooling fluid 50. Although reference has been made herein to the heat exchanger 56, it should be understood that the present disclosure contemplates the use of any present or future method for transferring thermal energy that will function as described and claimed.

[0051] In some examples, the flow of cooling fluid 50 can be considered a closed loop. However, during normal operation, losses of cooling fluid 50 are expected. To this end, the cooling system 42 can further include a reservoir 58 in communication with the return line 48 to replenish any losses of cooling fluid 50.

[0052] In addition, in some embodiments, the cooling system 42, the stator 22, and / or the motor 38 may further include a computing system 60 (or be operably coupled to a computing system 60) that causes the motor 38 to perform certain functions, such as actuation of the pump assembly 52. The one or more functions may be any of the components that control the cooling system 42 and / or the motor 38. The computing system 60 may include one or more computing devices 62. The computing device(s) 62 may include one or more processors 64 and one or more memory devices 66. The one or more processors 64 may include any suitable processing device, such as a microprocessor, a microcontroller, an integrated circuit, a logic device, and / or other suitable processing device. The one or more memory devices 66 may include one or more computer-readable media, including, but not limited to, non-transitory computer-readable media, RAM, ROM, a hard drive, a flash drive, and / or other memory devices.

[0053] One or more memory devices 66 may store information accessible by one or more processors 64, including computer-readable instructions 68 executable by one or more processors 64. Instructions 68 may be any set of instructions that, when executed by one or more processors 64, cause one or more processors 64 to perform operations. In some embodiments, instructions 68 may be executed by one or more processors 64 to cause one or more processors 64 to perform operations, such as any of the operations and functions for which computing system 60 and / or computing device(s) 62 are configured, operations for operating cooling system 42 and / or motor 38, and / or any other operations or functions of one or more computing devices 62. Instructions 68 may be software written in any suitable programming language or may be implemented in hardware. Additionally and / or alternatively, instructions 68 may be executed on processor(s) 64 in logically and / or virtually separate threads. Memory device(s) 66 may further store data 70 accessible by processor(s) 64. For example, the data 70 may include data indicative of motor temperature, winding temperature, cooling fluid temperature, cooling fluid flow rate, efficiency gains based on usage of the cooling system 42 , and / or any other information.

[0054] The computing device(s) 62 may also include a network interface 72 for communicating with other components of the system 500 (e.g., via a network). The network interface 72 may include any suitable components for interfacing with one or more networks, including, for example, transmitters, receivers, ports, controllers, antennas, and / or other suitable components. One or more external display devices (not depicted) may be configured to receive one or more commands, data, and / or information from the computing device(s) 62.

[0055] refer to Figures 9A-9D In various embodiments, one or more turbulators 54 positioned within the channel can affect the flow of fluid through the channel 44 by: changing the pressure; changing the flow rate; changing the flow from laminar to turbulent (or vice versa); increasing the surface area of the channel 44 along the winding 24, thereby improving the heat removal properties of the winding 24, etc. Generally, the more turbulent the flow, the greater the heat transfer rate, all other things being equal. In other words, the higher the Reynolds number, the faster the heat transfer rate. In addition, the laminar flow of the fluid within the channel 44 can make uniform heat transfer and / or a desired heat transfer rate more difficult. Moreover, the turbulators 54 can have varying concentrations along the channel 44 of the winding 24 based on the localized heat generation of various portions of the winding 24, which can enhance heat removal from the winding 24 by the cooling system 42 and / or maintain a more uniform temperature along the winding 24.

[0056] One or more channels 44 and / or turbulators 54 located within one or more channels 44 may be formed by an additive manufacturing process. In some embodiments, the turbulators 54 may be formed simultaneously with various portions of the windings 24 during the additive manufacturing process. In some examples, electron beam melting (EBM) may be used to form the windings 24 from a material having a high conductivity. For example, the windings 24 may be formed from a material that at least partially contains copper (e.g., 99.95% pure copper). In other examples, the windings 24 may be formed from any other conductive material, such as a copper alloy, silver, aluminum, an aluminum alloy, and / or carbon nanotubes (CNTs). Furthermore, it will be appreciated that the turbulators 54 may be formed in any manner without departing from the scope of the present disclosure.

