Mid-Frame Electric Machine Layout for Compact Wiring and Cooling
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Solution Overview
Problem
Existing electrical machine assemblies face challenges with space constraints and inefficient wiring configurations, particularly when the terminal box is spaced from the housing or positioned radially outward, leading to increased space requirements and complex internal wiring paths.
Innovation Solution
The electric machine assembly features a housing divided into compartments by a mid-frame, with a terminal box coupled to the mid-frame, allowing efficient wiring through compartments and a sealed design to prevent moisture ingress, along with a fan system for cooling and a rotor frame with integrated fins for enhanced airflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the terminal box is spaced from the housing to allow fan shroud extension, then cooling air channeling is improved, but space requirements increase
Solution Approach 1:
The patent merges the terminal box mounting to the housing in a radially outward position, eliminating the need for spacing between the terminal box and housing. This allows the fan shroud to extend directly between the terminal box and housing, maintaining cooling air channeling functionality while reducing overall space requirements.
Solution Approach 2:
The terminal box is positioned in a radial direction outward from the housing rather than being spaced axially, changing the dimensional arrangement from axial spacing to radial positioning. This dimensional change enables the fan shroud to effectively channel cooling air while minimizing the overall envelope volume of the assembly.
2Device complexity
If the terminal box is positioned radially outward of the drive portion, then wiring efficiency is improved, but device complexity increases
Solution Approach 1:
The terminal box is designed with multiple mounting surfaces that can be coupled to different portions of the housing, providing universal adaptability for various mounting configurations. This multi-functionality allows the same terminal box design to accommodate different mounting options while maintaining efficient wiring paths.
Solution Approach 2:
The housing is divided into multiple portions with the terminal box positioned radially outward, creating distinct functional zones. This segmentation allows wiring to exit efficiently from the drive portion to the terminal box while maintaining structural integrity and enabling versatile mounting configurations.
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 configuration optimizes space utilization, enhances cooling efficiency, and ensures effective moisture protection while simplifying wiring, making it suitable for diverse mounting options and compact designs.
Implementation Method 1
a fan positioned within the housing and configured to provide a cooling airflow to the at least one electrical component
Implementation Method 2
a rotor frame with integrated fins for enhanced airflow
Data Source
AI summary
An electric machine assembly includes a housing having a first portion and a second portion. The electric machine assembly also includes a midframe coupled between the first and second portions such that the mid-frame and the first portion partially define a first compartment and such that the mid-frame and the second portion partially define a second compartment. A terminal box is coupled to the mid-frame and configured to house a first plurality of electrical components. A stator is positioned within the first compartment and a second plurality of electrical components positioned with the second compartment. The stator and the second plurality of electrical components are electrically coupled by a first plurality of wires extending through the mid-frame, and the first plurality of electrical components are electrically coupled to the second plurality of electrical components by a second plurality of wires extending through the second compartment and into the terminal box.