Modular Axial Flux Stator Assembly for Flexible Liquid Cooling
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Solution Overview
Problem
The stator design of axial flux machines faces challenges in achieving high performance due to complex assembly processes, robustness issues, and limited flexibility in cooling fluid flow patterns, which affect cooling efficiency and durability.
Innovation Solution
A manufacturing method using a mould with movable spacers to compress stator elements and inject molten material, creating a skeleton with integrated cooling channels, allowing for reduced complexity, increased robustness, and adaptable cooling flow patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If liquid cooling is implemented with hollow stator housing and guiding walls, then cooling efficiency is improved, but device complexity increases
Solution Approach 1:
The patent merges the cooling channels directly into the stator housing structure, eliminating the need for separate guiding walls. The housing itself forms the cooling fluid pathways, integrating the cooling function into the structural component rather than adding separate cooling elements.
Solution Approach 2:
The stator housing serves multiple functions simultaneously: it provides structural support for the stator elements and inherently defines the cooling fluid flow paths. This multi-functionality reduces the need for additional dedicated cooling components.
2Temperature
If split cores and multiple assembly steps are used, then cooling channels can be formed, but manufacturing complexity increases
Solution Approach 1:
The patent uses a two-part mold system that segments the molding process into two stages: first forming the housing with integrated cooling channels, then adding the stator elements. This segmentation of the manufacturing process simplifies each individual step while achieving the complex integrated result.
Solution Approach 2:
The cooling channels are pre-formed as integral parts of the stator housing before the stator elements are assembled. This preliminary formation of cooling structures eliminates the need for complex post-assembly cooling channel creation.
3Reliability
If sealing measures are added to prevent cooling liquid leakage, then reliability is improved, but device complexity increases
Solution Approach 1:
The sealing function is merged into the stator elements themselves rather than being a separate component. The stator elements are designed to seal against the housing, integrating the sealing function into the primary structural elements.
4Reliability
If coils are securely anchored, then durability is improved, but manufacturing complexity increases
Solution Approach 1:
The anchoring function is merged into the housing structure through direct molding. The housing is formed with integrated anchoring features that secure the stator elements and coils during the molding process itself, eliminating the need for separate anchoring components.
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 method results in a stator with improved copper fill factor, enhanced cooling efficiency, reduced assembly costs, and increased durability by minimizing gaps and ensuring direct contact between cooling fluid and coils, while allowing for flexible design adjustments.
Implementation Method 1
applying an injection moulding process, such that the stator elements are overmoulded, thereby obtaining the structure
Implementation Method 2
applying an injection moulding process, such that the stator elements are overmoulded
Implementation Method 3
a cooling liquid is circulated inside a hollow stator housing, thereby directly submerging the coils in the cooling liquid
Implementation Method 4
the cooling fluid is forced against the respective coils, thereby allowing for an efficient heat evacuation
Implementation Method 5
radially compressing the stator elements, thereby reducing gaps between the coils and the elongated portion of respective spacers
Data Source
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AI summary
Method for manufacturing a stator of an axial flux machine, comprising: - providing a ring-shaped intermediate structure (1000), comprising: o stator elements (300) fixed in a skeleton; o radial channels (1301), present between any pair of adjacent stator elements (300); - providing a flow distributor (1500, 1900), the flow distributor (1500, 1900) and the intermediate structure (1000) being provided as separate parts; - mounting the flow distributor (1500, 1900) on the inner (1006) or outer surface (1007) of the intermediate structure (1000), wherein: o the flow distributor (1500, 1900) comprises a circumferential wall (1501, 1901), the circumferential wall comprising one or more recesses (1502, 1503, 1902), thereby defining at least one circumferential channel in fluid communication with one or more of the radial channels (1301), and o the flow distributor (1500, 1900) is adapted to define a flow pattern when circulating a cooling fluid between the stator elements (300).