Cantilever Stator Cooling Plates for High Power Density Motors
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Solution Overview
Problem
Traditional electric motors for aircraft applications face challenges in achieving high efficiency, power density, and reduced weight due to the dense permanent magnets used, which hinder weight minimization while maintaining performance.
Innovation Solution
The design incorporates a cantilever structure for the stator, featuring an inlet and outlet support manifold with cooling plates that extend to an unsupported end, providing structural support and efficient cooling while minimizing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If dense permanent magnets are used to achieve high torque density, then power density is improved, but weight increases
Solution Approach 1:
The patent combines the structural support function and cooling function into a single integrated stator structure. The stator serves both as the mechanical framework supporting the permanent magnets and as the cooling system with embedded channels, eliminating the need for separate support structures and reducing overall weight while maintaining high power density
Solution Approach 2:
The stator is designed with multi-functionality, serving as simultaneously a structural support element, a cooling system, and a magnetic circuit component. This universal design allows the same component to fulfill multiple roles, reducing the total number of parts and weight while supporting dense permanent magnet configurations for high power density
2Reliability
If traditional separate support structures and cooling systems are used, then structural support and cooling are provided, but device complexity and weight increase
Solution Approach 1:
The patent merges the support structure and cooling system into a single integrated stator assembly. The stator includes embedded cooling channels within its structure, eliminating the need for separate support brackets, mounting hardware, and external cooling systems, thereby reducing device complexity while maintaining reliable structural support and thermal management
Solution Approach 2:
The stator is designed as a universal component that simultaneously provides structural support for the permanent magnets, establishes the magnetic circuit path, and functions as the cooling system through integrated channels. This multi-functional design reduces the number of separate components needed, simplifying the overall device structure while ensuring reliable operation
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 configuration enhances power density and efficiency while reducing motor weight, achieving a balance between thermal management and structural support, thus addressing the limitations of traditional motor designs.
Implementation Method 1
Each cooling plate defines a cooling channel that fluidly couples the inlet support manifold and the outlet support manifold
Implementation Method 2
the coils and the core are structurally supported by the plurality of cooling plates in a cantilevered manner at the supported end
Data Source
AI summary
Stators for aircraft electric motors include a cantilever structure having a supported end and an unsupported end, wherein the cantilever structure includes an inlet support manifold and an outlet support manifold arranged at the supported end and a plurality of cooling plates extending from the inlet support manifold and the outlet support manifold to the unsupported end. A plurality of coils are arranged between and in thermal contact with the cooling plates and a core passes through the plurality of coils and the plurality of cooling plates. Each cooling plate defines a cooling channel that fluidly couples the inlet support manifold and the outlet support manifold, and the coils and the core are structurally supported by the plurality of cooling plates in a cantilevered manner at the supported end.