Coil Disc Module With Annular Cooling Channel for Compact Motors
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Solution Overview
Problem
Existing electric machine coil designs face inefficiencies due to the use of flat wire in meander configurations, leading to electromagnetic disadvantages and difficulties in multiphase structures, along with challenges in achieving compactness and effective cooling.
Innovation Solution
A coil module design featuring a coil disc with circumferentially arranged windings, where active regions contribute to torque and are in the magnetic field, and passive regions do not, with a thickness ratio greater in active regions than passive regions, allowing for a compact structure and efficient cooling through a fanned-out configuration and annular recesses for coolant channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If flat wire is used in meander configuration to achieve high density of electrically conductive material, then the density of conductive material in the magnetic field area is improved, but electromagnetic characteristics deteriorate leading to inefficiency
Solution Approach 1:
The patent changes the geometric parameters of the windings by varying the thickness in the axial direction between active and passive regions. This parameter change optimizes the distribution of conductive material to improve electromagnetic characteristics while maintaining high density, resolving the contradiction between material density and electromagnetic efficiency
Solution Approach 2:
The patent applies local quality by making the thickness of windings in the axial direction greater in active regions than in passive regions. This creates different properties in different parts of the same component, optimizing electromagnetic performance in the active regions while reducing material usage and improving cooling in passive regions
2Ease of manufacture
If uniform thickness windings are used to simplify manufacturing, then manufacturing complexity is reduced, but space utilization and cooling efficiency deteriorate
Solution Approach 1:
The patent implements local quality by varying the thickness of windings in the axial direction between active and passive regions. This allows optimization of space utilization and cooling efficiency in different regions without requiring complex manufacturing processes, as the variable thickness is integrated into the molding step
Solution Approach 2:
The patent utilizes the axial dimension to vary the thickness of windings, adding a dimensional variable to the winding structure. This enables improved space utilization and cooling efficiency by exploiting the axial direction, which can be integrated into the molding process without significantly increasing manufacturing complexity
3Strength
If passive regions have sufficient thickness to overlap adjacent windings, then structural integrity is improved, but the axial thickness of the coil disc increases reducing compactness
Solution Approach 1:
The patent applies local quality by making the thickness of windings in the axial direction greater in active regions than in passive regions. This allows the passive regions to have reduced thickness while maintaining sufficient structural integrity for the overlap function, thereby reducing the overall axial thickness of the coil disc and improving compactness
Solution Approach 2:
The patent uses partial action by providing thickness in the passive regions that is sufficient for the required overlap function but not excessive. This optimized thickness provides just enough structural integrity for the passive regions to perform their connecting function while minimizing the axial thickness of the coil disc
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 power density and efficiency by optimizing the use of conductive material, reducing space and weight, and enabling effective cooling without additional components, thus improving the performance of electric machines.
Implementation Method 1
the active regions of different windings do not overlap each other, but each passive region of one of the windings partially overlaps the corresponding passive regions of the two directly adjacent windings
Implementation Method 2
the active regions extending radially from the center... suitable to contribute to the torque of the electric machine and/or are located in the magnetic field
Implementation Method 3
A first coil disc (6) and a second coil disc (6) are attached to each other such that a substantially annular cooling channel (23) for a coolant is formed between the first coil disc (6) and the second coil disc (6) by the substantially annular recesses/recess (22)
Data Source
AI summary
The present invention relates to a coil module for an electric machine, comprising: a first coil disc having at least one winding of an electrically conductive material; a second coil disc having at least one winding of an electrically conductive material; wherein the first coil disc and/or the second coil disc comprise/comprises a substantially annular recess; wherein the first coil disc and the second coil disc are attached to each other such that a substantially annular cooling channel for a coolant is formed between the first coil disc and the second coil disc by the substantially annular recesses/recess.