Heat dissipation structure of high-voltage high-power alternating current motor and motor cooling system

Abstract

The invention discloses a heat dissipation structure of a high-voltage high-power alternating current motor and a motor cooling system.The heat dissipation structure comprises a machine shell water jacket, the machine shell water jacket is installed outside a stator iron core, a cooling channel is arranged in the machine shell water jacket, and the cooling channel is used for storing quantitative cooling media; the heat conduction piece is installed on the outer edge of the end portion of the machine shell water jacket, one part of the heat conduction piece is in thermal coupling with the inner circumferential side wall of the machine shell water jacket, and the other part of the heat conduction piece stretches into the position close to the end portion of the stator winding; and the thermosetting resin layer is formed by filling thermosetting resin into a gap between the casing water jacket and the end part of the stator iron core and a gap between the casing water jacket and the end part of the stator winding, and the heat conduction piece is positioned in the thermosetting resin layer. According to the technical scheme, high power density and efficient cooling of the motor can be considered, the space utilization rate of heat dissipation of the motor can be improved, and the cooling effect of the motor is remarkably improved.

Description

Technical Field

[0001] This invention relates to a high power density motor, and more particularly to a heat dissipation structure and motor cooling system for a high-voltage, high-power AC motor. Background Technology

[0002] High-power-density AC motors, with their wide range of applications and flexible structural characteristics, eliminate some of the complexity of mechanical transmissions, achieving breakthroughs in both power density and efficiency. They have become a key supporting technology in fields such as deep-sea operations, special vehicles, and mining traction drives. However, the extreme increase in power density leads to highly concentrated internal losses in the motor, and heat dissipation has become a core obstacle restricting its performance and reliability.

[0003] To achieve high power density, existing high-power AC motors employ two approaches: firstly, permanent magnet motors with low-loss silicon steel sheets and high-grade permanent magnets, but these are not economically viable; secondly, structural innovations such as internal rotor cooling channels and hollow windings are used, but these increase electromagnetic design complexity and manufacturing complexity. Therefore, optimizing and upgrading the heat dissipation and cooling technologies of these AC motors is both a practical necessity and a pressing technological imperative.

[0004] In view of this, it is necessary to propose improvements to the current heat dissipation structure of AC motors. Summary of the Invention

[0005] To solve at least one of the above-mentioned technical problems, the main objective of this invention is to provide a heat dissipation structure and a motor cooling system for a high-voltage, high-power AC motor.

[0006] To achieve the above objectives, one technical solution adopted by the present invention is as follows: A heat dissipation structure for a high-voltage, high-power AC motor is provided. The high-voltage, high-power AC motor includes a stator assembly and a rotor assembly located within the stator assembly. The stator assembly includes a stator core and stator windings embedded within the stator core. The heat dissipation structure includes: A housing water jacket is installed outside the stator core, and a cooling channel is provided inside the housing water jacket for storing a certain amount of cooling medium. A heat-conducting component is installed on the outer edge of the end of the water jacket of the housing. A portion of the heat-conducting component is thermally coupled to the inner peripheral sidewall of the water jacket of the housing, and another portion of the heat-conducting component extends into the vicinity of the end of the stator winding. Thermosetting resin layer, wherein the thermosetting resin layer is formed by filling the gap between the housing water jacket and the stator core end with thermosetting resin, and the gap between the housing water jacket and the stator winding end, and the heat-conducting element is located within the thermosetting resin layer. Specifically, a portion of the stator winding end is thermally coupled to the inner wall of the housing water jacket via thermosetting resin, and another portion of the stator winding end is thermally coupled to the inner wall of the housing water jacket via thermosetting resin and a heat-conducting component in sequence; the stator core end is thermally coupled to the inner wall of the housing water jacket via thermosetting resin and a heat-conducting component in sequence.

[0007] In one embodiment of the present invention, the heat-conducting component includes a first heat-conducting component and a second heat-conducting component, and the thermosetting resin layer includes a first thermosetting resin layer and a second thermosetting resin layer, wherein the first heat-conducting component is located within the first thermosetting resin layer, and the second heat-conducting component is located within the second thermosetting resin layer. The fixed first heat-conducting component and the first thermosetting resin layer are located between the inner wall of one end of the housing water jacket and the end of one end of the stator winding, and the fixed second heat-conducting component and the second thermosetting resin layer are located between the inner wall of the other end of the housing water jacket and the end of the other end of the stator winding.

[0008] In one embodiment of the present invention, the first heat-conducting element and the second heat-conducting element are both multiple heat pipes for storing condensing medium. Each heat pipe is radially distributed along the water jacket of the casing. Each heat pipe has an evaporation section and a condensation section, which are connected by a capillary wick. The evaporation section is located near the end of the stator winding, and the condensation section is located near the inner wall of the water jacket of the casing. The multiple heat pipes are arranged in a ring shape.

[0009] In one embodiment of the present invention, the heat dissipation structure further includes a first retainer and a second retainer arranged in a ring. The first retainer is located between one end of the stator core and the inner wall of one end of the water jacket of the housing, and the second retainer is located between the other end of the stator core and the inner wall of the other end of the water jacket of the housing. The first retainer is used to limit the heat pipe in the first heat-conducting component, and the second retainer is used to limit the heat pipe in the second heat-conducting component.

