Field Coil Separators With Coolant Paths for Rotor Winding Cooling
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Solution Overview
Problem
Existing cooling systems for electric motors, particularly in high-output systems installed in closed areas, fail to effectively cool internal rotor surfaces and rotor winding surfaces, leading to reduced operational efficiency.
Innovation Solution
A rotor design incorporating field coil separators with integrated coolant flow paths, featuring a resilient frame and outer shell, which guide coolant through external surfaces of field coils and direct it to balance rings for further distribution to stator ends, enhancing cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a liquid coolant system is used to cool external rotor surfaces, then cooling effectiveness is improved, but internal rotor surfaces including winding surfaces remain inadequately cooled
Solution Approach 1:
The cooling system is segmented into multiple independent coolant flow paths: external cooling jackets, internal shaft passages, and rotor lamination passages. Each segment targets specific heat-generating components, allowing differentiated cooling strategies for different rotor surfaces and improving overall thermal management effectiveness.
Solution Approach 2:
The cooling system employs a nested structure where coolant passages are embedded within the rotor laminations and shaft. The internal coolant passages are nested within the rotor core, while external jackets surround the stator, creating concentric cooling zones that maximize heat dissipation from both external and internal surfaces.
2Device complexity
If air flow is used for cooling, then system simplicity is maintained, but cooling sufficiency is inadequate for high-output systems in closed areas
Solution Approach 1:
The system transitions from air cooling to liquid coolant cooling, utilizing hydraulic principles to deliver efficient heat removal. The liquid coolant system with pressurized flow paths through jackets, shaft passages, and rotor laminations provides superior heat transfer coefficients compared to air flow, making it suitable for high-output systems in confined spaces.
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 solution effectively cools internal rotor surfaces and rotor windings, improving overall operational efficiency and thermal management of electric machines.
Implementation Method 1
Each of the plurality of field coil separators includes a coolant circulation system. The coolant circulation system includes a plurality of external coolant flow paths.
Implementation Method 2
The plurality of rotor laminations include a plurality of coolant passages extending between the inner surface portion and the outer surface portion.
Implementation Method 3
A plurality of field coil separators extend axially along the rotor between adjacent ones of the plurality of field coils. Each of the plurality of field coil separators includes a resilient frame
Data Source
AI summary
A rotor for an electric machine includes a shaft. A plurality of rotor laminations is mounted to the shaft. The plurality of rotor laminations includes a plurality of rotor teeth. A plurality of field coils is disposed about corresponding ones of the plurality of rotor teeth. A plurality of field coil separators extend axially along the rotor between adjacent ones of the plurality of field coils. Each of the plurality of field coil separators includes a coolant circulation system. The coolant circulation system includes a plurality of external coolant flow paths. Each of the plurality of field coil separators includes a resilient frame and an outer shell over molded onto the resilient frame, the outer shell including an outer surface.