Angled Heat Pipe Rotor Cooling for Electric Machines
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Solution Overview
Problem
The performance of electric machines, particularly in motor vehicles, is limited by inadequate heat dissipation from the rotor, as conventional cooling methods are inefficient in removing waste heat from the rotor laminate stack and squirrel cage.
Innovation Solution
Incorporating heat pipes angled relative to the rotor shaft to enhance thermal conductivity, allowing for improved radial heat transport and increased cooling power without weakening the winding support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling is produced by way of the gas surrounding the rotor, then some heat can be drawn off, but the amount of energy that can be drawn off is greatly limited
Solution Approach 1:
The invention extracts heat from the rotor by introducing heat pipes that directly contact the rotor laminate stack and squirrel cage, separating the heat extraction function from the surrounding gas cooling and achieving much higher heat removal efficiency through direct thermal contact
2Temperature
If internal rotor cooling is used with a cooling fluid conveyed through the rotating shaft, then heat transport through the rotor shaft is improved, but a major portion of the waste heat is formed at a distance from the rotor shaft, limiting the amount of heat to be drawn off by the thermal conductivity of the laminate stack
Solution Approach 1:
The invention changes the dimensional approach by using heat pipes that extend radially outward from the rotor shaft into direct contact with the rotor laminate stack and squirrel cage, creating multiple heat extraction paths in the radial direction rather than relying solely on axial heat transport through the shaft
3Temperature
If the rotor shaft is configured as a heat pipe with a coaxial cavity, then heat transport through the rotor shaft is enhanced, but the heat pipes do not extend into the rotor laminate stack, limiting heat extraction from the components where heat is generated
Solution Approach 1:
The invention implements a nested structure where heat pipes are positioned within the rotor assembly such that they extend from the rotor shaft into the rotor laminate stack and contact the squirrel cage, with the heat pipes being contained within the rotor structure while extracting heat from multiple components simultaneously
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 use of angled heat pipes significantly enhances cooling efficiency, thereby increasing the capability and long-term performance of electric machines by effectively dissipating heat from the rotor.
Implementation Method 1
the rotor comprises at least one heat pipe running at an angle to the rotor shaft
Implementation Method 2
The fluid may be evaporated at one end that is being cooled, and it may condense once more at a cooled end
Implementation Method 3
The fluid may be evaporated at one end that is being cooled
Implementation Method 4
it may condense once more at a cooled end
Implementation Method 5
The condensed fluid may be transported by capillary forces when using a heat pipe
Implementation Method 6
When using a heat pipe in a rotor, centrifugal force may also be used for the transport of the condensed fluid
Data Source
AI summary
A rotor for an electric machine having a rotor shaft, a winding support coupled to the rotor shaft in rotationally fixed manner, and at least one winding arranged on the winding support or a squirrel cage arranged on the winding support, wherein the rotor includes at least one heat pipe running at an angle to the rotor shaft.