Rotor End-Turn Support Structure for Windage Loss and Cooling
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Solution Overview
Problem
Conventional electric machines, such as generators, face challenges at high rotational speeds due to centrifugal and axial forces that can weaken or break rotor windings, leading to vibration and reduced efficiency. Additionally, the discontinuous architecture of winding end turn support structures results in windage losses, limiting operating efficiency.
Innovation Solution
The proposed solution involves an improved rotor winding end turn support structure that includes a winding support assembly with a first and second winding support disc and a retaining ring. This assembly provides continuous support to the rotor winding end turns, reducing deflection and relative movement, and incorporates fluid channels for effective cooling and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional discontinuous winding support structures are used, then manufacturing is simpler, but windage losses increase and dynamic balance deteriorates
Solution Approach 1:
The patent combines multiple winding support functions into a single integrated disc structure. The winding support disc integrates the support function for rotor windings with the cooling function through integrated fluid channels, eliminating the need for separate support structures and reducing windage losses by creating a continuous, streamlined architecture.
Solution Approach 2:
The winding support disc serves multiple functions simultaneously: it provides mechanical support for the rotor windings, acts as a coolant distribution manifold through integrated fluid channels, and serves as a structural element for maintaining rotor geometry. This multi-functionality reduces the number of separate components needed.
2Power
If high rotational speeds are used to increase power output, then power density improves, but centrifugal forces weaken rotor windings and cause vibration
Solution Approach 1:
The winding support disc provides pre-established mechanical reinforcement for the rotor windings before high-speed operation begins. The integrated support structure is designed to withstand centrifugal forces from the outset, preventing winding degradation and vibration that would occur at high rotational speeds without such preliminary structural reinforcement.
3Temperature
If conventional cooling methods are used, then thermal management is insufficient, but adding complex cooling systems increases device complexity
Solution Approach 1:
The cooling system is merged with the winding support structure itself. Fluid channels are integrated directly into the winding support disc, combining the mechanical support function with the thermal management function in a single component, thereby improving cooling efficiency without increasing overall system complexity.
Solution Approach 2:
The patent employs fluid-based cooling through channels formed in the winding support disc. Coolant flows through these channels to remove heat from the rotor windings, providing effective thermal management through hydraulic cooling rather than relying on less efficient conventional cooling methods.
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 improved rotor winding end turn support structure enhances the dynamic balance of the rotor core, reduces windage losses, and improves thermal management, leading to increased efficiency and power density of the electric machine while enabling easier and lower-cost assembly.
Implementation Method 1
delivering the fluid coolant flow through first channels defined through the first winding support disc
Implementation Method 2
improves thermal management, leading to increased efficiency and power density
Data Source
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AI summary
A rotor assembly (96) includes a rotor core (100) having a rotatable shaft (40) and defining at least one rotor post (108), a winding (110) wound around the post (108) and defining an end turn (112), and a winding support assembly (130) including a winding support assembly (130) coupled to the rotatable shaft (40). The end turn defines a set of channels therethrough and is disposed in a first chamber defined by the winding support assembly (130).