Fluid-Cooled Stator Active Part with Interlayer Cooling Channels
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Solution Overview
Problem
Existing electric machines used in hermetically sealed systems for the oil and gas sector face challenges such as material degradation from chemically aggressive process gases, high pressure fluctuations, and moisture absorption, leading to insulation failure and reduced performance.
Innovation Solution
A fluid-cooled active part design featuring a cooling channel between main and sub-conductor insulators, utilizing high-performance plastics like polyetheretherketone (PEEK) and fluororubber for insulation, which allows direct cooling of electrical conductors and maintains electrical isolation under adverse conditions, reducing heat transport losses and enhancing power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional resin-saturated films and fabric layers are used for insulation, then traditional insulation tasks are performed, but the insulation system is destroyed by chemically aggressive process gases and high pressure
Solution Approach 1:
The patent employs a composite insulation system combining PEEK film layers with fabric layers impregnated with polyamide resin. The PEEK provides chemical resistance to process gases while the resin-impregnated fabric provides mechanical strength and insulation. This composite structure resolves the contradiction by combining materials with complementary properties - one resistant to chemical aggression and another providing structural integrity.
Solution Approach 2:
The patent changes the material parameters of the insulation system by selecting PEEK (polyetheretherketone) with specific chemical resistance properties and polyamide resin with appropriate saturation characteristics. These parameter changes enable the insulation to withstand chemically aggressive environments and high pressures that would destroy conventional insulation materials.
2Loss of energy
If direct cooling of conductors is implemented, then heat transport losses are reduced and power density is enhanced, but electrical insulation under adverse conditions becomes more challenging
Solution Approach 1:
The patent introduces an intermediary cooling structure - a cooling channel with cooling ribs positioned between the conductor and the stator core. This intermediary structure enables direct cooling of the conductor while maintaining electrical insulation through the PEEK and resin-impregnated fabric layers that surround the conductor. The cooling ribs transfer heat from the conductor to the cooling medium flowing in the channel without compromising insulation.
3Device complexity
If hermetically sealed systems are used to eliminate seals on rotating parts, then integration is improved, but material aging is accelerated by chemically aggressive process gases
Solution Approach 1:
The patent uses composite materials including PEEK film, fabric layers, and polyamide resin to create an insulation system that is both hermetically sealed and resistant to chemically aggressive process gases. This composite structure maintains the hermetic seal while protecting against material aging from chemical exposure, resolving the contradiction between sealing integration and material durability.
4Temperature
If high pressure cooling is applied, then cooling efficiency is improved, but insulation delamination occurs due to pressure cycling
Solution Approach 1:
The patent employs a composite insulation system where PEEK film layers are combined with fabric layers impregnated with polyamide resin. The resin saturation process creates strong bonding between layers that can withstand high pressure cycling. The composite structure distributes mechanical stresses from pressure cycling across multiple materials with different mechanical properties, preventing delamination while maintaining cooling efficiency.
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 design provides a powerful, compact, and resistant active part capable of operating under high voltage and pressure conditions, with improved chemical and temperature resistance, reducing the risk of electrical breakdowns and extending operational lifespan.
Implementation Method 1
The fluid-cooled active part design features a cooling channel between main and sub-conductor insulators, utilizing high-performance plastics like polyetheretherketone (PEEK) and fluororubber for insulation, which allows direct cooling of electrical conductors and maintains electrical isolation under adverse conditions, reducing heat transport losses and enhancing power density.
Data Source
AI summary
The invention relates to a fluid-cooled active part (1) for an electric machine (38), wherein the active part (1) is substantially cylindrical or hollow cylindrical, having axially extending grooves (2), at least one electrical conductor (3), which is arranged in the associated groove (2) at least in some sections and which is composed of a plurality of partial conductors (4), one or more main insulators (5), each arranged between the associated conductor (3) and the associated groove (2), and partial-conductor insulators (6), each surrounding the associated partial conductor (4). The invention further relates to an electric machine (38), having such a fluid-cooled active part (1) designed as a stator (39) and/or such a fluid-cooled active part (1) designed as a rotatably mounted rotor (40), wherein the electric machine (38) can be operated with a voltage in the range of at least a few kilovolts, preferably a few tens of kilovolts. Finally, the invention relates to a drive System (41), having such an electric machine (38) and a fluid energy machine (42) for the fluid, wherein the fluid energy machine (42) is designed as a compressor, in particular for process gas, or as a pump, in particular for a process liquid. In order to provide, among other things, a high-performance fluid-cooled active part that is compact and, in particular, resistant in the environment of the fluid or of a process fluid, it is proposed, among other things, that the active part (1) has one or more cooling Channels (7) for conducting the fluid, in particular a process fluid, wherein each cooling Channel (7) is arranged between the associated main insulator (5) and the respective partial-conductor insulators (6).