Electric Machine End Turn Channels for Heat Transfer
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Solution Overview
Problem
Electric machines generate heat due to power loss in windings, leading to temperature increases that can alter their operating properties, and existing cooling systems may not effectively manage this heat.
Innovation Solution
The electric machine's stator end turns are designed with channels to increase surface area for fluid contact and direct a cooling medium flow, incorporating insulating and binding elements to optimize heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional windings without channels are used, then the structure is simple, but heat transfer efficiency is insufficient
Solution Approach 1:
The end turns are segmented to create multiple channels (first and second channels) that traverse through the conductors, allowing cooling fluid to flow through divided paths. This segmentation increases the surface area for heat transfer while maintaining a manageable structural complexity through systematic arrangement of the channels.
Solution Approach 2:
The end turns are formed with a porous or channelled structure that allows cooling fluid to pass through. The channels create an internal flow path network within the end turns, effectively increasing the heat transfer surface area without requiring a completely redesign of the winding structure.
2Area of stationary object
If end turns with channels are created, then heat transfer surface area increases, but manufacturing complexity increases
Solution Approach 1:
The channels are formed in the end turns during the winding fabrication process itself, rather than as a separate post-processing step. The winding structure is designed with integrated channels that are created as part of the initial winding formation, which simplifies manufacturing by combining structure creation with cooling channel formation in one process.
3Reliability
If cooling channels are added to end turns, then cooling performance improves, but structural integrity may be compromised
Solution Approach 1:
The channels are strategically positioned and dimensioned to provide adequate cooling where heat generation is highest, while maintaining sufficient material thickness in critical load-bearing areas. The channel size and distribution are optimized to balance cooling performance with structural integrity, creating different local properties within the end turns.
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 enhances heat transfer and cooling performance by maximizing surface area contact with the cooling medium, effectively managing temperature and improving the electric machine's operational stability.
Implementation Method 1
The end turns are formed to define at least one channel that traverses the conductors for increasing a surface area for fluid contact and directing a flow of fluid along the toroidal outline
Implementation Method 2
directing a flow of fluid along the toroidal outline
Implementation Method 3
increasing a surface area for fluid contact
Data Source
AI summary
An electric machine includes a stator with a core having an end face and a plurality of conductors forming windings that extend adjacent to the end face defining end turns having a toroidal outline. The end turns are formed to define at least one channel in the end turns that traverses the end turns for increasing a surface area for fluid contact and directing a flow of fluid along the toroidal surface.