Electro-dynamic Machine Coolant Bladder for End Turn Thermal Management
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Solution Overview
Problem
Electro-dynamic machines face challenges in thermal management, as existing heat removal methods are insufficient in efficiently cooling the conductive elements, which affects their lifecycle and performance reliability.
Innovation Solution
Incorporating a coolant chargeable bladder system that contacts the stator assembly's end turns, with a plumbing system to pressurize the coolant, increasing the surface area of contact and enhancing heat removal by using compliant or rigid bladder walls made of materials like silicone or thermally conductive materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a cooling jacket around the stator assembly is used, then heat removal is achieved, but the cooling efficiency for end turns is insufficient
Solution Approach 1:
The cooling system is segmented into multiple zones: the cooling jacket for the stator body and the separate coolant chargeable bladder specifically for the end turns. This segmentation allows targeted cooling where heat generation is highest, improving overall cooling efficiency and reliability.
Solution Approach 2:
The coolant chargeable bladder acts as an intermediary element between the coolant and the end turns. It provides direct thermal contact with the end turns, enabling efficient heat transfer from these high-heat-generation components to the coolant.
2Temperature
If coolant is sprayed onto the conductive elements, then heat removal is achieved, but consistent contact and surface area are insufficient
Solution Approach 1:
The bladder is designed to be chargeable with coolant, allowing dynamic adjustment of the coolant volume and pressure. This enables the bladder to expand and maintain optimal contact surface area with the end turns, ensuring consistent thermal coupling under varying operating conditions.
Solution Approach 2:
The plumbing system uses hydraulic pressure to charge the bladder with coolant and maintain it under pressure. This ensures the bladder remains in firm contact with the end turns, maximizing the surface area for heat transfer and maintaining consistent thermal contact.
3Temperature
If a coolant chargeable bladder is added, then heat removal from end turns is enhanced, but device complexity increases
Solution Approach 1:
The coolant chargeable bladder serves multiple functions: it provides direct thermal contact with the end turns, acts as a pressure-regulated coolant reservoir, and adapts to thermal expansion/contraction. This multi-functionality reduces the need for separate components, thereby limiting the increase in overall system complexity.
Solution Approach 2:
The bladder is constructed as a flexible shell that can deform to conform to the end turns geometry. This flexible design allows effective thermal contact without requiring complex rigid structures, simplifying the overall cooling system while maintaining high heat removal efficiency.
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 bladder system effectively increases heat removal from the end turns, improving the thermal management of electro-dynamic machines by maintaining consistent contact and increasing the surface area for heat transfer, thereby enhancing the machines' reliability and performance.
Implementation Method 1
the coolant is disposable to remove heat from the end turns
Implementation Method 2
a plumbing system configured to pressurize the coolant
Data Source
AI summary
An electro-dynamic machine is provided and includes stator assembly end turns and a coolant chargeable bladder disposable to contact the end turns.