[0010] In one embodiment of the present invention, a plurality of annularly distributed limiting grooves are provided on one side of both the first retainer and the second retainer. One end of the heat pipe near the condensation section is secured in the limiting groove and partially protrudes from the limiting groove, while the other end of the heat pipe extends out of the limiting groove, or The first and second retainers each have a plurality of ring-shaped limiting holes on one side. The heat pipe passes through the limiting holes, and one end of the heat pipe near the condensation section is fixed in the limiting hole and partially exposed. The other end of the heat pipe extends out of the limiting hole.

[0011] In one embodiment of the present invention, the length of the portion of the heat pipe extending out of the limiting groove is longer than the portion confined within the limiting groove, or The length of the portion of the heat pipe extending out of the limiting hole is longer than the portion confined within the limiting hole.

[0012] In one embodiment of the present invention, both the first thermosetting resin layer and the second thermosetting resin layer are annular in shape. Both the first thermosetting resin layer and the second thermosetting resin layer include a first ring and a second ring. The second ring is located on the first ring and protrudes from the first ring. The first ring is in close contact with the inner wall of one end of the water jacket of the housing, and the second ring is in close contact with the end of the stator winding.

[0013] In one embodiment of the present invention, both the first thermosetting resin layer and the second thermosetting resin layer are epoxy resin, polyurethane, acrylic resin, phenolic resin, amino resin or polyester resin.

[0014] In one embodiment of the present invention, the water jacket of the housing is provided with a liquid inlet and a liquid outlet, the liquid inlet being connected to one end of the cooling channel and the liquid outlet being connected to the other end of the cooling channel; The cooling channel is an axial meandering waterway, a spiral waterway, an axial waterway, or an irregularly shaped waterway.

[0015] To achieve the above objectives, another technical solution adopted by the present invention is to provide a motor cooling system, including a high-voltage high-power AC motor and a heat dissipation structure, wherein the heat dissipation structure is the heat dissipation structure of the high-voltage high-power AC motor described above.

[0016] The heat dissipation structure of this invention, by combining a heat-conducting component, thermosetting resin, and a housing water jacket with cooling channels, can dissipate heat from the ends of the stator winding and stator core. Specifically, a portion of the stator winding end is thermally coupled to the inner wall of the housing water jacket via thermosetting resin, and then rapidly dissipates heat through the cooling channels within the housing water jacket. Another portion of the stator winding end is thermally coupled to the inner wall of the housing water jacket via thermosetting resin and a heat-conducting component, and then rapidly dissipates heat through the cooling channels within the housing water jacket. This effectively provides two additional cooling paths for the stator winding, facilitating rapid heat dissipation. Similarly, the stator core end is thermally coupled to the inner wall of the housing water jacket via thermosetting resin and a heat-conducting component, and then rapidly dissipates heat through the cooling channels within the housing water jacket, effectively providing an additional cooling path for the stator core. Furthermore, the thermosetting resin can also thermally couple to the inner wall of the housing water jacket via the heat-conducting component, and then rapidly dissipate heat through the cooling channels within the housing water jacket. By achieving rapid heat transfer and synergistic optimization among the stator windings, stator core, and thermosetting resin, efficient cooling can be achieved, significantly extending the motor's service life. Furthermore, this solution boasts advantages such as a simplified structure, eliminating the need for additional heat dissipation components, and maximizing the utilization of heat dissipation space. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the structure of a high-voltage, high-power AC motor according to an embodiment of the present invention; Figure 2 for Figure 1 A sectional view; Figure 3 This is a partial cross-sectional view of a high-voltage, high-power AC motor according to an embodiment of the present invention; Figure 4 This is a cross-sectional view of the heat dissipation structure of a high-voltage, high-power AC motor according to an embodiment of the present invention; Figure 5 This is a schematic diagram of the water jacket structure of the housing in one embodiment of the present invention; Figure 6 This is a schematic diagram of the end structure of a high-voltage, high-power AC motor according to an embodiment of the present invention; Figure 7 This is a schematic diagram of the structure of the combination of the second heat-conducting element and the second retainer in one embodiment of the present invention; Figure 8 This is a schematic diagram of the structure of the first cage in one embodiment of the present invention; Figure 9 This is a schematic diagram of the structure of the combination of the second thermosetting resin layer, the second thermally conductive element and the second retainer in one embodiment of the present invention; Figure 10 This is a schematic diagram of the structure of the second thermosetting resin layer in one embodiment of the present invention; Figure 11 This is a schematic diagram illustrating the working principle of the heat pipe in this invention; Figure 12 The following are temperature distribution diagrams for each component in Scheme 1, where a is the temperature distribution diagram of the stator winding, b is the temperature distribution diagram of the stator core, c is the temperature distribution diagram of each component after the motor is radially cut open, and d is the temperature distribution diagram of each component after the motor is axially cut open. Figure 13 The following are temperature distribution diagrams for each component in Scheme 2: a is the temperature distribution diagram of the stator winding, b is the temperature distribution diagram of the stator core, c is the temperature distribution diagram of each component after the motor is radially cut open, and d is the temperature distribution diagram of each component after the motor is axially cut open. Figure 14These are temperature distribution diagrams for each component in this invention, where a is the temperature distribution diagram of the stator winding, b is the temperature distribution diagram of the stator core, c is the temperature distribution diagram of each component after the motor is radially cut open, and d is the temperature distribution diagram of each component after the motor is axially cut open.

