Rotary Electric Machine Terminal Block With Integrated Cooling Paths
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Solution Overview
Problem
Existing rotary electric machines face challenges in downsizing while maintaining effective cooling performance due to the restricted arrangement of metal conductors and refrigerant flow paths, leading to increased electrical resistance and heat generation.
Innovation Solution
The integration of a stator cooling flow path with a refrigerant flow path and a metal conductor that is bent to extend parallel to the current flow direction, with a bent portion to increase the transverse cross-sectional area, ensuring adequate conductive area without increasing the plate width, and incorporating a compact terminal block structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the terminal block and refrigerant flow path are integrated to downsize the overall structure, then the overall size is reduced, but the arrangement of the metal conductor and refrigerant flow path is restricted by positional relationships with the stator
Solution Approach 1:
The terminal block and refrigerant flow path are integrated into a single component structure. The metal conductor is formed as an integral part of the terminal block, which also incorporates the refrigerant flow path channels, eliminating the need for separate components and reducing overall size.
Solution Approach 2:
The metal conductor is bent into a three-dimensional configuration that extends in the energization direction while maintaining integration with the refrigerant flow path. This spatial arrangement allows both the conductor and flow path to coexist within the integrated structure without interfering with stator positioning.
2Volume of moving object
If the plate width of the metal conductor is reduced to make the terminal block compact, then the size is reduced, but the conductive area is reduced and electrical resistance is increased
Solution Approach 1:
The metal conductor is bent into a three-dimensional shape that extends in the energization direction (length dimension) rather than increasing plate width. This allows the conductive area to be maintained or increased through extended length while keeping the terminal block compact in the width dimension.
Solution Approach 2:
The metal conductor incorporates bent portions with curved geometries that allow it to navigate around the refrigerant flow path while maintaining adequate conductive cross-sectional area. The curved configuration optimizes space utilization without compromising electrical conductivity.
3Temperature
If the metal conductor and refrigerant flow path are arranged adjacently to improve cooling, then cooling performance is improved, but interference between the two components occurs
Solution Approach 1:
The metal conductor and refrigerant flow path are merged into a single integrated component where their relative positions are fixed by the manufacturing process. This eliminates interference issues while maintaining close proximity for effective heat exchange between the conductor and refrigerant.
Solution Approach 2:
The relative positions of the metal conductor and refrigerant flow path are predetermined during the integrated manufacturing process. This preliminary positioning ensures optimal cooling performance while preventing interference, as the arrangement is established before installation and cannot shift during operation.
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 design achieves excellent cooling performance and compact size by stabilizing the positional relationship between the metal conductor and refrigerant flow path, preventing interference, and facilitating heat exchange, thereby reducing electrical resistance and heat generation.
Implementation Method 1
the housing, which accommodates the stator that generates heat by energization during operation, is provided with the stator cooling flow path, through which the refrigerant circulates
Implementation Method 2
through which the refrigerant circulates
Implementation Method 3
the first conductive portion is provided with a bent portion that is bent along the refrigerant flow path when viewed in the energization direction, and thereby increases a transverse cross-sectional area
Implementation Method 4
constitutes a terminal block that includes a metal conductor for relaying electrical connection of these
Implementation Method 5
the positional relationship between the metal conductor and the refrigerant flow path is unchanged even when some impact is applied
Data Source
Figure 1
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AI summary
To achieve an excellent cooling performance and compactness, the disclosed technique includes: a stator cooling flow path (34) provided in a housing (30) to extend along a periphery of a stator (31); and an integrated structure portion (50) that is interposed between the stator (31) and an electrical power unit (7), and constitutes a terminal block that includes a metal conductor (80) for relaying electrical connection of these, and in which the stator cooling flow path (34) is integrally provided with refrigerant flow paths (100, 110) that relay circulation of a refrigerant. The metal conductor (80) has a first conductive portion (81) that is arranged substantially parallel to the refrigerant flow paths (100, 110) and extends in an energization direction in which a current flows. The first conductive portion (81) is provided with a bent portion (85).