Integrated E-Machine Controller Coolant Core for Turbomachines
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional controllers for turbomachines, such as those in turbochargers, are bulky, generate significant heat, and are inefficient to manufacture and assemble, making them unsuitable for high-temperature and vibrational environments.
Innovation Solution
An integrated e-machine controller with a coolant core that extends circumferentially over the e-machine stage, providing efficient cooling and compact packaging, and a method of manufacturing that supports the controller's integration with the turbomachine, reducing size and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional controllers are used for turbomachines, then control function is provided, but the controllers are heavy and bulky
Solution Approach 1:
The controller is integrated directly into the e-machine assembly, combining the control electronics with the motor/generator structure. This merging eliminates the need for separate controller housings and mounting structures, significantly reducing overall weight and volume while maintaining full control functionality.
Solution Approach 2:
The controller housing serves multiple functions simultaneously: it provides structural support, acts as a heat sink for thermal management, and serves as a mounting platform for electronic components. This multi-functionality reduces the need for additional components, thereby reducing weight while maintaining operational effectiveness.
2Temperature
If conventional controllers are used for turbomachines, then control function is provided, but the electronics generate significant heat
Solution Approach 1:
The heat generated by the control electronics, which is normally a harmful byproduct, is converted into a beneficial feature by using the controller housing as a heat sink. The thermal energy is dissipated through the housing structure, which has adequate thermal mass and surface area, turning the heat problem into a passive cooling solution.
Solution Approach 2:
The controller housing acts as an intermediary thermal management component between the heat-generating electronics and the surrounding environment. It provides a controlled thermal pathway that dissipates heat efficiently without requiring active cooling systems, thereby managing temperature while minimizing energy loss.
3Productivity
If conventional controllers are used for turbomachines, then control function is provided, but manufacture and assembly are difficult and time consuming
Solution Approach 1:
The controller is designed as an integrated assembly with the e-machine, combining multiple components into a single manufacturable unit. This reduces the number of separate parts that need to be manufactured and assembled, thereby improving productivity while reducing the overall complexity of the assembly process.
Solution Approach 2:
The controller is designed as a modular assembly that can be manufactured as a pre-integrated unit and then installed as a single component into the turbomachine. This segmentation of the manufacturing process allows for specialized production techniques to be applied to the controller assembly, improving efficiency while reducing the complexity of final system assembly.
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 integrated controller effectively cools electronics and surrounding components, maintaining operational temperatures within acceptable ranges while reducing the turbomachine's size and improving manufacturing efficiency.
Implementation Method 1
a coolant core that receives a flow of a coolant therethrough for cooling the integrated controller
Data Source
AI summary
A fluid compressor device includes a housing and a rotating group supported for rotation within the housing about an axis. The device also includes a compressor stage including a compressor wheel of the rotating group that is supported on a shaft of the rotating group. The device also includes an e-machine stage including an e-machine that is operably coupled to the shaft and that is configured to operate as at least one of a motor and a generator. Additionally, the device includes an integrated controller that extends at least partly over the e-machine stage in a circumferential direction about the axis. The integrated controller includes a coolant core that receives a flow of a coolant therethrough for cooling the integrated controller. The coolant core extends over the e-machine stage in a circumferential direction about the axis.