Axial Flux Stator Cooling Ring for Heat and Load Stability
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Solution Overview
Problem
Axial flux machines face issues with excessive heat generation leading to performance impairment and component damage, and existing cooling solutions are technically complex and prone to errors, while also lacking load-bearing functionality.
Innovation Solution
An annular structural element is integrated into the stator, providing effective cooling, load-bearing support, and precise positioning, with high thermal conductivity materials and configurations that enhance cooling performance and structural stability, including fastening and bearing functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling solutions with cooling channels or hoses are used, then cooling function is provided, but device complexity increases and reliability decreases
Solution Approach 1:
The patent combines the cooling function with the stator yoke structure by integrating cooling channels directly into the stator yoke. This merging of functions eliminates the need for separate cooling components while providing effective heat dissipation, thereby reducing device complexity and improving reliability.
Solution Approach 2:
The stator yoke serves multiple functions: it provides structural support, magnetic flux path, and heat dissipation through integrated cooling channels. This multi-functionality reduces the number of separate components needed, simplifying the overall device while maintaining effective cooling.
2Temperature
If conventional cooling solutions are used, then cooling function is provided, but the solution is prone to errors and lacks load-bearing functionality
Solution Approach 1:
By merging the cooling function with the load-bearing stator yoke structure, the patent creates a unified component that is both structurally sound and thermally efficient. This integration eliminates potential failure points associated with separate cooling systems and ensures reliable operation under load.
Solution Approach 2:
The stator yoke with integrated cooling channels serves itself by providing both structural support and heat dissipation functions. The cooling channels are self-contained within the yoke structure, eliminating dependence on external cooling systems that could fail.
3Power
If an axial flux machine operates at high power, then performance is improved, but excessive heat generation leads to performance impairment and component damage
Solution Approach 1:
The integrated cooling channels in the stator yoke provide continuous heat dissipation during operation, allowing the machine to maintain high power output without excessive temperature buildup. The cooling action continues throughout the operational cycle, preventing thermal accumulation that would otherwise limit power output or cause damage.
Solution Approach 2:
The patent converts the harmful heat generated during high-power operation into a manageable thermal flow through the integrated cooling channels. By providing dedicated heat dissipation paths within the stator yoke, the harmful thermal energy is efficiently removed, allowing sustained high-power operation without performance degradation or component damage.
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 annular structural element effectively reduces heat buildup, stabilizes the stator, and improves the axial flux machine's performance by introducing load forces and torques into the motor housing, while enabling precise air gap adjustment and efficient production.
Implementation Method 1
an annular structural element, which is arranged on the stator and connected to the stator yoke in a rotation-proof manner, is provided for cooling the stator
Implementation Method 2
The structural element has a suitable size, whereby it acts at least partially as a structurally supporting element and thus supports and stabilizes the structure of the stator and/or the components of the stator and/or the axial flux machine
Implementation Method 3
the majority, in particular more than 60%, preferably more than 80%, of the load forces and load torques occurring at the stator are introduced into the motor housing via the annular structural element
Data Source
AI summary
An axial flux machine has a motor housing and at least two active parts, of which at least one active part is configured as a rotor which has a number of permanent magnets and is mounted rotatably about a rotational rotor axis, and a stator is the second active part. The stator has a stator yoke, a number of stator teeth and coils arranged around the stator teeth, and an annular structural element for cooling the stator is arranged on the stator and is connected in a rotation-proof manner to the stator yoke and, as a cooling element, extends at least partially into the stator groove of at least one of the stator teeth and projects at least partially beyond the stator yoke at the outer and/or inner diameter of the stator.