Electric Generator Vapor Compression Cooling to Reduce Friction Losses

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Solution Overview

Problem

Existing cooling systems for electric generators face inefficiencies due to high air velocity requirements, insufficient cooling of internal components, and limitations in active distribution of cooling fluids, leading to reduced power and economic efficiency.

Innovation Solution

Incorporating hollow ducts as evaporators within the electric generator's rotor, stator, shaft, or housing, which utilize a closed-cycle compression refrigeration system or jet pump with ionic liquids to efficiently absorb and release heat, allowing for direct cooling of conductors and stator bars, and optionally using an interposed heat transfer medium for enhanced effectiveness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If forced cooling system with high air velocity is used, then cooling effect is improved, but friction losses of air neutralize the cooling effect and power efficiency deteriorates

Engineering Contradiction:
Improvecooling effectVSAvoidfriction losses
Core Design Contradiction:
TemperatureVSLoss of energy

Solution Approach 1:

The patent replaces the mechanical forced air cooling system with a thermodynamic vapor compression refrigeration system. Instead of using high-velocity air flow that causes friction losses, the invention uses a refrigerant cycle with evaporator, compressor, condenser, and expansion device to achieve cooling without mechanical air movement, thereby eliminating the friction losses that previously neutralized the cooling effect.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes phase transitions of the refrigerant (evaporation and condensation) to achieve cooling. The refrigerant evaporates in the evaporator absorbing heat from the generator components, then is compressed, condensed, and expanded in a cyclic process. This phase change mechanism provides efficient heat transfer without requiring high-velocity fluid flow, resolving the contradiction between cooling effectiveness and friction losses.

Inventive Principle:
Principle #36Phase transitions

2Temperature

If high air velocity is required for cooling, then cooling effectiveness is improved, but geometry requirements become very demanding and internal components are insufficiently cooled

Engineering Contradiction:
Improvecooling effectivenessVSAvoidgeometry requirements
Core Design Contradiction:
TemperatureVSDevice complexity

Solution Approach 1:

The patent replaces the complex high-velocity air cooling system with a vapor compression refrigeration system that uses phase change for heat transfer. This substitution eliminates the need for complex geometric designs to achieve high air velocities, as the refrigerant naturally undergoes phase transitions that provide efficient cooling without demanding geometric constraints.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a refrigerant as an intermediary substance between the heat source (generator components) and the cooling system. The refrigerant circulates through the evaporator, compressor, condenser, and expansion device, mediating the heat transfer process. This intermediary approach allows cooling to be achieved without directly forcing high-velocity air through the generator's internal geometry, simplifying the geometric requirements while improving cooling effectiveness.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Ease of operation

If thermosiphon cooling system is installed, then passive cooling is achieved, but active distribution of cooling fluid cannot be influenced

Engineering Contradiction:
Improvepassive cooling operationVSAvoidactive distribution control
Core Design Contradiction:
Ease of operationVSAdaptability or versatility

Solution Approach 1:

The patent transforms the static thermosiphon system into a dynamic vapor compression refrigeration system. The refrigerant circulation is actively controlled through the compressor, condenser, and expansion device, allowing dynamic adjustment of cooling fluid distribution. This dynamic system enables active control of cooling parameters while maintaining operational flexibility, resolving the contradiction between passive operation and active distribution control.

Inventive Principle:
Principle #15Dynamics

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 approach increases the efficiency of the cooling system, reduces temperature, and allows for a more compact design, achieving higher cooling effectiveness and economic efficiency by leveraging the phase change of the cooling fluid and minimizing mechanical work requirements.

Implementation Method 1

the hollow duct is designed as an evaporator for absorbing heat energy from the electric generator via the cooling fluid

Methodology Applied
Scientific EffectEvaporation: Evaporation

Implementation Method 2

leveraging the phase change of the cooling fluid

Methodology Applied
Scientific EffectPhase change: Phase Change

Implementation Method 3

the compressor is designed for maintaining transfer of the cooling fluid by absorbing mechanical work

Methodology Applied
Scientific EffectCompression: Compression

Implementation Method 4

feeds the cooling fluid to a condenser for heat release

Methodology Applied
Scientific EffectCondensation: Condensation

Implementation Method 5

directed to a restrictor for expansion

Methodology Applied
Scientific EffectPressure drop: Pressure Drop

Data Source

PatentUS9882455B2Cooling system for electric generators
Publication Date: 2018.01.30 SIEMENS AG
  • US9882455B2 patent drawing
  • US9882455B2 patent drawing
  • US9882455B2 patent drawing

AI summary

An electric generator, in particular a power station generator is provided, having at least one inlet and an outlet for at least one hollow conduit for receiving a coolant fluid. The hollow conduit is situated in or on a rotor and/or a stator/stator bars and/or a shaft and/or a housing of the electric generator wherein the hollow conduit is set up as an evaporator for receiving thermal energy from the electric generator via the coolant fluid. The cooling process allows the efficiency of the electric generator to be increased.