Connection Device for Hollow Conductor Cooling in Electric Machines
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Solution Overview
Problem
Existing electric machines, particularly those in vehicles, face challenges in efficiently dissipating heat from high-current density windings due to the inefficiency of traditional cooling methods, which often require significant space and weight, and can lead to overheating risks.
Innovation Solution
A connection device that allows a coolant to be introduced into and extracted from electrical hollow conductors, enabling counter-flow cooling and efficient heat dissipation, thereby reducing the need for additional cooling components and minimizing space and weight requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional cooling methods are used for high current density windings, then heat dissipation is achieved, but the system requires significant space and weight
Solution Approach 1:
The patent combines the electrical connection function and coolant supply function into a single integrated connection device. The connection device includes both electrical contacts for connecting the hollow conductor to the energy source and coolant conduits for supplying coolant to the hollow conductor, eliminating the need for separate cooling components and reducing overall system weight
Solution Approach 2:
The connection device serves multiple functions simultaneously: it provides electrical connection between the hollow conductor and the energy source, supplies coolant to the hollow conductor through integrated conduits, and facilitates heat dissipation. This multi-functional design reduces the number of separate components needed in the system
2Temperature
If elaborate cooling measures are implemented to prevent overheating, then temperature control is improved, but device complexity increases
Solution Approach 1:
The connection device merges the electrical connection and coolant supply functions into a single integrated component. The coolant conduits are built into the connection device structure itself, eliminating the need for separate cooling channels or additional cooling system components, thereby simplifying the overall system
Solution Approach 2:
The hollow conductor serves its primary electrical function while simultaneously acting as its own cooling channel. The coolant flows directly through the hollow interior of the conductor, allowing the conductor to self-cool without requiring external cooling infrastructure or complex cooling system integration
3Temperature
If hollow conductors with large diameters are used for coolant flow, then cooling efficiency is improved, but mounting space and weight increase
Solution Approach 1:
The hollow conductor utilizes its own internal volume for coolant flow, eliminating the need for separate cooling channels or additional space for cooling infrastructure. The conductor's hollow interior serves dual purposes: electrical current conduction and coolant transport, maximizing space efficiency
Solution Approach 2:
The patent employs multiple smaller hollow conductors rather than a single large-diameter conductor. This approach provides sufficient total cooling capacity while maintaining smaller individual conductor diameters that are easier to integrate into the motor structure, reducing both mounting space requirements and rotational inertia
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 solution provides a compact, efficient cooling system that maintains uniform temperature distribution, reduces the risk of overheating, and allows for high-current, low-voltage configurations, enhancing safety and performance by avoiding high-voltage system risks.
Implementation Method 1
heat that is generated during operation of the electric machine from the hollow conductors
Implementation Method 2
via which the coolant can be conducted out of the at least one hollow conductor... neighboring coolant can flow through hollow conductors in different, i.e., opposite, directions
Data Source
AI summary
A connection device for connecting at least one electrical hollow conductor as used in a winding of an electric machine for a motor vehicle to an electrical energy source or an electrical energy storage or user is disclosed, wherein the connection device includes a first channel adapted for introduction of a coolant into the at least one hollow conductor.