Motor Stator Mist Cooling for Debris Blockage

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Solution Overview

Problem

Air cooling systems for motors are prone to foreign object debris blockages, leading to reduced cooling efficiency and potential overheating, with no automated debris removal mechanism, resulting in motor failure.

Innovation Solution

A mist cooling system that integrates a casing with a liquid inlet and perforations to generate a water-air mist, enhancing heat transfer by using a two-phase spray and water-air mist generator ring fitted on the motor housing, which operates as a redundant cooling system to air cooling, effectively reducing motor temperature through latent heat evaporation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If air cooling systems are used for motor cooling, then the cooling system is simple and easy to implement, but foreign object debris can enter and block cooling channels, reducing cooling efficiency and causing motor overheating

Engineering Contradiction:

Improvecooling reliabilityVSAvoidforeign object debris blockage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

A liquid coolant system is introduced as an intermediary between the motor and the external environment. The coolant circulates through closed-loop channels, providing thermal coupling while preventing direct exposure to foreign objects. This mediator approach allows heat transfer without the cooling medium being susceptible to debris contamination.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the mechanical air cooling system with a liquid-based thermal management system. This substitution eliminates the vulnerability to foreign object debris that plagues air cooling, as the liquid coolant flows through enclosed channels that are not exposed to the external environment where debris exists.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Device complexity

If traditional air cooling systems are used, then the system structure is simple, but there is no automated debris removal mechanism, requiring manual service intervention

Engineering Contradiction:

Improvecooling system structureVSAvoiddebris removal automation

Core Design Contradiction:

Device complexityVSExtent of automation

Solution Approach 1:

The liquid coolant system performs self-cleaning functions by continuously circulating and flushing the cooling channels. The flowing coolant automatically removes debris and contaminants from the cooling passages, providing self-maintenance capabilities without requiring external intervention or complex automated mechanisms.

Inventive Principle:

Principle #25Self-service

3Reliability

If a liquid coolant system is implemented, then foreign object debris blockage is prevented, but the system complexity increases with additional components

Engineering Contradiction:

Improvecooling reliabilityVSAvoidcooling system structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent integrates the coolant circulation system with the motor structure itself, merging the cooling function into the existing motor housing and components. By combining the cooling channels with the motor housing and using the motor's own structure as part of the cooling system, the overall complexity is reduced despite adding liquid cooling functionality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The motor housing and internal structures are designed to serve multiple functions: structural support, magnetic flux path, and coolant flow channel. This multi-functionality eliminates the need for separate dedicated cooling components, reducing overall system complexity while maintaining reliable liquid cooling.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 mist cooling system significantly reduces motor temperature by up to 13 degrees Celsius, providing enhanced cooling and preventing overheating even with foreign object debris blockages, thereby increasing motor reliability and lifespan.

Implementation Method 1

latent heat evaporation

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 2

latent heat of evaporation results in additional heat transfer from the heated housing

Methodology Applied

Scientific EffectLatent heat: Latent Heat

Implementation Method 3

heat transfer on a motor housing is enhanced by an air/water mist cooling

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 4

phase change from water to vapor

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentEP3035505B1Motor stator cooling with dual coolant two-phase heat exchanger

Publication Date: 2019.03.06 HAMILTON SUNDSTRAND CORP

Figure 1A~1B
Figure 2

AI summary

A mist cooling system (100) that includes a casing (101) and a liquid inlet (103). The casing (101) is configured to receive a liquid flow (102) from a source through the liquid inlet (103) and then provide the liquid flow as a mist (104) to a housing of a motor so as to increase a cooling of the motor and prevent any failure of the motor due to overheating.