[0019] Explanation of reference numerals in the attached figures: 100. Stator assembly; 110. Stator core; 120. Stator winding; 130. Slot insulation; 200. Rotor assembly; 210. Rotor core; 220. Permanent magnet; 230. Shaft. 300. Housing water jacket; 310. Cooling channel; 320. Liquid inlet; 330. Liquid outlet; 400. Thermal conductive component; 410. First thermal conductive component; 420. Second thermal conductive component; 500. Thermosetting resin layer; 510. First thermosetting resin layer; 511. First ring; 512. Second ring; 520. Second thermosetting resin layer. 610. First retainer; 611. Limiting groove; 620. Second retainer.

[0020] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0022] It should be noted that the descriptions involving "first," "second," etc., in this invention are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature. Furthermore, the technical solutions of the various embodiments can be combined with each other, but only on the basis of being achievable by those skilled in the art. When the combination of technical solutions is contradictory or impossible to implement, such a combination of technical solutions should be considered non-existent and not within the scope of protection claimed by this invention.

[0023] To address the limited heat dissipation channels in AC motors, some existing solutions employ simple systems such as "water cooling + fan + heat sink fins," but their heat dissipation capacity is limited and cannot meet the requirements of high-speed, high-load conditions. For example, one example involves a shaped heat pipe and permanent magnet motor for improving heat dissipation in a permanent magnet rotor. The shaped heat pipe is uniformly arranged on the rotating rotor. The presence of the shaped curved surface increases the contact area between the heat pipe and the heat source, thereby increasing heat dissipation efficiency and achieving a cooling effect on the permanent magnet rotor. However, this method utilizes heat pipes to dissipate heat from the permanent magnet and rotor, where losses are minimal, without considering heat dissipation from the winding and stator ends, where losses are higher. Furthermore, using a single heat dissipation structure results in low heat dissipation efficiency, which cannot meet the requirements of high-power-density permanent magnet motors.

[0024] Other solutions employ dual cooling channels ("casing + end cap") or other multiple cooling channels, but these systems are complex and reduce the motor's power density. For example, one automotive water-cooled motor cooling channel structure consists of a combination of L-shaped, C-shaped, and Z-shaped cooling channels, forming a continuous ring from top to bottom. The water inlet and water channel are positioned near the winding welding end, aiming to cool the hottest area first. While this solution has three cooling channels, all three only dissipate heat from the main motor winding. The water inlet provides localized cooling to the winding ends, but it doesn't consider that the winding ends are entirely exposed to air, where the low thermal conductivity prevents effective heat transfer. Furthermore, the complex water channel structure increases manufacturing costs.

[0025] To solve at least one of the above-mentioned technical problems, the present invention provides a heat dissipation structure for a high-voltage, high-power AC motor, which aims to improve the space utilization rate for motor heat dissipation and significantly enhance the cooling effect of the motor.

[0026] To better understand this solution, some names in this invention are explained below: Alternating current (AC) motors: a type of rotating electric motor that converts electrical energy into mechanical energy using the principle of electromagnetic induction. They are driven by alternating current (current whose direction and magnitude change periodically with time). AC motors and direct current (DC) motors are the two main categories in the field of electric motors.

[0027] AC permanent magnet motor: A motor that uses permanent magnets as the excitation source and generates a rotating magnetic field by passing alternating current through the stator windings. The magnetic field of the rotor permanent magnets interacts with the magnetic field of the rotor to generate electromagnetic torque. It is mainly divided into permanent magnet synchronous motors and brushless DC motors.

[0028] Permanent magnets: Functional materials with persistent magnetism, used as excitation sources in permanent magnet motors, which can generate a constant magnetic field without external power supply. Common types include neodymium iron boron permanent magnets and samarium cobalt permanent magnets.

[0029] Slot insulation: Insulating material embedded in the stator core slots, used to isolate the stator windings from the core and the winding conductors. Common materials are insulating paper, epoxy resin coating or insulating film.

[0030] Epoxy resin: A thermosetting polymer material composed of epoxy resin as the base material, with added curing agents, fillers and functional additives. It is specifically used for filling and encapsulating the ends of motor windings (i.e. the part of the winding that extends out of the iron core). Through curing, it forms a three-dimensional network structure, providing insulation, fixation, heat dissipation and protection functions for the winding.

[0031] Heat pipe: A passive heat transfer element that achieves efficient heat transfer based on the phase change (evaporation-condensation) of the working fluid. Its core structure is a sealed metal tube (such as copper or aluminum), with a capillary porous structure attached to the inner wall. After the tube is evacuated, a small amount of working medium (such as pure water, acetone, or ammonia) is filled in. Heat is quickly transferred through the phase change of the working fluid and capillary circulation.

[0032] Power density: The rated power output per unit volume or unit weight of a motor, with the core unit being kW / m³ (kilowatts per cubic meter) or kW / kg (kilowatts per kilogram).

