Integral Pipe End Plate Rotor Cooling Assembly
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Solution Overview
Problem
The assembly of electric machine rotors with cooling pipes is complex due to the need for multiple operating steps to connect pipes to end plates, which increases production complexity and time.
Innovation Solution
The integration of pipes and end plates as a single cast component with built-in cooling channels simplifies assembly by eliminating the need for separate pipe connections, allowing sheets to be placed directly on the pipes, and enabling a coolant circuit for efficient heat exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pipes are connected to end plates using separate components and multiple operating steps, then reliable cooling function is achieved, but assembly complexity increases
Solution Approach 1:
The pipe and first end plate are merged into a single integral component (pipe/end plate), eliminating the need for separate connection operations. The pipe is formed as an extension of the end plate, with the pipe opening directly accessible from the end plate surface, thereby reducing assembly steps while maintaining the cooling function.
2Strength
If multiple operating steps are used to connect pipes to end plates, then secure connection is achieved, but production time increases
Solution Approach 1:
The pipe is pre-integrated into the first end plate during manufacturing, so that the connection is already established before assembly. This preliminary integration eliminates the need for time-consuming connection operations during production, while ensuring a secure, pre-verfied connection.
3Temperature
If pipes extend completely inside the sheet stack, then thermal coupling is improved, but assembly difficulty increases
Solution Approach 1:
The pipe is divided into two functional segments: a first section that extends completely through the sheet stack for optimal thermal coupling, and a second section that protrudes from the second end plate to enable coolant connection. This segmentation allows the pipe to achieve full thermal contact while maintaining assembly feasibility through the protruding connection section.
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 approach reduces production complexity and time by simplifying the assembly process while enhancing thermal coupling and heat exchange efficiency through a coolant circuit, allowing for effective cooling of a larger sheet stack region.
Implementation Method 1
Each pipe has a cooling channel for conducting a coolant... to improve the heat exchange between the coolant in the respective pipe and the sheet stack that surrounds the pipe
Data Source
AI summary
A rotor (1) for an electric machine has a sheet stack (2) arranged between a first end plate (3) and a second end plate (4). The first end plate and the second end plate (3, 4) are connected to each other by pipes (5) that extend at least partially through the sheet stack (2). Each pipe (5) has a cooling channel (6) for conducting a coolant. The pipes (5) and the first end plate (3) are constructed as an integral pipe/end plate (8).