End Shield Spray Apertures for Cooling Electric Machine End Coils
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Solution Overview
Problem
Conventional liquid-cooled electric machines require additional components like spray rings with tight tolerances, increasing costs and complexity, and lack flexibility in spray pattern orientation, which complicates production and maintenance.
Innovation Solution
The use of end shields with a cap, hub ring, and collar structure that includes a plurality of spray openings to direct fluid onto end coils, eliminating the need for spray rings and allowing for adjustable spray patterns by easy mounting and swapping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If spray rings are used to direct coolant onto end windings, then cooling effectiveness is improved, but device complexity and manufacturing cost increase due to additional components and tight tolerances
Solution Approach 1:
The spray feature is merged directly into the end shield structure by forming spray openings in the collar portion of the end shield. This eliminates the need for separate spray rings while maintaining the cooling function, as the end shield itself becomes the fluid directing component.
Solution Approach 2:
The end shield is given multiple functions: it provides structural support for the electric machine components and simultaneously serves as a fluid directing element through its integrated spray openings. This multi-functionality eliminates the need for dedicated spray rings.
2Reliability
If spray rings with tight tolerances are manufactured to minimize leakage, then sealing performance is improved, but manufacturing precision requirements and production cost increase
Solution Approach 1:
The spray openings are formed as an integral part of the end shield structure rather than as a separate spray ring component. This integration eliminates the interface between spray ring and housing, removing the source of leakage issues and tight tolerance requirements.
Solution Approach 2:
The end shield with spray openings can be manufactured as a single-piece structure using cost-effective methods, eliminating the need for precision-machined spray rings with tight tolerances.
3Temperature
If conventional spray rings are used, then cooling function is achieved, but adaptability in spray pattern orientation is reduced, complicating production and maintenance
Solution Approach 1:
The spray openings in the collar can be oriented in different directions to achieve various spray patterns. The collar structure allows for flexible positioning of spray openings to direct fluid onto different portions of the end coil, enabling adaptation to different cooling 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
This solution reduces production and component costs, simplifies the assembly process, and allows for flexible and symmetrical spray patterns, enhancing the efficiency and maintainability of liquid cooling in electric machines.
Implementation Method 1
spray coolant on end windings of the electric machine
Implementation Method 2
liquid cooled electric machines may be liquid cooled
Data Source
AI summary
An end shield for an electric machine is provided. The end shield includes a collar extending between a housing of the electric machine and an end coil. The collar includes one or more spray apertures for directing a fluid onto the end coil.