Rotary Electric Machine Cooling Jacket Separator for Better Flow
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Solution Overview
Problem
Existing cooling systems for rotating electrical machines face challenges in attaching separator elements to cooling chambers with varying thicknesses, leading to inefficient fluid circulation and reduced cooling capacity due to manufacturing complexities and costs.
Innovation Solution
A cooling system design featuring a separator element with a fixing part and an inclined separation part, allowing for better separation between inlet and outlet zones, made from sheet material with folding zones to adapt to chamber shapes, reducing manufacturing costs and improving fluid circulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a separator element is used to separate inlet and outlet zones of the cooling chamber, then cooling performance is improved, but manufacturing complexity and cost increase due to the need to adapt the separator to varying chamber thickness
Solution Approach 1:
The separator element's geometry is changed from a uniform thickness design to a variable thickness design that adapts to the cooling chamber's varying wall thickness. The separator includes a first portion with a first thickness and a second portion with a second thickness greater than the first, allowing it to conform to chambers with different thickness profiles without requiring complex machining or adaptation processes.
Solution Approach 2:
The separator element is divided into distinct portions (first portion and second portion) with different thicknesses, each optimized for specific regions of the cooling chamber. This segmentation allows the separator to adapt to varying chamber geometries while maintaining manufacturing simplicity through standardized production methods.
2Productivity
If the separator element thickness is adapted to match very small thickness areas of the cooling chamber, then fluid circulation efficiency is improved, but manufacturing difficulty increases significantly
Solution Approach 1:
The separator element employs variable thickness parameters throughout its structure, with the first portion having a smaller thickness suitable for thin-walled chamber regions and the second portion having a greater thickness for thicker regions. This parameter variation optimizes fluid circulation by preventing short-circuiting while maintaining manufacturing feasibility through progressive forming or stamping processes.
Solution Approach 2:
The separator element's geometry is designed to dynamically adapt to the cooling chamber's thickness variations along its length. The transition from the first portion to the second portion with increasing thickness allows the separator to maintain optimal positioning and sealing in regions with varying wall thickness without requiring custom machining for each chamber configuration.
3Ease of manufacture
If a separate separator element is used instead of integrating it with the cooling jacket or housing, then manufacturing of the cooling jacket and housing is simplified, but the separator element itself requires additional manufacturing steps
Solution Approach 1:
The separator element is designed as a distinct, separate component from the cooling jacket and housing, allowing each part to be manufactured using optimized processes for its specific function. The cooling jacket and housing can be produced using standard casting or stamping methods without the complexity of integrating the separator's variable thickness geometry into their tooling, while the separator itself can be manufactured using specialized progressive forming or stamping processes designed for its specific shape.
Solution Approach 2:
The separator element serves as an intermediary component that provides the separation function without requiring the cooling jacket or housing to be modified. By making the separator a separate part with adapted geometry, the complexity of accommodating variable chamber thickness is isolated to the separator component, allowing the main structural elements (cooling jacket and housing) to maintain simple, standardized manufacturing processes.
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 simplifies manufacturing, reduces costs, and enhances cooling performance by optimizing fluid circulation and thermal exchanges within the cooling chamber, even in areas with minimal thickness, thereby improving the overall cooling capacity of the system.
Implementation Method 1
a cooling jacket capable of receiving a stator of the rotating electrical machine... an outer wall of the cooling jacket forms with an inner wall of the housing a cooling chamber capable of being traversed by a cooling fluid
Implementation Method 2
a cooling chamber capable of being traversed by a cooling fluid... an inlet opening for the inlet of the cooling fluid into an inlet zone of the cooling chamber and an outlet opening for the outlet of the cooling fluid from an outlet zone of the cooling chamber
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a cooling system for a rotary electric machine (1) having an axis of rotation (A), comprising: - a cooling jacket (3) suitable for receiving a stator of the rotary electrical machine (1), - a housing (2) receiving the cooling jacket, in which an outer wall (11) of the cooling jacket (2) forms, with an inner wall (10) of the housing, a cooling chamber (6) through which a cooling fluid can flow, and in which a separator element (9, 29) separates an inlet zone (7) of the cooling chamber (6) and an outlet zone (8) of the cooling chamber (6), the separator element (9, 29) comprising: - a fastening part (12), of a first length (13), fastened to the outer wall (11) of the cooling jacket (3) or the inner wall (10) of the housing (2), - a first separating part (14), of a second length (15), inclined relative to the fastening part (12) and non-parallel to the fastening part (12), the first length (13) being less than the second length (15) such that the first separating part (14) comprises a first free end (16) that is not directly connected to the fastening part (12). The invention also relates to an electric machine equipped with such a cooling system.