Electric Machine Baffle for Moisture Separation and Drainage
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Solution Overview
Problem
Electric machines, such as vehicle alternators, face premature failure due to corrosive salt-containing moisture in the air flow, which causes damaging corrosion, especially in environments like city buses where salt is used on streets during winter.
Innovation Solution
An electric machine with a baffle member that removes moisture from the air flow before it enters the machine, featuring a passageway with impact surfaces redirecting airflow and a drain port to discharge moisture by gravity, thereby protecting the machine from corrosive effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If axial air flow is used to cool the electric machine, then cooling effectiveness is improved, but exposure to corrosive salt-containing moisture increases
Solution Approach 1:
A baffle member is introduced as an intermediary component between the air flow source and the electric machine housing. This baffle includes a passageway with impact surfaces that force the air flow to change direction, causing moisture to separate and drain away before air enters the housing, thus mediating between cooling needs and corrosion protection
Solution Approach 2:
The baffle member performs preliminary action by removing moisture from the air flow before it enters the electric machine housing. The impact surfaces cause moisture to condense and drain through drain ports in advance, preventing the harmful moisture from reaching the electric machine components
2Productivity
If air flow path is shortened to improve efficiency, then productivity is improved, but moisture removal effectiveness decreases
Solution Approach 1:
The baffle member introduces a spatial dimension change by forcing the air flow to move from a direct axial path to a redirected path through the passageway. The impact surfaces redirect air flow radially and axially, creating an S-shaped path that increases moisture exposure time without significantly impacting overall cooling 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 baffle effectively limits the entry of corrosive moisture into the electric machine, reducing the risk of premature failure and extending the lifespan of alternators in salt-exposed environments.
Implementation Method 1
the baffle defines at least one impact surface within the passageway for changing a direction of the airflow path between the inlet and the outlet
Implementation Method 2
the baffle is configured to direct moisture collecting on the impact surface to the drain port where the moisture is discharged from the baffle to the ambient air
Data Source
AI summary
An electric machine having a housing with the rotor and stator disposed within the housing. The housing defines at least one housing opening allowing the inflow of air into the housing. A baffle is mounted on the housing and controls the inflow of air into the housing opening. The baffle member defines an inlet in communication with the ambient air, an outlet in communication with the housing opening, and a passageway extending from the inlet to the outlet. The baffle defines at least one impact surface within the passageway for changing the direction of air flow between the inlet and the outlet and the baffle further defines a drain port wherein the passageway directs moisture collecting on the impact surface to the drain port where it is discharged from the baffle. The electric motor may be an axial flow air-cooled alternator having a fan for generating the air flow.