[0057] Further references Figures 9A-9D The turbulators 54 may include pins, dimples, and various other protruding shapes that improve heat transfer by increasing turbulence. The location, size, and frequency of the turbulators 54 are selected to minimize the increase in the power loss coefficient due to their presence, thereby resulting in a higher pressure loss for moving the cooling fluid 50 through the passages 44.

[0058] like Figures 9A-9DAs illustrated in FIG, each of the turbulators 54 may be aligned along the channel 44 or vary in distance from a side portion of the channel 44 and / or an adjacent turbulator 54. For example, Figure 9A As illustrated in FIG, the first and second turbulators 54 may be positioned a first distance d1 from each other. In some embodiments, the first distance d1 may be substantially equal to a second distance d2 defined between the first turbulator 54a and a side portion of the channel 44 and / or a third distance d3 defined between the second turbulator 54b and an opposite side portion of the channel 44.

[0059] In some embodiments (such as Figure 9B ), the first turbulator 54a and the second turbulator 54b may be separated by a first distance d1, which may be substantially less than a second distance d2 and a third distance d3 defined between the first turbulator 54a and the side portion of the channel 44 and the second turbulator 54b and the side portion of the channel 44, respectively. Additionally or alternatively, as Figure 9C As illustrated in FIG, the first distance d1 may be substantially greater than the second distance d2 and the third distance d3 defined between the first turbulator 54a and the side portion of the channel 44 and the second turbulator 54b and the side portion of the channel 44, respectively.

[0060] In some embodiments (such as Figure 9D ), the second distance d2 defined between the first turbulator 54a and the side portion of the channel 44 may be less than the third distance d3 defined between the first turbulator 54a and the side portion of the channel 44. As provided herein, the channel 44 may include any number of turbulators 54 along the winding 24. Each of the turbulators 54 may be positioned such that some of the turbulators 54 are similar to Figures 9A-9D , but the other turbulators 54 may be oriented in any other feasible orientation without departing from the scope of the present disclosure.

[0061] refer to Figures 10A-10D The turbulators 54 may have any feasible width, and the widths and shapes of the various turbulators 54 may be generally common (e.g., geometrically similar) or vary along the length of the channel 44. For example, the first turbulator 54a and the second turbulator 54b may have a first width w1 that is preferably greater than the width of the first turbulator 54a. Figure 10A ) may be between 0.02 millimeters (mm) and 0.6 mm; a second width w2, which in embodiments such as Figure 10B ) may be between 0.3 mm and 0.8 mm; and / or a third width w3, which in embodiments such as, Figure 10C) may be between 0.6 mm and 2 mm (or any other feasible width). In some embodiments, the first turbulator 54a may have a fourth width w4 that is different from the fifth width w5 of the second turbulator 54b. In some examples, the fourth width w4 may be greater than the fifth width w5. However, in various embodiments, the fourth width w4 may be less than the fifth width w5. Additionally, the width of each turbulator 54 may be substantially uniform and / or vary along the respective turbulator 54.

[0062] refer to Figures 11A-11F In various embodiments, the turbulators 54 may extend from the upper portion 76 of the passage 44 and / or the lower portion 78 of the passage 44. In some embodiments (such as Figure 11A In one embodiment shown in FIG. Figure 11A One or more turbulators 54 are provided along the windings 24 , and the turbulators 54 may extend continuously between an upper portion 76 of the channel 44 and a lower portion 78 of the channel 44 .

[0063] It is worth noting that, as used herein, the terms "upper" and "lower" as used to describe aspects of the channel 44 refer only to opposite sides in a direction perpendicular to the direction of flow. Unless otherwise stated, the terms upper and lower do not imply any particular positioning or orientation relative to the vertical direction.

