Embedded Winding Cooling Channels for Compact Electric Machines
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Solution Overview
Problem
Electric machines generate heat during operation, which can negatively affect their efficiency and performance, and existing cooling systems may not adequately address this issue to maintain optimal operating temperatures.
Innovation Solution
The electric machine incorporates a cooling system fluidly coupled with windings that include a tube with a channel and Litz-wires, allowing for efficient heat transfer through a cooling fluid, which is then cooled externally, enhancing thermal performance and reducing packaging size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling systems are used, then the electric machine can operate, but heat rejection is insufficient and packaging size increases
Solution Approach 1:
The cooling channels are nested within the winding structure itself, with tubes positioned inside or adjacent to the winding turns. This integration allows the cooling system to occupy space that would otherwise be unused, eliminating the need for separate external cooling components and reducing overall packaging size.
Solution Approach 2:
The invention transitions from conventional external cooling to internal cooling by embedding channels within the winding structure. This dimensional integration moves the cooling function from an external accessory to an intrinsic part of the winding, improving heat rejection efficiency while compacting the overall structure.
2Temperature
If conventional cooling systems are used, then the structure remains simple, but thermal performance is insufficient
Solution Approach 1:
The cooling channels and winding structure are merged into a single integrated component. The tubes are positioned within or adjacent to the winding turns, combining the electrical conductor function with the thermal management function in one structure, thereby improving heat rejection without requiring separate cooling systems.
Solution Approach 2:
The winding structure serves dual functions: electrical conduction and thermal management. By embedding cooling channels within the winding assembly, the same structural element performs both electrical and thermal roles, eliminating the need for dedicated separate cooling components.
3Temperature
If cooling channels are integrated into windings, then thermal performance improves, but manufacturing complexity increases
Solution Approach 1:
The cooling tubes are pre-positioned within the winding structure during the winding manufacturing process. By establishing the cooling channel geometry and tube positions as integral parts of the winding fabrication, the cooling system is created simultaneously with the electrical winding, avoiding subsequent complex assembly operations.
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 configuration improves the thermal performance of electric machines by maintaining optimal operating temperatures, increasing efficiency, and enabling higher power production while reducing size compared to current electric machines.
Implementation Method 1
A cooling system is operably coupled with the channel and is configured to move a cooling fluid through the channel
Data Source
AI summary
An electric machine can include a stator core having a plurality of core teeth that define a plurality of core slots in a surface thereof. A winding can be housed at least partially in the core slots. The winding can include a tube defining a channel through at least a portion thereof and one or more wires disposed along a surface of the tube that is opposite the channel. A cooling system can be operably coupled with the channel and configured to move a cooling fluid through the channel.