Air Core Stator Installation with Non-Magnetic Supports
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing stator designs for electrical machines face challenges in effectively supporting stator coils in an air gap configuration without direct fixation to magnetic back iron, which can lead to instability and inefficiencies in cooling and AC loss reduction.
Innovation Solution
The stator design incorporates non-magnetic support frame sections and coil supports with cooling channels and support rods, allowing for the placement of stator coils in slots spaced apart from magnetic back iron sections, enabling an air gap winding configuration without direct fixation to the magnetic back iron, and facilitating cooling and reduced AC losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If stator coils are directly fixed to magnetic back iron sections, then structural support is simplified, but AC losses increase and cooling efficiency decreases
Solution Approach 1:
The patent introduces non-magnetic support frame sections and non-magnetic coil supports as intermediary components between the magnetic back iron sections and stator coils. These intermediaries prevent direct contact between magnetic and conductive materials, thereby reducing AC losses while providing structural support. The support rods act as mediators to fix the coil supports to the back iron sections without creating harmful magnetic-conductive direct contact.
Solution Approach 2:
The stator structure is segmented into distinct functional components: magnetic back iron sections, non-magnetic support frame sections, non-magnetic coil supports, and stator coils. This segmentation allows each component to perform its specific function optimally - the magnetic sections provide magnetic flux paths, the non-magnetic sections provide structural support without inducing AC losses, and the coils perform electromagnetic functions.
2Temperature
If stator coils are placed in direct contact with magnetic back iron, then manufacturing is simpler, but cooling efficiency deteriorates
Solution Approach 1:
The non-magnetic support frame sections and coil supports serve as intermediary structures that enable effective cooling channel placement. These intermediaries provide pathways for cooling fluid to reach the stator coils efficiently without requiring direct contact between coils and magnetic back iron, thus improving cooling efficiency while maintaining manufacturability.
Solution Approach 2:
The patent introduces a new dimensional aspect to the stator structure by adding radial support faces and axial positioning features. The first and second radial support faces of the non-magnetic support frame sections, along with the axial positioning of coil supports, create a three-dimensional cooling fluid pathway that enhances cooling efficiency without complicating the manufacturing process.
3Reliability
If non-magnetic support components are added to create air gap configuration, then AC losses are reduced, but device complexity increases
Solution Approach 1:
The patent merges multiple functions into the non-magnetic support frame sections and coil supports. These components simultaneously provide structural support, enable air gap configuration, facilitate cooling fluid flow, and prevent direct magnetic-conductive contact. By combining these functions into integrated components rather than separate elements, the patent reduces the overall number of parts needed.
Solution Approach 2:
The non-magnetic support frame sections and coil supports are designed as multi-functional components. They provide mechanical support for the coils, maintain the air gap configuration, guide cooling fluid flow, and prevent AC losses by avoiding direct magnetic-conductive contact. This multi-functionality reduces the need for additional specialized components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances the stability and cooling efficiency of stator coils, reducing AC losses and improving the overall performance of electrical machines by maintaining an air gap while supporting coils effectively without direct contact to the magnetic back iron.
Implementation Method 1
the support body comprises cooling channels
Data Source
AI summary
Stator for use in an electrical machine. A non-magnetic support frame section and a non-magnetic coil support are used to provide an air gap stator configuration. The present stators provide an air gap winding configuration that facilitates the fixing of stator coils in the air gap, spaced apart from the magnetic back iron.