[0064] In some embodiments (such as Figures 11B to 11E , one or more turbulators 54 along the winding 24 may extend generally from one of the upper portion 76 and the lower portion 78 of the channel 44. In such an embodiment, a first section 80 of the turbulator 54 may extend from the upper portion 76 of the channel 44, while a second section 82 of the turbulator 54 may extend from a bottom portion of the channel 44. In various embodiments, the first section 80 and the second section 82 may be generally vertically aligned and / or the first section 80 and the second section 82 may be generally vertically offset from each other. As used herein, generally vertically offset means that the axis of extension A1 of the first section 80 is not vertically aligned and / or parallel to the axis of extension A2 of the second section 82.

[0065] Further references Figures 11B to 11E In examples where the turbulators 54 extend less than the entire distance of the passage 44, a gap 84 may be defined between the first section 80 and the second section 82 of the turbulator 54. In various embodiments, the gap 84 has a distance greater than the length of the first section 80 or the second section 82. Additionally, the gap 84 between the various turbulators 54 of the passage 44 may be generally consistent or vary from one turbulator 54 to the next.

[0066] In some examples, the height h of gap 84 is g may be less than the total height h between the upper portion 76 and the lower portion 78 of the channel 44 t 15% (such as approximately 10% ( Figure 11B )), may be at a total height h between the upper portion 76 and the lower portion 78 of the channel 44 t between 15% and 50% (such as approximately 25% ( Figure 11C )), may be at a total height h between the upper portion 76 and the lower portion 78 of the channel 44 t between 40% and 70% (such as approximately 50% ( Figure 11D )), and may be at a total height h between the upper portion 76 and the lower portion 78 of the channel 44 t between 50% and 99.9%, such as approximately 75% ( Figure 11E In various embodiments, the turbulators 54 may extend between side portions of the channel 44 and include the first segment 80 and / or the second segment 82 provided herein. Additionally, the turbulators 54 may extend along the winding 24 from the top portion, bottom portion, and / or side portions in any combination.

[0067] In some embodiments, as Figure 11F As shown in FIG, the turbulator 54 may include only the first section 80 and / or only the second section 82. In such an example, the turbulator 54 may extend from the top portion, the bottom portion, and / or the side portion of the channel 44. Figure 11F As illustrated in FIG, a first section 80 of a turbulator 54 may be longer (or shorter) than a second section 82 of the same turbulator 54. Thus, a gap 84 defined between the first section 80 and the second section 82 is asymmetrical relative to the centerline of the passage 44.

[0068] refer to Figure 12A and Figure 12B In various portions of the passage 44, turbulators 54 may be provided as Figure 12A Positioned in a staggered orientation as shown in FIG and / or as Figure 12B Furthermore, the turbulators 54 may be solid or hollow (e.g., generally formed of Figure 12A and Figure 12B turbulators 54 as shown by the imaginary circles within each turbulator 54 to minimize the additional mass of the winding 24.

[0069] Each turbulator 54 is positioned within the cooling fluid flow path FP of the passage 44 and is configured to modify the flow of the cooling fluid 50. In the example where the turbulators 54 are positioned in a staggered orientation, such as Figure 12A, the laterally outer turbulators 54 of the first row of turbulators 54 may be positioned a first distance from the side portions of the passage 44, and the laterally outer turbulators 54 of the second row 90 of turbulators 54 (which is located downstream of the first row 88 of turbulators 54) may be positioned a second, greater distance from the side portions of the passage 44. By incorporating a staggered orientation, a wake effect of the cooling fluid 50 may be reduced and / or prevented within the passage 44. Additionally, the staggered orientation may enhance heat transfer while maintaining or minimizing a lower pressure increase within the passage 44. It will be appreciated that each row 88, 90 may include any number (one or more) of turbulators 54, and that each successive row (e.g., 90) may be positioned downstream of the previous row (e.g., 88). In some examples, some of the turbulators 54 may be staggered, while others may be aligned, without departing from the scope of the present disclosure.

