3D-Airgap Electric Machine With Embedded Winding Liquid Cooling
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Solution Overview
Problem
Conventional slotless electric machines face challenges in achieving high power and torque density due to poor thermal management and inefficient utilization of inactive regions, leading to increased operating temperatures and reduced mass and volume power density.
Innovation Solution
The introduction of a 3D-airgap machine design that integrates radial and axial flux machines, converting inactive regions into torque-producing components, combined with winding embedded liquid cooling (WELC) to enhance thermal management and increase current density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If non-magnetic winding support is used in slotless motor to reduce mass, then mass is reduced, but thermal conductivity deteriorates leading to higher operating temperature
Solution Approach 1:
The patent introduces a thermal management system with cooling channels as an intermediary component between the winding support and the external environment. This mediator enables heat dissipation from the non-magnetic winding support without requiring the support material itself to have high thermal conductivity, thus resolving the contradiction between using lightweight non-magnetic materials and maintaining acceptable operating temperatures.
2Temperature
If conventional liquid cooling is applied to slotless motor, then thermal management is improved, but device complexity increases
Solution Approach 1:
The patent merges the cooling channels directly into the winding support structure, combining two previously separate components (winding support and cooling system) into a single integrated structure. This integration improves thermal management while minimizing the increase in device complexity by eliminating the need for separate cooling system installation.
Solution Approach 2:
The winding support structure serves dual functions: it provides mechanical support for the windings and simultaneously acts as a thermal management component through integrated cooling channels. This multi-functionality approach improves thermal management without adding dedicated cooling components that would increase device complexity.
3Device complexity
If inactive regions are not utilized in slotless motor, then structure is simple, but power density is reduced
Solution Approach 1:
The patent makes the inactive regions (end-winding and endplate areas) serve multiple functions: they continue to provide structural support while simultaneously being equipped with cooling channels for thermal management. This multi-functional utilization of inactive regions improves power density without significantly increasing structural complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The 3D-airgap machine achieves a 110% increase in torque density and 70% increase in torque per unit dc-conductor loss, with superior power density in kW/kg and kW/liter compared to conventional designs, while maintaining efficiency and reducing thermal burden.
Implementation Method 1
winding embedded liquid cooling (WELC) to enhance thermal management
Implementation Method 2
liquid cooling channels extend through the outer end of the support structure
Data Source
AI summary
Various examples are provided related to 3D airgap electric machines and winding embedded liquid cooling. In one example, an electric machine includes a stator assembly with stator windings supported by a stator core and an outer rotor assembly includes a radial plate surrounding the stator assembly and an endplate at a first end of the radial plate adjacent to the first end of the stator core. The stator windings can include a first portion extending along an axial length of the stator core and a second portion at a first end of the stator core that extends radially inward towards a shaft of the electric machine. The radial plate can include magnets distributed about the radial plate. In another example, a stator assembly includes stator windings supported by a stator core with a winding support including cooling channels distributed between the stator windings. The winding support can be nonmagnetic.