[0033] Please refer to the following embodiment for the specific structure of the heat dissipation structure of the high-voltage, high-power AC motor.

[0034] Please refer to Figures 1 to 5 , Figure 1 This is a schematic diagram of the structure of a high-voltage, high-power AC motor according to an embodiment of the present invention; Figure 2 for Figure 1 A sectional view; Figure 3 This is a partial cross-sectional view of a high-voltage, high-power AC motor according to an embodiment of the present invention; Figure 4 This is a cross-sectional view of the heat dissipation structure of a high-voltage, high-power AC motor according to an embodiment of the present invention; Figure 5This is a schematic diagram of the water jacket structure of the casing in one embodiment of the present invention. In this embodiment, the heat dissipation structure of the high-voltage, high-power AC motor is used to dissipate heat from the stator assembly 100 of the high-voltage, high-power AC motor. This high-voltage, high-power AC motor is suitable for deep-sea operation motors, port machinery motors, special vehicle motors, mining traction drive motors, or other types of high-voltage, high-power motors. The high-voltage, high-power AC motor includes a stator assembly 100 and a rotor assembly 200 located within the stator assembly 100. The stator assembly 100 includes a stator core 110, stator windings 120 embedded in the stator core 110, and slot insulation 130 sleeved on the stator windings 120. The stator windings 120 are insulated from each other by the slot insulation 130, and the number of slot insulation 130 is the same as the number of stator windings 120. The rotor assembly 200 includes a rotor core 210, a permanent magnet 220 axially inserted into the rotor core 210, and a rotating shaft 230 installed at the center of the rotor core 210. The rotor assembly 200 can be replaced with an induction motor rotor, a reluctance motor rotor, or other types of motor rotors. The heat dissipation structure mainly includes: a water jacket 300, a heat-conducting component 400, and a thermosetting resin layer 500, as described in detail below: A housing water jacket 300 is installed outside the stator core 110. The housing water jacket 300 contains a cooling channel 310 for storing a fixed amount of cooling medium. The housing water jacket 300 is generally hollow and cylindrical, with internal space to accommodate the stator assembly 100 and rotor assembly 200 of the motor. The inner wall of the housing water jacket 300 is directly or indirectly thermally coupled to the stator core 110. To improve heat dissipation efficiency, the housing water jacket 300 has a cooling channel 310 that stores a certain amount of cooling medium. The cooling medium can remove heat from the housing water jacket 300 through thermal convection, achieving rapid heat dissipation. The position and shape of the cooling channel 310 within the housing water jacket 300 can be flexibly configured according to requirements. The cooling medium can be water, oil, etc., designed to quickly remove heat through liquid thermal convection.

[0035] A heat-conducting element 400 is installed on the outer edge of the end of the water jacket 300 of the motor housing. A portion of the heat-conducting element 400 is thermally coupled to the inner circumferential sidewall of the water jacket 300, and another portion extends into the vicinity of the end of the stator winding 120. The heat-conducting element 400 is radially arranged, and the end of the stator winding 120 can be thermally coupled to the water jacket 300 of the motor housing through the heat-conducting element 400, so as to transfer heat to the stator winding 120, which generates a relatively high amount of heat in the motor, and reduce the temperature of the stator winding 120 during operation.

[0036] A thermosetting resin layer 500 is formed by filling the gaps between the housing water jacket 300 and the stator core 110, and between the housing water jacket 300 and the stator winding 120 with thermosetting resin. The heat-conducting component 400 is located within the thermosetting resin layer 500. In this design, considering that the heat-conducting component 400 does not directly contact the stator winding 120, and that the stator core 110 is also a component in the motor with relatively high heat generation, this design uses the filling of thermosetting resin to achieve thermal coupling between the heat-conducting component 400 and the stator winding 120, as well as thermal coupling between the stator core 110 and the heat-conducting component 400. Specifically, manual glue filling or a handheld glue filling machine can be used for glue filling. After potting, a thermosetting resin layer 500 is formed. This thermosetting resin layer 500 is specifically distributed in the area between the inner diameter and outer diameter of the stator assembly 100 in the radial direction, and between the end surface of the stator assembly 100 and the inner wall of the end of the water jacket 300 in the axial direction. In addition to its heat transfer function, the thermosetting resin layer 500 formed by potting also provides advantages such as fixing the heat-conducting component 400, the stator winding 120, and the stator core 110, as well as providing insulation protection.

[0037] Specifically, a portion of the stator winding 120 end is thermally coupled to the inner wall of the housing water jacket 300 via thermosetting resin, and another portion of the stator winding 120 end is thermally coupled to the inner wall of the housing water jacket 300 via thermosetting resin and a heat-conducting component 400 in sequence; the stator core 110 end is thermally coupled to the inner wall of the housing water jacket 300 via thermosetting resin and a heat-conducting component 400 in sequence.

