Linear Motor Conductor Arrangement Cooling
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Solution Overview
Problem
Linear motors with conductor arrangements face challenges in cooling due to the small gap between the conductor arrangement and magnetically active components, leading to limited continuous output and potential damage from high temperatures, especially when using indirect cooling methods like fans or cooling lines.
Innovation Solution
A linear motor design with a conductor arrangement featuring outer conductor sections with larger cross sections than inner sections, arranged in a meandering pattern, allowing for direct thermal energy dissipation from the edge region, enhancing cooling efficiency and enabling higher current densities without damaging the conductor arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the gap between the conductor arrangement and magnetically active components is reduced to achieve high efficiency, then efficiency is improved, but cooling capability deteriorates due to limited air circulation
Solution Approach 1:
The patent introduces a dielectric cooling plate as an intermediary component between the conductor arrangement and the external environment. This cooling plate with integrated cooling channels serves as a mediator that conducts heat away from the conductor arrangement through its thermally conductive material, while the dielectric properties prevent electrical discharge, thus resolving the contradiction between maintaining small gap for efficiency and enabling effective cooling
Solution Approach 2:
The patent employs fluid-based cooling through cooling channels formed in the dielectric cooling plate. By circulating coolant through these channels, the system effectively removes heat from the conductor arrangement, addressing the cooling capability deterioration that occurs when the gap is reduced for higher efficiency operation
2Temperature
If air cooling is used to cool the conductor arrangement, then cooling is improved, but the gap size must be increased which reduces efficiency
Solution Approach 1:
The patent transitions from air cooling to fluid-based cooling through integrated cooling channels in the dielectric cooling plate. This hydraulic cooling system provides superior heat removal capability without requiring increased gap size, thus maintaining both effective cooling and high efficiency operation
Solution Approach 2:
The dielectric cooling plate acts as an intermediary that enables efficient heat transfer from the conductor arrangement through its thermal conductivity, while the fluid circulation system provides enhanced cooling effectiveness without compromising the magnetic gap for efficiency
3Temperature
If additional fan devices or cooling lines are added to cool the conductor arrangement, then cooling capability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the cooling function with the structural support function by integrating cooling channels directly into the dielectric cooling plate that also serves as a structural component holding the conductor arrangement. This consolidation eliminates the need for separate fan devices or externally mounted cooling lines, reducing device complexity and manufacturing cost while maintaining improved cooling capability
Solution Approach 2:
The dielectric cooling plate performs multiple functions simultaneously: it provides structural support for the conductor arrangement, acts as a thermal conductor for heat removal, provides electrical insulation, and serves as a pathway for coolant circulation. This multi-functionality reduces the need for additional cooling components, thereby reducing device complexity
4Volume of moving object
If the conductor arrangement is miniaturized to achieve small-scale design, then size is reduced, but cooling becomes more difficult due to smaller gap volume
Solution Approach 1:
The patent employs fluid-based cooling through integrated cooling channels that efficiently remove heat from the miniaturized conductor arrangement. The high heat transfer coefficient of fluid cooling compensates for the reduced gap volume, enabling effective cooling of compact motor designs without requiring larger dimensions
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 design enables effective thermal energy dissipation, increasing the continuous output of the electrical machine while minimizing damage from heat, as the larger outer conductor sections concentrate and dissipate heat more efficiently than the smaller inner sections, even with poor thermal conductivity materials.
Implementation Method 1
the larger outer conductor sections concentrate and dissipate heat more efficiently than the smaller inner sections
Implementation Method 2
Since a current flows through the coil, the material resistance of the coil causes it to heat up
Data Source
Figure 1~3
Figure 4~8
AI summary
The invention relates to a conductor arrangement (10), to a method for the production thereof, and to a method for using a conductor arrangement, wherein the conductor arrangement for an electric machine, particularly an electric motor, can be moved relative to magnetically active components of the electric machine, wherein the conductor arrangement comprises at least one electrical conductor (12, 13, 14, 15) and a carrier (11) for spatially positioning the conductor, wherein the conductor comprises at least one conductor strand (18, 19, 20, 21) and is arranged in the manner of a coil, and wherein the conductor strand comprises conductor sections (27, 28, 29, 30) that are arranged, at least in sections, perpendicular and parallel to a direction of motion of the carrier or the components, and wherein at least one outer conductor section (27, 28) arranged parallel to the direction of motion has a cross section that is larger than the cross section of the other conductor sections (29, 30).