Hollow Electric Machine Conductor for Direct Winding Cooling
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Solution Overview
Problem
Existing electric machine windings, particularly in the stator stack, are difficult to cool effectively due to their distance from conventional cooling sources, leading to higher heat concentrations and potential insulation deterioration.
Innovation Solution
A conductor design comprising hollow winding elements and connecting members that form a continuous cooling channel, allowing coolant flow directly through the conductors, which are easily connected without welding, ensuring mechanical, electrical, and fluidic integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling sources are used for electric machine windings, then the cooling system is simple to implement, but the windings are difficult to cool effectively due to their distance from cooling sources, leading to higher heat concentrations
Solution Approach 1:
The cooling channel is nested within the hollow conductor structure itself. The conductor is designed as a hollow tube with an inner cooling channel that runs through its entire length, allowing coolant to flow directly through the winding conductor to remove heat at the source, rather than relying on external cooling sources distant from the windings.
Solution Approach 2:
A connecting member acts as an intermediary component that couples multiple conductors together both electrically and fluidically. This connecting member includes a coupling portion that engages with the cooling channels of adjacent conductors, enabling continuous coolant flow through multiple windings while maintaining electrical insulation and mechanical strength.
2Temperature
If hollow conductors with cooling channels are used, then direct cooling of the winding source is achieved, but the manufacturing complexity and production cost increase
Solution Approach 1:
The conductor is segmented into modular components: a winding element with integrated cooling channel and a separate connecting member. This segmentation allows each component to be manufactured independently using standard processes, then assembled together, reducing overall manufacturing complexity compared to producing a single complex integrated structure.
Solution Approach 2:
The electrical conductor function and cooling channel function are merged into a single hollow conductor structure. The conductor serves dual purposes: conducting electrical current through its wall and conducting coolant through its hollow interior, eliminating the need for separate cooling systems and reducing overall system complexity.
3Temperature
If multiple conductors are connected to form continuous cooling channels, then effective cooling is achieved, but the connection complexity increases
Solution Approach 1:
A connecting member acts as an intermediary component that couples multiple conductors together both electrically and fluidically. This connecting member includes a coupling portion that engages with the cooling channels of adjacent conductors, enabling continuous coolant flow through multiple windings while maintaining electrical insulation and mechanical strength.
Solution Approach 2:
The connecting member performs multiple functions simultaneously: it provides electrical connection between conductors, maintains fluidic continuity of the cooling channel, provides mechanical support and alignment, and ensures proper positioning of the conductor assembly within the stator slot.
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 enables direct cooling of the winding source of heat loss, reducing operating temperatures and allowing higher torque densities and improved continuous operation, while being cost-effective and suitable for mass production.
Implementation Method 1
a hollow winding element made of an electrically conductive material as a hollow conductor with a channel through which a coolant can flow
Implementation Method 2
The first straight portion, reverse portion and second straight portion form one piece... the hollow winding elements and hollow connecting members can serve as electric conductors with a coolant flow circulating inside them
Data Source
AI summary
A conductor for an electric machine, comprising: a first winding element made of an electrically conductive material and having a channel through which a coolant can flow, wherein the first winding element is integrally formed with a first straight portion, a reverse portion and a second straight portion parallel to the first straight portion, wherein the first straight portion has a first end section and the second straight portion has a second end section; a hollow connecting member made of electrically conductive material; wherein the hollow connecting member and the first end section of the winding element are axially insertable into each other to form an axially overlapping electrical and fluidic connection. The disclosure further relates to an electric machine with such a conductor.