Concentrated Winding Stator with Edge Form Coils and Liquid Cooling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional stator winding designs in rotary electric machines face challenges such as complex end turns, reduced efficiency, and acoustic noise due to separate teeth, as well as inefficient cooling methods that limit power density and thermal performance.
Innovation Solution
A novel stator design incorporating a concentrated winding with edge form wound coils, pre-insulated wire, and an in-slot liquid cooling manifold using conductive fluids like ethylene glycol, which ensures metal-on-metal contact for secure assembly and enhances thermal management with higher current density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate teeth are used to facilitate winding assembly, then ease of manufacture is improved, but acoustic noise increases due to structural instability
Solution Approach 1:
The patent merges the separate teeth into a single integrated stator laminations structure. The concentrated windings are designed to be inserted into slots of the unified stator structure, eliminating the need for separate teeth. This integration maintains structural stability to reduce acoustic noise while preserving the manufacturing advantages of concentrated windings.
2Device complexity
If conventional cooling methods are used, then device complexity is reduced, but thermal performance and power density are limited
Solution Approach 1:
The patent implements an in-slot cooling manifold nested within the stator slots, integrating the cooling system into the existing stator structure. The cooling channels are positioned within the slot space, allowing direct thermal contact with the concentrated windings. This nested configuration provides enhanced thermal management and higher power density without significantly increasing overall device complexity.
3Reliability
If rectangular wire with mica tape is used for form winding, then reliability is improved through robust insulation, but manufacturing complexity and labor intensity increase
Solution Approach 1:
The patent changes the wire geometry from rectangular to round configuration, and modifies the insulation approach by using pre-insulated round wire without mica tape. The pre-insulated wire provides sufficient electrical isolation for the concentrated winding application, simplifying the construction process while maintaining adequate reliability for the specific operational conditions.
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 design achieves higher power density, reduced eddy current losses, and improved thermal performance, resulting in a more efficient, reliable, and cost-effective rotary electric machine.
Implementation Method 1
an in-slot liquid cooling manifold using conductive fluids like ethylene glycol
Implementation Method 2
liquid cooling manifold
Implementation Method 3
concentrated winding with edge form wound coils
Data Source
AI summary
A permanent magnet motor, generator or the like that is constructed with a concentrated winding and edge form wound stator coils. This achieves less eddy current losses in the windings as well as a much higher power density than conventional techniques.