Generator Wedge Spray Cooling Heat Transfer
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Solution Overview
Problem
Conventional heat removal methods in generators, such as conduction cooling, are inefficient due to high thermal resistance and require high fluid flow, which is impractical for rotating high-powered machines, especially when trying to manage heat from copper components.
Innovation Solution
A spray cooling system that uses a manifold with 90-degree pipes and holes to distribute a cooling fluid into the wedges of a generator rotor, enhancing heat transfer efficiency by dispersing a cooling fluid spray directly into the wedges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conduction cooling is used with fluid flow through rotor shaft or hollow wedges, then heat removal from copper is improved, but heat transfer coefficient remains low requiring very high fluid flow
Solution Approach 1:
The invention changes the heat transfer mechanism from conduction to spray cooling, fundamentally altering the physical process parameters. By introducing direct liquid spray contact with the copper surface, the heat transfer coefficient increases dramatically from typical conduction values to spray cooling ranges, enabling effective heat removal at much lower fluid flow rates
Solution Approach 2:
The invention employs hydraulic spray cooling by delivering liquid coolant through hollow wedges that are centrifugally forced against the rotor shaft. The cooling fluid is sprayed directly onto the copper surface through holes in the wedge, utilizing fluid dynamics and pressure control to achieve high heat transfer coefficients without requiring large volumes of coolant
2Temperature
If high fluid flow is used to achieve reasonable heat transfer coefficient for conduction cooling, then heat removal is improved, but it becomes impractical for high powered larger diameter and high speed machines
Solution Approach 1:
The invention utilizes the dynamic rotation of the rotor to generate centrifugal force that pushes the hollow wedges outward against the rotor shaft. This dynamic mechanism automatically adjusts the wedge position and cooling fluid delivery based on rotational speed, enabling practical operation across a range of high speeds without requiring complex external control systems
Solution Approach 2:
The hollow wedges serve multiple functions simultaneously: they provide mechanical support for the copper, enable cooling fluid delivery, and utilize centrifugal force from rotation to position themselves against the rotor shaft. The system is self-regulating, where the rotational energy itself provides the mechanism for cooling fluid delivery without requiring separate actuation systems
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 spray cooling method achieves a significantly higher heat transfer coefficient (2000-3000 W/m2C) compared to conduction cooling (200-300 W/m2C), effectively managing heat in high-powered generators with reduced fluid volume and flow requirements.
Implementation Method 1
spray cooling manifold comprises... a pipe extending from the second, opposite end of the manifold pipe, the pipe adapted to extend into a wedge of the rotating machine, the pipe having a plurality of holes formed therealong
Implementation Method 2
The spray cooling method achieves a significantly higher heat transfer coefficient (2000-3000 W/m2C) compared to conduction cooling (200-300 W/m2C)
Data Source
AI summary
A wedge cooling apparatus and method for cooling a rotating machine, such as a generator, disperses a spray of cooling fluid into the wedges of the generator via a pipe that runs along the length of each of the wedges. The pipe may include a plurality of spray delivery devices to spray cooling fluid from the pipe to the inside of the wedges. The spray cooling method results in a high heat transfer coefficient of about 2000-3000 W/m2C as opposed to conventional conduction cooling, which has a heat transfer coefficient of about 200-300 W/m2C. The apparatus and method of the present invention efficiently removes heat from high powered, high current density designed generators.