[0038] When a high-voltage, high-power AC motor is operating, the stator winding 120 and stator core 110 experience high losses and generate significant heat, which can easily lead to heat accumulation and rapid temperature rise. To achieve rapid heat dissipation for the stator winding 120 and stator core 110, this solution primarily employs a combined heat dissipation structure consisting of a housing water jacket 300 with cooling channels 310, a heat-conducting component 400, and a thermosetting resin layer 500 formed by injection. Specifically, a portion of the stator winding 120 end is thermally coupled to the inner wall of the housing water jacket 300 via thermosetting resin, and then rapidly dissipates heat through the cooling channels 310 within the housing water jacket 300. The other portion of the stator winding 120 end is thermally coupled to the inner wall of the housing water jacket 300 via thermosetting resin and the heat-conducting component 400, and then rapidly dissipates heat through the cooling channels 310 within the housing water jacket 300. This effectively provides two additional cooling pathways for the stator winding 120, facilitating rapid heat dissipation. The stator core 110 ends are thermally coupled to the inner wall of the housing water jacket 300 via thermosetting resin and a heat-conducting component 400, and then rapidly dissipate heat through the cooling channel 310 within the housing water jacket 300, effectively providing an additional cooling path for the stator core 110. Furthermore, the thermosetting resin can also be thermally coupled to the inner wall of the housing water jacket 300 via the heat-conducting component 400, and then rapidly dissipate heat through the cooling channel 310 within the housing water jacket 300. By achieving rapid heat transfer and synergistic optimization among the stator winding 120, stator core 110, and thermosetting resin, a highly efficient cooling effect can be achieved, significantly extending the motor's service life.

[0039] In one specific embodiment, the heat-conducting component 400 includes a first heat-conducting component 410 and a second heat-conducting component 420, and the thermosetting resin layer 500 includes a first thermosetting resin layer 510 and a second thermosetting resin layer 520, wherein the first heat-conducting component 410 is located within the first thermosetting resin layer 510, and the second heat-conducting component 420 is located within the second thermosetting resin layer 520. The fixed first heat-conducting element 410 and the first thermosetting resin layer 510 are located between the inner wall of one end of the housing water jacket 300 and the end of one end of the stator winding 120. The fixed second heat-conducting element 420 and the second thermosetting resin layer 520 are located between the inner wall of the other end of the housing water jacket 300 and the end of the other end of the stator winding 120. Through the provision of the first heat-conducting element 410 and the first thermosetting resin layer 510, and the second heat-conducting element 420 and the second thermosetting resin layer 520, heat can be simultaneously dissipated from both ends of the stator assembly 100, thereby improving heat dissipation efficiency and uniformity.

[0040] Please refer to Figure 6 , Figure 7 and Figure 11Specifically, both the first heat-conducting element 410 and the second heat-conducting element 420 consist of multiple heat pipes for storing the condensate medium. Each heat pipe is radially distributed along the water jacket 300 of the casing. Each heat pipe has an evaporation section and a condensation section, which are connected by a capillary wick. The evaporation section is located near the end of the stator winding 120, and the condensation section is located near the inner wall of the water jacket 300. The multiple heat pipes are arranged in a ring. The condensate medium is specifically condensate. The shape of the heat pipes can be square, circular, or irregular. The number and size of the heat pipes can be designed according to actual requirements and are not limited here. The use of multiple uniformly spaced heat pipes aims to improve the heat transfer efficiency of the heat-conducting element 400. Specifically, this solution uses copper-water heat pipes, whose working principle can be divided into four steps: heat absorption evaporation, steam flow, heat release condensation, and working fluid reflux, which cycle repeatedly without external force driving the process.

[0041] 1) Heat absorption and evaporation: The end of the heat pipe closest to the heat source of the motor (such as the stator winding or stator core) (evaporation section) absorbs heat, and the working fluid (such as liquid water) inside the heat pipe evaporates into a gaseous state, instantly absorbing a large amount of heat.

[0042] 2) Steam flow: Under the action of pressure difference in the pipe, the gaseous working fluid flows rapidly to the end with lower temperature (condensation section) with minimal flow resistance.

[0043] 3) Exothermic condensation: The gaseous working fluid exchanges heat with the external heat dissipation structure (such as coolant, water jacket of the casing) in the condensation section, and condenses into liquid after releasing heat.

[0044] 4) Working fluid reflux: Under the capillary force of the heat pipe wick, the liquid working fluid refluxes back to the evaporation section, completing the cycle and continuously transferring heat.

[0045] Please refer to Figure 6 , Figure 6 This is a schematic diagram of the end structure of a high-voltage, high-power AC motor according to an embodiment of the present invention. To fix the position of the heat pipes and prevent them from shifting during potting, the heat dissipation structure further includes a first retainer 610 and a second retainer 620 arranged in a ring. The first retainer 610 is located between one end of the stator core 110 and the inner wall of one end of the water jacket 300 of the housing. The second retainer 620 is located between the other end of the stator core 110 and the inner wall of the other end of the water jacket 300 of the housing. The first retainer 610 is used to limit the heat pipes in the first heat-conducting element 410, and the second retainer 620 is used to limit the heat pipes in the second heat-conducting element 420. The heat pipes can be uniformly fixed on the first retainer 610 or the second retainer 620. The shape of the first retainer 610 or the second retainer 620 can also be other shapes, such as polygons or crosses, as long as their limiting positions and numbers correspond to the positions and numbers of the heat pipes.

