Electromagnetic Machine Bobbin Cooling and Standardization
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Solution Overview
Problem
Designing electromagnetic machines, such as electric motors and generators, requires standardization of dimensions while allowing for variations in operating characteristics, particularly in motor axial length to accommodate different windings, which poses challenges in motor efficiency, cooling, cost reduction, and part standardization.
Innovation Solution
The electromagnetic machine features a rotor and stator with a support structure including concentric rings and bobbins with cooling holes for air flow, allowing for radial and axial cooling, and a dual rotor configuration with inner and outer segments for enhanced cooling, along with a circuit board for universal coil configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If motor axial length is changed to accommodate different windings, then operating characteristics can be varied, but manufacturing complexity and part standardization increase
Solution Approach 1:
The patent employs universal bobbins with standardized dimensions that can be used across different motor sizes and configurations. These bobbins feature axial cooling holes and flanges that engage with standardized rings, allowing the same bobbin design to serve multiple motor types while accommodating different windings through variable coil configurations rather than different bobbin dimensions.
Solution Approach 2:
The motor structure is divided into modular components including standardized bobbins, rings, and cooling assemblies. The bobbins are segmented with separate flanges for radial and axial engagement, and cooling holes are positioned to create distinct cooling pathways. This segmentation allows independent optimization of each component while maintaining overall standardization.
2Temperature
If cooling structures are added to improve motor cooling, then thermal management improves, but device complexity increases
Solution Approach 1:
The cooling function is merged into the existing bobbin structure by incorporating cooling holes directly into the bobbin body. The bobbins serve dual purposes: supporting the windings and providing cooling pathways. This integration eliminates the need for separate cooling components while improving thermal management through radial and axial cooling air flow paths.
3Ease of manufacture
If standardized parts are used to reduce costs, then manufacturing cost decreases, but adaptability to different operating requirements decreases
Solution Approach 1:
The patent maintains standardized bobbin dimensions and features while achieving different operating characteristics through parameter changes in the coil windings, number of coils, and electrical connections. The standardized bobbins have fixed geometric parameters, but the electromagnetic parameters can be varied by changing the winding configurations, allowing different motor performance characteristics from the same physical support structure.
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 enhances motor efficiency, cooling, and cost-effectiveness by allowing for standardized parts and dynamic coil configuration adjustments, improving packaging and scalability while reducing material costs and core losses.
Implementation Method 1
each one of the plurality of bobbins include at least one cooling hole for the flow of cooling air in a radial direction
Implementation Method 2
cooling air flow flows radially outward from the gap, through the at least one cooling hole, and outward through the at least one cooling flow opening
Implementation Method 3
an electromagnetic machine includes a rotor adapted to rotate about an axis; and a stator including a support structure, a plurality of bobbins engaged to the support structure, and a plurality of electric coils with each one wound about a respective bobbin
Data Source
AI summary
An electromagnetic machine includes a rotor and a stator. The rotor is adapted to rotate about an axis. The stator includes a support structure, a plurality of bobbins engaged to the support structure, and a plurality of electric coils with each one wound about a respective bobbin of the plurality of bobbins.