Overmolded Stator Assembly for Hermetic Cooling Gas Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Rotary electrical machines used in aggressive and explosive gas environments, such as those involving hydrogen, hydrocarbons, carbon dioxide, steam, and liquid water, suffer from degradation due to incompatible cooling methods and structural incompatibilities, leading to reduced lifespan.
Innovation Solution
A stator assembly with a sealing and cooling element overmolded onto the stator, made of polymeric materials like epoxy resin or PEEK resin, combined with amagnetic flanges and protective sleeves for the rotor and stator, enhances sealing and cooling while maintaining magnetic integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If processed gas (H2, flare gas) is used for cooling the electrical machine, then cooling effectiveness is improved, but the machine structure degrades due to aggressive and corrosive gas
Solution Approach 1:
The electrical machine is divided into separate zones: a first hermetic chamber containing the stator and a second hermetic chamber containing the rotor, separated by a partition. This segmentation allows different atmospheric conditions in each chamber, protecting sensitive components from aggressive cooling gas while maintaining effective cooling.
Solution Approach 2:
A hermetic seal is introduced as an intermediary element between the stator and rotor chambers. This seal prevents direct contact between the aggressive processed cooling gas and the electrical machine components, mediating the interaction between the cooling system and the machine structure.
2Temperature
If conventional cooling means (water-glycol mixture, processed gas) are used, then cooling performance is improved, but incompatibility with aggressive gas leads to early deterioration
Solution Approach 1:
The stator is housed in a first hermetic chamber that creates a protected, inert environment for the electrical components. This hermetic enclosure isolates the stator from the aggressive processed cooling gas, preventing corrosion and degradation while allowing the cooling gas to effectively cool the rotor in the second chamber.
3Temperature
If the stator is directly exposed to processed gas for cooling, then internal part cooling is improved, but the aggressive gas causes degradation of electrical machine parts
Solution Approach 1:
The electrical machine is divided into separate zones: a first hermetic chamber containing the stator and a second hermetic chamber containing the rotor, separated by a partition. This segmentation allows different atmospheric conditions in each chamber, protecting sensitive components from aggressive cooling gas while maintaining effective cooling.
Solution Approach 2:
The stator is housed in a first hermetic chamber that creates a protected, inert environment for the electrical components. This hermetic enclosure isolates the stator from the aggressive processed cooling gas, preventing corrosion and degradation while allowing the cooling gas to effectively cool the rotor in the second chamber.
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 effective protection against aggressive and explosive gases, ensuring prolonged machine life and efficient cooling, thereby preventing corrosion and explosion risks.
Implementation Method 1
a sealing and cooling element overmolded onto the stator
Implementation Method 2
the overmolded element is made of a polymeric material with a polymerization temperature close to the operating temperature of rotary electrical machine
Data Source
AI summary
A stator assembly for rotary electrical machine including a stator provided with windings. A sealing and cooling element is overmolded onto the stator.