[0070] refer to Figure 12B In some embodiments, one or more turbulators 54 in a first row 88 may be oriented generally aligned with one or more turbulators 54 in a subsequent second row 90. In various embodiments, this alignment may be generally along the cooling fluid flow path FP of the passage 44.

[0071] refer to Figures 13A-13C In the nonlinear portion of the winding 24, one or more rows 88, 90, 92, 94, 96, 98, 100 of turbulators 54 may be positioned in a common or varying orientation. Figure 13A As shown in FIG, the turbulators 54 are aligned in seven rows 88, 90, 92, 94, 96, 98, 100, with one or more turbulators 54 in each row 88, 90, 92, 94, 96, 98, 100. In the illustrated embodiment, a first pair of rows 88, 92 may be located on a linear portion of the winding 24 and include at least one turbulator 54 in each row 88, 92. The one or more turbulators 54 may be oriented at a common distance from a side portion of the passage 44 and separated by a first length l1 generally along the cooling fluid flow path FP. A second pair of rows 96, 100 may be arranged on a curved portion of the winding 24 and include at least one turbulator 54 in each row 96, 100. The one or more turbulators 54 in the second pair of rows 96, 100 may be oriented at a common distance from a side portion of the passage 44 and separated by a second length l2 generally along the cooling fluid flow path FP. As used herein, a "common" distance may be any distance that is within 10% of the distance between two members.In various embodiments, the first length 11 and the second length 12 may be substantially equal.

[0072] refer to Figure 13BIn some embodiments, a row of turbulators 54 (e.g., 92) may be positioned on a transition portion 102 between a linear portion and a curved portion of the channel 44. The row 88 of turbulators 54 may be positioned upstream and separated from the row 92 of turbulators 54 located on the transition portion 102 by a third length l3. Similarly, the row 96 of turbulators 54 may be positioned downstream and separated from the row 92 of turbulators 54 located on the transition portion 102 by a fourth length l3. The third length l3 and the fourth length l4 may be equal and / or vary along various portions of the winding 24 and / or in various embodiments. Furthermore, each of the third length l3 and the fourth length l4 may be greater than the first length l1 and the second length l2.

[0073] refer to Figure 13C In some examples, the first pair of rows 88, 92 can be positioned in a first portion, such as a linear portion of the winding 24, and separated by a fifth length 15. The second pair of rows 94, 98 can be positioned in a second portion, which can be at least partially within a curved portion of the winding 24, and separated by a sixth length 16. The fifth length 15 and the sixth length 16 can be equal and / or vary along various portions of the winding 24 and / or in various embodiments.

[0074] Now refer to Figure 14 , a flow chart of a method 200 for manufacturing an electric motor 38 according to various aspects of the present disclosure is provided. The electric motor 38 manufactured by the disclosed method can be manufactured according to the method described above and in Figures 1 to 13C As such, in at least some aspects, an electric machine 38 operated by the method 200 may be incorporated into an engine, such as an aircraft gas turbine engine, and may include a stator 22 and a rotor 30.

[0075] As depicted, method 200 includes forming a stator core 10 ( Figure 4 ) and rotor 30( Figure 4 As provided herein, the stator core 10 and the rotor 30 can be formed by any feasible method. Furthermore, in various embodiments, the stator can be positioned outside and / or inside the rotor 30.

[0076] At (204), the method includes forming the winding 24 ( Figure 8A ), the winding 24 has a channel 44 at least partially defined therethrough. As provided herein, one or more turbulators 54 are positioned within the channel 44. The turbulators 54 can be configured to: change pressure, change flow rate, change flow from laminar to turbulent (or vice versa); increase the surface area of the channel 44 along the winding 24, thereby improving heat removal properties of the winding 24, and the like.

