Integrated Rotary Machine Wiring and Cooling Flow Path Layout
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Solution Overview
Problem
Existing rotary electric machines face challenges in cooling the terminal block and refrigerant flow path, leading to increased size and inefficiencies due to separate configurations that do not effectively manage heat generation and electrical resistance.
Innovation Solution
An integrated structure is developed where the refrigerant flow paths and electric power wires are positioned in proximity from different directions, with a molded structure using insulating resin and higher thermal conductivity fillers, allowing for compact design and efficient heat exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the terminal block and refrigerant flow path are configured separately and arranged adjacent to each other, then the cooling performance can be provided, but the overall size is increased
Solution Approach 1:
The patent integrates the terminal block and refrigerant flow path into a single integrated structure portion. The flow paths are formed inside the terminal block body, merging the electrical connection function and refrigerant circulation function into one component. This eliminates the need for separate arrangement of adjacent components, thereby reducing overall size while maintaining cooling performance.
Solution Approach 2:
The terminal block is designed to perform multiple functions simultaneously: electrical connection (terminal block function), refrigerant flow guidance (flow path function), and heat dissipation (cooling function). The integrated structure portion serves as both an electrical connector and a refrigerant channel,实现 multi-functionality that reduces the number of components and overall size.
2Reliability
If the electric power wire is made with larger transverse cross-sectional area to handle large current, then the electrical resistance is reduced, but the weight and size are increased
Solution Approach 1:
The refrigerant acts as an intermediary cooling medium that directly contacts the electric power wire through the integrated structure. The refrigerant absorbs heat from the wire, providing efficient heat dissipation that allows the wire to operate at higher current densities without excessive temperature rise. This intermediary cooling mechanism enables the use of thinner wires with lower weight while maintaining reliable electrical performance.
3Temperature
If the terminal block and refrigerant flow path are arranged to cool the heat generation portions, then the temperature increase is suppressed, but the arrangement complexity and interference risk are increased
Solution Approach 1:
The flow paths are integrated inside the terminal block structure, merging the cooling function into the electrical connection component. The refrigerant flow paths are formed within the body of the terminal block, eliminating the need for complex external arrangement of separate cooling components. This integrated design simplifies the overall structure and reduces arrangement complexity while effectively cooling heat generation portions.
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 achieves excellent cooling performance while reducing the size and weight of the rotary electric machine, maintaining stable electrical connections and preventing interference, thus enhancing overall efficiency.
Implementation Method 1
the first flow path and the second flow path are arranged inside the integrated structure portion in a manner to be in proximity to the first wire from different directions
Implementation Method 2
cool the rotary electric machine by circulation of a refrigerant
Implementation Method 3
The integrated structure portion may have a molded structure that is made of an insulating resin
Implementation Method 4
The molded structure may include an insulating filler that has higher thermal conductivity than the insulating resin
Data Source
Figure 1
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AI summary
To realize an excellent cooling performance and compactness, two refrigerant flow paths (100, 110), through each of which a refrigerant flows, and an electric power wire (80), through which a current to energize a rotary electric machine (2) flows, are provided. The two refrigerant flow paths (100, 110) are arranged inside an integrated structure portion (50) in a manner to be in proximity to the electric power wire (80) from different directions.