[0046] Please refer to Figure 7 and Figure 8 , Figure 7 This is a schematic diagram of the structure of the combination of the second heat-conducting element and the second retainer in one embodiment of the present invention; Figure 8 This is a schematic diagram of the structure of the first retainer in one embodiment of the present invention. To facilitate the installation of the heat pipe onto the first retainer 610 or the second retainer 620, the first retainer 610 or the second retainer 620 has a corresponding limiting structure. Specifically, both the first retainer 610 and the second retainer 620 have multiple annularly distributed limiting grooves 611 on one side. One end of the heat pipe near the condensation section is secured within the limiting groove 611 and partially exposed, while the other end of the heat pipe extends beyond the limiting groove 611. The first retainer 610 and the second retainer 620 each have a plurality of ring-shaped limiting holes on one side. The heat pipe passes through the limiting holes, and one end of the heat pipe near the condensation section is fixed in the limiting hole and partially exposed. The other end of the heat pipe extends out of the limiting hole.

[0047] The aforementioned limiting structure is not limited to the limiting groove 611 or the limiting hole; it can also be a snap-fit ​​part or a clamping part, etc., which can limit or fix the position of the heat pipe. When designing the limiting structure, to facilitate the assembly of the heat pipe, it is preferred to design it as a limiting groove 611 or a limiting hole.

[0048] To improve the heat transfer efficiency of the heat pipe, the length of the portion of the heat pipe extending out of the limiting groove 611 is longer than the portion confined within the limiting groove 611, or The length of the portion of the heat pipe extending out of the limiting hole is longer than the portion confined within the limiting hole. By increasing the length of the portion of the heat pipe extending out of the limiting groove 611 or the limiting hole, the contact area between the heat pipe and the thermosetting resin layer 500 can be increased, achieving rapid heat conduction. In some embodiments, the dimension of the portion of the heat pipe extending out of the limiting hole is larger than the portion within the limiting hole or the limiting groove 611.

[0049] Please refer to Figure 9 and Figure 10 , Figure 9 This is a schematic diagram of the structure of the combination of the second thermosetting resin layer, the second thermally conductive element and the second retainer in one embodiment of the present invention; Figure 10This is a schematic diagram of the structure of the second thermosetting resin layer in one embodiment of the present invention. In a specific embodiment, both the first thermosetting resin layer 510 and the second thermosetting resin layer 520 are annular. Each of the first thermosetting resin layer 510 and the second thermosetting resin layer 520 includes a first annular ring 511 and a second annular ring 512. The second annular ring 512 is located on and protrudes from the first annular ring 511. The first annular ring 511 is in close contact with the inner wall of one end of the water jacket 300 of the housing, and the second annular ring 512 is in close contact with the end of the stator winding 120. After the stator winding 120, heat pipe, first retainer 610, and second retainer 620 of the motor are assembled, the thermosetting resin is initially poured into the end position of the stator assembly 100 in liquid form, filling the remaining space at the end, and finally solidifying into a solid state. The shape of the epoxy resin depends on the shape of the remaining space at the end of the motor; it can be the shape described above or an irregular shape. In terms of general shape, due to the space occupied by the first cage 610 and the second cage 620, the area of ​​the first thermosetting resin layer 510 and the second thermosetting resin layer 520 near the water jacket 300 of the housing is larger than the area near the end of the stator winding 120.

[0050] In a specific embodiment, both the first thermosetting resin layer 510 and the second thermosetting resin layer 520 are epoxy resin, polyurethane, acrylic resin, phenolic resin, amino resin, or polyester resin. It is understood that the first thermosetting resin layer 510 and the second thermosetting resin layer 520 can also be made of materials with other thermal conductivity properties. Epoxy resin is preferred in this embodiment. By using epoxy resin for potting, the stator winding 120 can be provided with comprehensive protection in four aspects: insulation protection, mechanical fixing, heat dissipation channel, and environmental protection. Epoxy resin can fill the tiny gaps between the end windings, eliminating air and thus preventing moisture and dust intrusion, avoiding a decline in insulation performance. Furthermore, epoxy resin itself has excellent chemical corrosion resistance and anti-aging properties, ensuring that the winding maintains good working condition for a long time in high-temperature, humid, or polluted environments. Selecting a suitable epoxy resin and strictly implementing the potting process can significantly improve the reliability, service life, and environmental adaptability of the motor.

[0051] Please continue to refer to Figure 5 In one specific embodiment, the housing water jacket 300 is provided with a liquid inlet 320 and a liquid outlet 330. The liquid inlet 320 is connected to one end of the cooling channel 310, and the liquid outlet 330 is connected to the other end of the cooling channel 310. The cooling channel 310 is an axial meandering waterway, a spiral waterway, an axial waterway, or an irregularly shaped waterway.

[0052] The aforementioned liquid inlet 320 and liquid outlet 330 can be arranged side by side or parallel to facilitate liquid injection or drainage. The shape of the cooling channel 310 can be flexibly set according to requirements, and should be distributed as evenly as possible within the housing water jacket 300. Since this solution provides a heat-conducting component 400 and a thermosetting resin layer 500 at the end of the stator assembly 100, the corresponding housing water jacket 300 is axially lengthened based on the existing housing. When designing the cooling channel 310, the cooling channel 310 can be extended at both ends of the housing water jacket 300, resulting in a longer cooling channel 310 with a larger area, thus providing better heat dissipation.

