Integrated Cooling Assembly for Electrical Machines
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Solution Overview
Problem
Conventional cooling systems for electrical machines, such as generators, are often bulky, costly, and inefficient, particularly in compact operational housings like wind turbines, where they can decrease efficiency due to eddy current flow and inefficient heat transfer.
Innovation Solution
A cooling assembly comprising a supply header, return header, and flow members configured in a serpentine pattern to channel a flow agent effectively from the supply header to the return header, with each flow member coupled to the coil and end turns to enhance heat transfer and minimize eddy currents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional forced-air cooling systems are used, then cooling capability is improved, but device size and complexity increase
Solution Approach 1:
The patent merges the cooling function directly into the coil structure by integrating flow members with the coil former, eliminating the need for separate blowers and heat exchangers. The flow members are coupled to the coil former with flow communication between end turns, creating an integrated cooling system that reduces overall system complexity while maintaining effective cooling capability.
Solution Approach 2:
The flow members are nested within the coil structure, with flow members coupled to the coil former and positioned to channel flow agent through the coil windings. This nesting approach allows the cooling system to be embedded within the existing coil geometry, reducing external components and simplifying the overall system architecture.
2Temperature
If liquid cooling systems are used, then cooling efficiency is improved, but eddy current losses increase
Solution Approach 1:
The patent applies local quality by using non-conductive materials for the flow members that contact the coil former, such as plastics or composites with non-conductive matrices. This localized application of non-conductive materials at the interface between cooling channels and coil structure eliminates eddy current paths while maintaining effective thermal coupling through direct contact or thermal interface materials.
3Device complexity
If cooling tubes are coupled to the coil former, then system simplicity is improved, but heat transfer efficiency decreases
Solution Approach 1:
The patent segments the cooling system into multiple flow members, each coupled to different portions of the coil former and end turns. This segmentation allows the cooling channels to be distributed throughout the coil structure, providing direct thermal coupling with heat-generating regions while maintaining system simplicity through modular flow member design.
Solution Approach 2:
The patent extends the cooling system into the third dimension by coupling flow members to end turns in addition to the coil former. This multi-dimensional coupling approach creates additional heat transfer pathways that penetrate deeper into the coil structure, improving thermal efficiency while maintaining a relatively simple overall system architecture.
4Volume of moving object
If compact cooling systems are designed, then device size is reduced, but cooling effectiveness may decrease
Solution Approach 1:
The flow members are nested within the coil structure, utilizing the existing space between the coil former and windings. This nesting approach maximizes the use of available volume, allowing effective cooling channels to be positioned close to heat-generating regions without increasing overall system size.
Solution Approach 2:
The patent utilizes the radial and axial dimensions of the coil structure by coupling flow members to both the coil former and end turns. This multi-dimensional heat transfer approach efficiently removes heat from all regions of the coil, maintaining high cooling effectiveness while keeping the system compact.
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 solution provides a compact, efficient cooling system that increases heat transfer and reduces the size of the electrical machine while maintaining high power density and efficiency, suitable for use in compact operational housings like wind turbines.
Implementation Method 1
Each flow member of the plurality of flow members includes a first portion coupled to the first coil; a second portion coupled to the second coil... configured to channel a flow agent from supply header to the return header
Data Source
AI summary
An assembly for cooling an electrical coil winding having a first coil, a second coil, a first end turn and a second end turn is provided. The assembly includes a supply header; a return header; and a plurality of flow members coupled in flow communication to the supply header and the return header. The flow members are configured to channel a flow agent from supply header to the return header. Each the flow member of the plurality of flow members includes a first portion coupled to the first coil; a second portion coupled to the second coil; a first end portion coupled to the first end turn and coupled in flow communication to the first portion and the second portion; and a second end portion coupled to the second end turn and coupled in flow communication to the second portion.