Electric Machine Windings With Integrated Cooling Channels
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Solution Overview
Problem
Existing electric machines generate heat during operation, which negatively affects their efficiency and performance, and existing cooling systems are inadequate for effectively managing this heat.
Innovation Solution
The electric machine incorporates a cooling system that utilizes a channel within the windings to circulate a high-specific-heat-capacity cooling fluid, which is then cooled through a heat exchanger, and includes internal surface features to enhance turbulence and heat transfer, thereby improving thermal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a cooling system is added to manage heat in electric machines, then thermal performance is improved, but device complexity increases
Solution Approach 1:
The cooling channels are integrated directly into the winding structure itself, merging the electrical conductor function with the thermal management function. The windings contain internal passages that allow cooling fluid to flow through them, eliminating the need for separate cooling systems and reducing overall device complexity while improving thermal performance
Solution Approach 2:
The windings serve dual purposes: they conduct electricity and they provide thermal management pathways. The same structural component (winding) performs both electrical and thermal functions, reducing the number of separate components needed and simplifying the overall system architecture
2Loss of energy
If internal surface features are added to enhance turbulence and heat transfer, then heat transfer efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The windings incorporate porous or textured internal surfaces within their structure, creating turbulence-promoting features directly in the flow passages. These surface characteristics enhance heat transfer efficiency while being integrated into the manufacturing process of the windings themselves, avoiding separate precision machining steps
Solution Approach 2:
The windings utilize composite structures that combine conductive materials with surface features designed for enhanced heat transfer. The composite nature allows integration of thermal management properties during the winding fabrication process, reducing post-manufacturing precision requirements
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 the thermal performance of electric machines, allowing them to operate at higher efficiency, produce more power, and reduce packaging size while maintaining optimal operating temperatures.
Implementation Method 1
a cooling system fluidly coupled with one or more windings of the electric machine... configured to move a cooling fluid through the channel... heat is accepted from the windings into the cooling fluid
Implementation Method 2
heat exchanger, and includes internal surface features to enhance turbulence and heat transfer
Implementation Method 3
internal surface features to enhance turbulence and heat transfer
Data Source
Figure 1~2
Figure 3
Figure 4~6
AI summary
An electric machine (10) can include a stator core (18) having a plurality of core teeth that define a plurality of core slots (20) in a surface thereof. A winding (16) can be housed at least partially in the core slots (20). The winding (16) can include a tube (74) defining a channel (42) through at least a portion thereof and one or more wires (76) disposed along a surface of the tube (74) that is opposite the channel (42). A cooling system (40) can be operably coupled with the channel (42) and configured to move a cooling fluid (44) through the channel (42).