Conformal Cooling Wedges for Generator Rotor Heat Dissipation
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Solution Overview
Problem
Conventional cooling systems for high-speed electrical generators, such as those in aerospace applications, are limited by straight-line cooling channels that do not provide optimal conductive cooling, leading to reduced power generating capacity and shorter component life due to insufficient heat dissipation.
Innovation Solution
The implementation of conformal cooling devices with helical or V-shaped internal cooling channels in support wedges, manufactured using additive manufacturing techniques, which securely fasten rotor windings and enhance conductive cooling by closely conforming to the shape of the support wedges, allowing for improved heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional straight-line cooling channels are used in support wedges, then the device complexity and manufacturing ease are improved, but the heat dissipation capacity and power generating capacity deteriorate
Solution Approach 1:
The patent applies curvature by transitioning from straight-line cooling channels to helical or V-shaped conformal cooling channels within the support wedges. This curved configuration increases the cooling surface area and improves heat dissipation capacity, directly addressing the power generating capacity deterioration while maintaining manufacturability through additive manufacturing processes.
Solution Approach 2:
The patent introduces three-dimensional helical and V-shaped cooling channel configurations instead of conventional two-dimensional straight channels. This dimensional change allows the cooling medium to traverse greater path lengths and contact more surface area within the same wedge volume, enhancing heat dissipation without significantly increasing device complexity.
2Ease of manufacture
If conventional straight-line cooling channels are used in support wedges, then the device complexity and manufacturing ease are improved, but the component life deteriorates due to insufficient heat dissipation
Solution Approach 1:
The helical and V-shaped curved cooling channels increase the effective cooling surface area and improve thermal contact between the cooling medium and the support wedge. This enhanced heat dissipation prevents excessive temperature buildup that would otherwise degrade the wire insulation and reduce component life, while the additive manufacturing process keeps production feasible.
Solution Approach 2:
The conformal cooling channels provide continuous cooling along the entire path of the support wedge, ensuring sustained heat dissipation throughout operation. This continuous thermal management prevents localized overheating and maintains component reliability over extended operational periods.
3Power
If conformal cooling channels with helical or V-shaped configurations are implemented, then the heat dissipation capacity and power generating capacity are improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges the support wedge structure with the cooling channel function into a single integrated component. The conformal cooling channels are embedded within the support wedge body, combining structural support and thermal management functions. This integration improves heat dissipation while avoiding the need for separate cooling systems that would increase overall device complexity.
Solution Approach 2:
The patent changes the geometric parameters of the cooling channels from simple straight lines to helical and V-shaped configurations. These parameter changes optimize the cooling surface area and thermal efficiency, enhancing power generating capacity while the additive manufacturing process accommodates these complex geometries without proportionally increasing manufacturing difficulty.
4Power
If conformal cooling channels with helical or V-shaped configurations are implemented, then the heat dissipation capacity and power generating capacity are improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent replaces conventional mechanical manufacturing processes (drilling, milling, machining) with additive manufacturing technology. This substitution enables the creation of complex helical and V-shaped cooling channel geometries that would be difficult or impossible to achieve with traditional methods, while maintaining acceptable manufacturing precision through digital modeling and controlled layer-by-layer fabrication.
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 conformal cooling devices effectively increase conductive cooling capacity, leading to enhanced power generation efficiency and extended component life by closely matching the cooling channel configuration to the support wedge shape, surpassing the limitations of conventional axial cooling channels.
Implementation Method 1
the cooling medium flows under pressure through the axial channel and provides conductive cooling
Implementation Method 2
the cooling medium flows under pressure through the axial channel and provides conductive cooling
Data Source
AI summary
Electrical generators having one or more conformal support and cooling devices for use in supporting and cooling rotating elements of the generator are disclosed herein. An electrical generator includes a housing, a shaft disposed axially through the housing, a rotor assembly including a plurality of poles that are disposed within the housing and mounted on the shaft, a support wedge disposed between two of the plurality of poles. The conformal support and cooling device includes an internal cooling channel in a helical configuration or a V-shape configuration that extends from a first length-wise end of the support and cooling device to a second length-wise end of the support and cooling device. Additive manufacturing processes are employed to fabricate the conformal support and cooling device.