[0077] As provided herein, the winding 24 can be formed by an additive manufacturing process such that one or more turbulators 54 are integrally formed with a portion of the winding 24. In various examples, the additive manufacturing process can allow the method to include forming at least partially vertically aligned first and second segments 80, 82 of the turbulator 54 at step (206). A gap 84 is defined between the first and second segments 80, 82 of the turbulator 54. When produced in the additive manufacturing process, one of the first or second segments 80, 82 of the turbulator 54 can be formed before the remaining first or second segments 80, 82 of the turbulator 54.

[0078] At step (208), the method may include operatively coupling the windings 24 to the stator core 10 or the rotor 30. Once the windings 24 are coupled to one of the stator cores 10 and the rotor 30, at step (210), the method may include fluidly coupling the cooling system 42 to the passage 44. In some examples, at step (212), the method may include fluidly coupling the cooling system 42 to the passage 44, including coupling a supply line 46 to one end portion of the windings 24 and coupling a return line 48 to a second end portion of the windings 24.

[0079] By operating according to one or more of these aspects, Figure 1-13C The motor and / or Figure 14 The method 200 provided in the embodiment of the present invention may provide a more efficient electric machine due to reduced operating temperature. The electric machine may therefore be able to generate more electrical power when operating as a generator and / or use electrical power more efficiently when operating as a motor.

[0080] Further aspects of the present disclosure may be provided in the following terms: An electric machine includes: a stator core defining a plurality of core slots in a surface thereof; a winding received in at least one of the plurality of core slots, the winding defining a channel through at least a portion thereof; a cooling system operably coupled to the channel and configured to move a cooling fluid through the channel; and a turbulator positioned within the channel, wherein the turbulator is located within a flow path of the cooling fluid.

[0081] The electric machine of one or more of these clauses, further comprising: a controller operably coupled to the cooling system and configured to actuate a pump assembly of the cooling system.

[0082] The electric machine of one or more of these clauses, wherein the turbulators include a first turbulator separated by a first distance from a first side portion of the channel and a second turbulator separated by a second distance from an opposite second side portion of the channel.

[0083] The motor of one or more of these clauses, wherein the first distance is substantially equal to the second distance.

[0084] An electric machine as claimed in one or more of these clauses, wherein the turbulators are integrally formed with the windings.

[0085] The electric machine of one or more of these clauses, wherein the turbulators include a first turbulator having a first width and a second turbulator having a second width.

[0086] The motor of one or more of these clauses, wherein the first width is substantially equal to the second width.

[0087] The motor of one or more of these clauses, wherein the first width is greater than the second width.

[0088] The motor of one or more of these clauses, wherein the turbulator comprises a first segment extending from an upper portion of the channel and a second segment extending from a bottom portion of the channel, wherein the first segment and the second segment define a gap therebetween.

[0089] The electric machine of one or more of these clauses, wherein the first section and the second section are vertically offset from each other.

[0090] The electric machine of one or more of these clauses, wherein the gap defined between the first segment and the second segment is asymmetric with respect to a centerline of the channel.

[0091] The motor of one or more of these clauses, wherein the turbulator comprises a first segment extending from an upper portion of the channel and a second segment extending from a bottom portion of the channel, wherein the first segment and the second segment define a gap therebetween.

[0092] An electric machine of one or more of these clauses, wherein the turbulators include a plurality of turbulators having a first pair of rows separated by a first length generally along the direction of the cooling fluid flow path and arranged on a linear portion of the winding and a second pair of rows separated by a second length generally along the direction of the cooling fluid flow path and arranged on a curved portion of the winding, wherein the first length and the second length may be generally equal.

[0093] A method of manufacturing an electric machine having a stator core and a rotor includes forming a winding for the stator core or rotor of the electric machine, the winding having a channel at least partially defined therethrough, wherein forming the winding further includes integrally forming one or more turbulators within the channel.

