Air Compressor Stator Cooling via Reused Compressed Air

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Solution Overview

Problem

Air compressors in fuel cell vehicles face challenges in effectively cooling the stator, rotor, and bearings, which affects their operational efficiency and longevity due to high heat generation during operation.

Innovation Solution

The air compressor design incorporates an air cooling unit that utilizes part of the compressed air to cool the stator, rotor, and bearings through a bypass passage system, including an intercooler and outlet passages, and also employs a water cooling unit along the motor housing to enhance heat dissipation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the air compressor operates at high speed (5,000-100,000 rpm) to compress air for the fuel cell stack, then the compression efficiency and power output are improved, but the heat generation in the stator, rotor, and bearings increases significantly

Engineering Contradiction:

Improvecompression efficiencyVSAvoidheat generation

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The patent utilizes the compressed air itself, which would otherwise be wasted, as a cooling medium to remove heat from the stator, rotor, and bearings. The compressed air flows through cooling passages in these components, absorbing heat and then being discharged through exhaust passages. This converts the harmful heat into a useful cooling function, eliminating the need for separate cooling systems while improving component temperature management during high-speed operation.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Temperature

If conventional cooling methods are used for the stator and rotor, then additional cooling systems and components are required, but this increases device complexity and space requirements

Engineering Contradiction:

Improvecomponent coolingVSAvoidcooling system complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent integrates multiple functions into the compressed air system: the compressed air not only serves its primary purpose of supplying oxygen to the fuel cell stack but also simultaneously cools the stator, rotor, and bearings. The same compressed air flow path is used for both power generation and thermal management, eliminating the need for separate cooling systems and reducing overall device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The cooling passages for the stator, rotor, and bearings are merged into a single integrated system that uses compressed air as the common cooling medium. The air flow paths are combined such that one compressed air stream serves multiple cooling purposes, consolidating what would traditionally require separate cooling circuits into a unified thermal management system.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If heat dissipation is insufficient in the stator and rotor, then the operational lifetime and maintenance period of the air compressor are reduced, but improving cooling requires additional system components

Engineering Contradiction:

Improveoperational lifetimeVSAvoidsystem components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system uses its own compressed air output to cool its critical components. The compressed air, after serving its primary function, is redirected through cooling passages in the stator, rotor, and bearings, allowing the system to self-regulate its temperature without external cooling infrastructure. This self-service approach extends operational lifetime while avoiding additional system components.

Inventive Principle:

Principle #25Self-service

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 effectively cools the components using reused compressed air, improving cooling efficiency and extending the operational lifespan of the air compressor by efficiently dissipating heat generated during operation.

Implementation Method 1

an air cooling unit coupled with the compressor scroll to receive compressed air from the compressor scroll and cool the stator and the rotating shaft

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

a compressor scroll configured to compress drawn air

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 3

a turbine impeller coupled with the rotating shaft, and a turbine scroll formed in the rear housing and configured to exhaust air that has passed through the turbine impeller

Methodology Applied

Scientific EffectTurbine energy conversion: Turbine

Data Source

PatentUS11143204B2Air compressor

Publication Date: 2021.10.12 HANON SYST CO LTD

AI summary

Disclosed herein is an air compressor. The air compressor may include: a compressor unit including a front housing having a front inlet and a compressor scroll, and a compressor impeller configured to transfer the air drawn through the front inlet toward the compressor scroll; a motor unit including a motor housing coupled with the front housing, a stator disposed along an inner circumferential surface of the motor housing, and a rotor disposed to pass through the stator and coupled with the compressor impeller by a rotating shaft; a turbine unit including a rear housing coupled with the motor housing, a turbine impeller coupled with the rotating shaft, and a turbine blower formed in the rear housing and configured to exhaust air that has passed through the turbine impeller to the outside; and an air cooling unit coupled with the compressor scroll to cool the stator and the rotating shaft.