[0053] In combination with the above embodiments, the advantages of this solution are: Based on the use of ordinary housing cooling channels, the cooling channels are extended to both ends. Combined with the radial embedding of heat-conducting components (such as heat pipes) at the ends of the stator assembly, the heat-conducting components are evenly arranged in the cage. At the same time, thermosetting resin (such as epoxy resin) is filled at the ends of the stator assembly. This can not only make full use of the space at the inner and outer ends to achieve dedicated cooling at the ends of the stator assembly, but also ensure that the position of the heat pipes does not deviate under high-speed and high-load conditions. By combining heat-conducting components with thermosetting resin for cooling, two additional high-efficiency cooling paths are provided for the stator windings: stator winding end - thermosetting resin housing - coolant, and winding end - thermosetting resin - heat pipe - housing - coolant. An additional high-efficiency cooling path is provided for the stator core: stator core - thermosetting resin - heat pipe - housing water jacket - coolant. An additional high-efficiency cooling path is provided for the thermosetting resin: thermosetting resin - heat pipe - housing water jacket - coolant. Through these solutions, rapid heat transfer can be achieved among the stator windings, stator core, and thermosetting resin, along with synergistic optimization and efficient cooling, significantly extending the motor's service life.

[0054] To better illustrate the effectiveness of this solution, some test examples are provided below.

[0055] Taking a certain AC permanent magnet motor as an example, the thermal performance parameters of each component of the AC permanent magnet motor are shown in Table 1, and the loss parameters of each part of the AC permanent magnet motor are shown in Table 2.

[0056] Table 1. Material Performance Parameters of Motors Table 2 Motor Loss Parameters Option 1 uses only a single housing cooling channel, exposing the motor winding ends to air. Since air has a very low thermal conductivity, most of the heat from the windings cannot be transferred away. The temperature distribution in Option 1 is as follows: Figure 12As shown, the winding end temperature even exceeded 180℃, with a maximum temperature difference of about 24℃; the stator core temperature reached a maximum of 127℃, with an internal and external temperature difference of 44℃, indicating extremely poor cooling effect.

[0057] Option 2, based on the housing cooling channel, also involves filling the winding ends with epoxy resin. For example, Figure 13 As shown, the winding end temperature is 155℃, which is about 27℃ lower than that of Scheme 1; however, the presence of epoxy resin does not provide a significant effect on the stator core, and the temperature is close to that of Scheme 1. The temperature distribution of Scheme 2 is as follows: Figure 13 As shown.

[0058] Option 3: Based on the housing cooling channel, this invention extends the water channel to both ends, embeds heat pipes within the stator assembly, and then fills it with epoxy resin. The temperature distribution diagram of this invention is shown below. Figure 14 As shown, compared with Scheme 2, the maximum temperature of the winding and stator core is reduced by about 19°C, which greatly optimizes the temperature rise and ensures the service life of the motor.

[0059] Table 3 compares the cooling effects of the windings and stator cores, which exhibit significant temperature changes, in Schemes 1, 2, and 3 (of this invention). The temperature data reveals that when using a single cooling channel (Scheme 1), the temperature rise of both the windings and stator core is quite severe. When the cooling channel and epoxy resin work together (Scheme 2), the temperature rise of the windings is improved by approximately 26.8%, but the effect on the stator core is not significant. When using the "cooling channel + epoxy resin + heat pipe" cooling technology (of this invention), compared to the single cooling channel (Scheme 1), the temperature rise of the windings is improved by approximately 47.9%, and the temperature rise of the stator core is improved by approximately 40.3%; compared to the "cooling channel + epoxy resin" (Scheme 2) cooling technology, the temperature rise of the windings is improved by approximately 28.8%.

[0060] Table 3 Comparison of Cooling Effects of Different Schemes Based on the comparison results of the test examples of the above schemes, under the same initial conditions (such as loss parameters, material performance parameters, flow rate, flow velocity, and initial temperature), only the structural model is different. Compared with ordinary motor cooling schemes, the present invention, based on the combined effect of heat pipe and epoxy resin, has a significant cooling effect on motors. It can greatly reduce the temperature rise of stator windings and stator cores, increase the upper limit of motor power and torque, and meet the requirements of high power density and efficient cooling effect of motors.

[0061] In an embodiment of the present invention, the motor cooling system includes a high-voltage, high-power AC motor and a heat dissipation structure, wherein the heat dissipation structure is the same as described above for the high-voltage, high-power AC motor. The specific structure of the heat dissipation structure for the high-voltage, high-power AC motor is described in the above embodiments and will not be repeated here. Since the motor cooling system of this solution adopts all the technical solutions of all embodiments of the heat dissipation structure for the high-voltage, high-power AC motor described above, it possesses at least all the advantages and beneficial effects brought about by the technical solutions of the embodiments of the heat dissipation structure for the high-voltage, high-power AC motor, which will not be repeated here.