[0094] The method of one or more of these clauses, further comprising: operably coupling the winding to one of the stator core or the rotor; and fluidly coupling a cooling system to the channel, wherein fluidly coupling the cooling system to the channel comprises coupling a supply line to one end portion of the winding and coupling a return line to a second end portion of the winding.

[0095] The method of one or more of these clauses, wherein forming one or more turbulators within the channel further comprises forming at least partially vertically aligned first and second segments of the one or more turbulators, wherein a gap is defined between the first and second segments of the one or more turbulators.

[0096] A winding for an electric machine includes: an elongated body, wherein the elongated body is configured to be operably coupled to at least one of a stator or a rotor; a channel defined by the elongated body and extending through at least a portion of the elongated body; and a turbulator positioned within the channel, wherein the turbulator is located within a flow path of a cooling fluid through the channel.

[0097] The winding for an electric machine of claim 17, wherein the passage is operably coupled to a cooling system configured to move a cooling fluid through the passage.

[0098] The winding for an electric machine of claim 17, wherein the turbulator comprises a first turbulator and an offset second turbulator.

[0099] The winding for an electric machine of claim 19, wherein each of the first turbulator and the second turbulator includes a first section extending from a first portion of the channel and a second section extending from a second portion of the channel, the first section and the second section being separated by a gap.

[0100] The techniques discussed herein refer to computer-based systems and the actions taken by computer-based systems and information sent to and from computer-based systems. Those skilled in the art will recognize that the inherent flexibility of computer-based systems allows for a wide variety of possible configurations, combinations, and the division of tasks and functionality between and within components. For example, the processes discussed herein can be implemented using a single computing device or multiple computing devices working in combination. Databases, memories, instructions, and applications can be implemented on a single system or distributed across multiple systems. The distributed components can operate serially or in parallel.

[0101] Although specific features of various embodiments may be shown in some drawings and not in others, this is for convenience only. According to the principles of the present disclosure, any feature of a drawing may be referenced and / or claimed in combination with any feature of any other drawing.

[0102] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Claims

1. A motor comprising: a stator core defining a plurality of core slots in a surface thereof; a winding received in at least one of the plurality of core slots, the winding having a passage extending through at least a portion of the winding; a cooling system operably coupled to the passage and configured to move a cooling fluid through the passage; as well as a first turbulator positioned within the channel and within a flow path of the cooling fluid, the first turbulator comprising a first segment extending from an upper portion of the channel and a second segment extending from a bottom portion of the channel, wherein the first segment and the second segment of the first turbulator define a first gap therebetween, and wherein one of the first segment or the second segment extends beyond a vertical midpoint of the channel.

2. The motor according to claim 1, further comprising: A controller is operably coupled to the cooling system and configured to actuate a pump assembly of the cooling system.

3. The motor according to claim 1, further comprising: The second turbulator is positioned within the channel and within a flow path of the cooling fluid, the second turbulator including a first section extending from an upper portion of the channel and a second section extending from a bottom portion of the channel, wherein the first and second sections of the second turbulator define a second gap therebetween.

4. The motor according to claim 3, wherein The second gap is vertically offset from the first gap.

5. The motor according to claim 3, wherein The first gap is positioned on a first side of a vertical midpoint of the channel and the second gap is positioned on a second, opposite side of the vertical midpoint of the channel.

6. The motor according to claim 3, wherein The first turbulator defines a first width, and the second turbulator defines a second width.

7. The motor according to claim 6, wherein The first width is substantially equal to the second width.

8. The motor according to claim 6, wherein The first width is greater than the second width.

9. The motor according to claim 1, wherein The turbulators include a first turbulator separated by a first distance from a first side portion of the channel and a second turbulator separated by a second distance from an opposite second side portion of the channel.

10. The motor according to claim 1, wherein The first turbulator is at least partially hollow.

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