DC Motor Cooling Channels via Stator Recesses
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Solution Overview
Problem
Existing direct-current motors with liquid flow, used in high-power applications like pumps, face inefficiencies in heat dissipation due to complex assembly and large number of parts, which hinder effective cooling and increase manufacturing complexity.
Innovation Solution
The solution integrates cooling channels formed by the stator extrusion coating and end shield, reducing the number of components and allowing precise positioning, with open channels towards the rotor for efficient coolant flow, eliminating the need for a hollow shaft and utilizing a duroplastic material for enhanced sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling channels are formed by inserting additional parts between stator coils, then cooling effect is improved, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent merges the cooling channel function with existing structural components (stator assembly and end shields) by forming cooling channels through recesses in these components. This eliminates the need for separate inserted cooling parts, reducing the total number of parts while maintaining effective cooling. The cooling channels are integrated into the stator assembly and end shields, which are already present in the motor structure.
Solution Approach 2:
The end shields and stator assembly serve multiple functions: they provide structural support, housing for the motor components, and simultaneously form the cooling channels through their recesses. This multi-functionality reduces the need for dedicated cooling components, simplifying the overall device structure while achieving effective cooling.
2Stability of the object's composition
If additional cooling parts with large wall thickness are used, then installation stability is improved, but heat transfer efficiency deteriorates
Solution Approach 1:
The cooling channels are formed as recesses within the existing stator assembly and end shields rather than as separate thick-walled inserted parts. This integration allows for optimized wall thickness in the cooling channel structures, maintaining installation stability while minimizing thermal resistance and maximizing heat transfer efficiency from the stator coils to the cooling medium.
3Ease of manufacture
If multiple separate components are assembled, then manufacturing flexibility is improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple functions into fewer components: the stator assembly and end shields both incorporate cooling channel recesses, eliminating the need for separate cooling channel inserts. This reduction in part count simplifies the assembly process and reduces manufacturing complexity while maintaining the flexibility to manufacture the motor in a cost-effective manner.
4Reliability
If cooling channels are closed, then coolant flow control is improved, but flow efficiency deteriorates
Solution Approach 1:
The cooling channels are segmented into different sections with different opening configurations. Some sections are closed to provide flow control and direction, while other sections are open to maintain efficient coolant flow. This segmentation allows for optimized coolant flow control without significantly compromising overall flow 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
This design achieves efficient heat dissipation with fewer components, simplifying assembly and manufacturing, while ensuring precise part alignment and effective coolant flow, enhancing the motor's thermal efficiency and economic viability.
Implementation Method 1
One way of dissipating heat is through heat conduction to an attachment and to the environment
Implementation Method 2
liquid cooling must be provided. Since a medium is already present in pump motors, this is expediently used for liquid cooling
Data Source
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AI summary
The invention relates to a fluid-cooled DC motor (1) comprising a bearing shield (2), a stator winding (3) arranged in slots (11) of a stator core (9), which has spaces for cooling channels (4) between stator coils (10) of the stator winding (3), and a permanent magnet rotor (5). The object of the present invention is to provide a fluid-cooled DC motor that consists of as few components as possible and has a very high efficiency with regard to heat dissipation from the stator winding into the fluid. Furthermore, the invention aims to enable simple and economical manufacturing of the DC motor. This object is achieved according to the invention by the features of claim 1.