[0062] The above description is only a preferred embodiment of the present invention and does not limit the patent scope of the present invention. All equivalent structural transformations made using the contents of the present invention specification and drawings under the technical concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A heat dissipation structure for a high-voltage, high-power AC motor, the high-voltage, high-power AC motor comprising a stator assembly and a rotor assembly located within the stator assembly, the stator assembly comprising a stator core and stator windings embedded within the stator core, characterized in that, The heat dissipation structure includes: A housing water jacket is installed outside the stator core, and a cooling channel is provided inside the housing water jacket for storing a certain amount of cooling medium. A heat-conducting component is installed on the outer edge of the end of the water jacket of the housing. A portion of the heat-conducting component is thermally coupled to the inner peripheral sidewall of the water jacket of the housing, and another portion of the heat-conducting component extends into the vicinity of the end of the stator winding. Thermosetting resin layer, wherein the thermosetting resin layer is formed by filling the gap between the housing water jacket and the stator core end with thermosetting resin, and the gap between the housing water jacket and the stator winding end, and the heat-conducting element is located within the thermosetting resin layer. Specifically, a portion of the stator winding end is thermally coupled to the inner wall of the housing water jacket via thermosetting resin, and another portion of the stator winding end is thermally coupled to the inner wall of the housing water jacket via thermosetting resin and a heat-conducting component in sequence; the stator core end is thermally coupled to the inner wall of the housing water jacket via thermosetting resin and a heat-conducting component in sequence.

2. The heat dissipation structure for a high-voltage, high-power AC motor as described in claim 1, characterized in that, The thermal conductive component includes a first thermal conductive component and a second thermal conductive component, and the thermosetting resin layer includes a first thermosetting resin layer and a second thermosetting resin layer. The first thermal conductive component is located within the first thermosetting resin layer, and the second thermal conductive component is located within the second thermosetting resin layer. The fixed first heat-conducting component and the first thermosetting resin layer are located between the inner wall of one end of the housing water jacket and the end of one end of the stator winding, and the fixed second heat-conducting component and the second thermosetting resin layer are located between the inner wall of the other end of the housing water jacket and the end of the other end of the stator winding.

3. The heat dissipation structure for a high-voltage, high-power AC motor as described in claim 2, characterized in that, Both the first and second heat-conducting elements are multiple heat pipes for storing condensate. Each heat pipe is radially distributed along the water jacket of the casing. Each heat pipe has an evaporation section and a condensation section, which are connected by a capillary wick. The evaporation section is located near the end of the stator winding, and the condensation section is located near the inner wall of the water jacket of the casing. The multiple heat pipes are arranged in a ring.

4. The heat dissipation structure for a high-voltage, high-power AC motor as described in claim 3, characterized in that, The heat dissipation structure further includes a first retainer and a second retainer arranged in a ring. The first retainer is located between one end of the stator core and the inner wall of one end of the water jacket of the housing, and the second retainer is located between the other end of the stator core and the inner wall of the other end of the water jacket of the housing. The first retainer is used to limit the heat pipe in the first heat-conducting component, and the second retainer is used to limit the heat pipe in the second heat-conducting component.

5. The heat dissipation structure for a high-voltage, high-power AC motor as described in claim 4, characterized in that, Both the first and second retainers have multiple annularly distributed limiting grooves on one side. One end of the heat pipe near the condenser section is secured within the limiting groove and partially protrudes from it. The other end of the heat pipe extends out of the limiting groove, or... The first and second retainers each have a plurality of ring-shaped limiting holes on one side. The heat pipe passes through the limiting holes, and one end of the heat pipe near the condensation section is fixed in the limiting hole and partially exposed. The other end of the heat pipe extends out of the limiting hole.

6. The heat dissipation structure for a high-voltage, high-power AC motor as described in claim 5, characterized in that, The length of the portion of the heat pipe extending out of the limiting groove is longer than the portion confined within the limiting groove, or The length of the portion of the heat pipe extending out of the limiting hole is longer than the portion confined within the limiting hole.

7. The heat dissipation structure for a high-voltage, high-power AC motor as described in claim 5, characterized in that, Both the first thermosetting resin layer and the second thermosetting resin layer are annular in shape. Both the first thermosetting resin layer and the second thermosetting resin layer include a first ring and a second ring. The second ring is located on the first ring and protrudes from the first ring. The first ring is in close contact with the inner wall of one end of the water jacket of the housing, and the second ring is in close contact with the end of the stator winding.

8. The heat dissipation structure for a high-voltage, high-power AC motor as described in claim 2, characterized in that, Both the first thermosetting resin layer and the second thermosetting resin layer are epoxy resin, polyurethane, acrylic resin, phenolic resin, amino resin or polyester resin.

9. The heat dissipation structure for a high-voltage, high-power AC motor as described in claim 2, characterized in that, The housing water jacket is provided with a liquid inlet and a liquid outlet. The liquid inlet is connected to one end of the cooling channel, and the liquid outlet is connected to the other end of the cooling channel. The cooling channel is an axial meandering waterway, a spiral waterway, an axial waterway, or an irregularly shaped waterway.

10. A motor cooling system, comprising a high-voltage, high-power AC motor and a heat dissipation structure, characterized in that, The heat dissipation structure is the heat dissipation structure of a high-voltage, high-power AC motor as described in any one of claims 1 to 9.

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