Distribution Plate Fluid Passages Stator Cooling
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Solution Overview
Problem
In high power density electrical machines, non-uniform fluid flow through the stator windings leads to inadequate cooling, resulting in potentially damaging hot-spots due to fluid tendentially bypassing areas of the winding chamber in favor of alternative routes.
Innovation Solution
An annular distribution plate with fluid passages of varying cross-sectional areas is introduced to create a pressure differential, ensuring more uniform fluid flow through the winding chamber by increasing resistance in lower flow paths and decreasing it in higher paths, thereby reducing the formation of hot-spots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If fluid is passed directly through the winding chamber without a distribution plate, then the fluid flow path is simple and device complexity is reduced, but fluid flow uniformity deteriorates causing hot-spots in the stator windings
Solution Approach 1:
A distribution plate is introduced as an intermediary component between the fluid inlet and the winding chamber. This plate contains multiple fluid passages that distribute the coolant uniformly across the winding chamber, preventing direct bypass flow and ensuring reliable cooling without excessive structural complexity
Solution Approach 2:
The distribution plate features passages with varying cross-sectional areas - smaller passages in regions prone to high flow and larger passages in regions prone to low flow. This parameter variation equalizes the flow resistance across different paths, achieving uniform cooling distribution
2Reliability
If passages of varying cross-sectional areas are used in the distribution plate, then fluid flow uniformity is improved, but manufacturing precision requirements increase
Solution Approach 1:
The distribution plate incorporates passages with deliberately varying cross-sectional areas to compensate for non-uniform flow distribution. By adjusting passage dimensions - smaller where flow is excessive, larger where flow is insufficient - the system achieves uniform cooling while accounting for manufacturing tolerances through design compensation
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 solution enhances fluid flow uniformity, reducing the incidence and severity of hot-spots in the stator windings, improving cooling efficiency and extending the lifespan of the stator insulation.
Implementation Method 1
the array of fluid passages optionally comprises passages of at least two different cross-sectional areas... the distribution plate may create a pressure differential at different locations within the stator cavity, reducing flow that would otherwise occur along preferred fluid flow paths and increasing it elsewhere
Implementation Method 2
the cross-sectional area of the fluid passages increase from a minimum at the bottom of the distribution plate to a maximum at the top of the distribution plate... By increasing the resistance to such lower flow paths by comparison with the resistance to higher flow paths, a more favourable flow distribution may be attained
Implementation Method 3
The fluid coolant is passed through a winding chamber, preferably flooding the area around the windings of the stator... Where however there is non-uniformity in the fluid flow and/or penetration around the windings, areas may be inadequately cooled, resulting in potentially damaging hot-spots
Implementation Method 4
the stator of electrical machines is heated during operation as a result of magnetic and electrical losses. In order to preserve the stator, and in particular its insulation, the stator may be fluid cooled
Data Source
AI summary
An electrical machine is disclosed comprising a stator cavity. The stator cavity is axially divided by a distribution plate into a winding chamber containing stator windings of the electrical machine and a handling chamber. The handling chamber has one of a fluid inlet and a fluid outlet and the winding chamber has the other of the fluid inlet and fluid outlet. In use fluid is passed from the fluid inlet to the fluid outlet via the handling chamber, the winding chamber and an array of fluid passages in the distribution plate providing fluid communication between the handling chamber and winding chamber. The array of fluid passages comprises passages of at least two different cross-sectional areas.