Rotating Electrical Machine Coolant Path via Stator Core Gap
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Solution Overview
Problem
Existing rotating electrical machines face challenges in maintaining effective cooling while ensuring insulation, particularly in compact, high-output designs where the centralized winding type stator structure limits coolant contact with hot spots and degrades cooling efficiency.
Innovation Solution
A rotating electrical machine design featuring a stator with a distribution unit supported by a resin holder, where a gap between the stator core and the distribution unit forms a coolant path, and a bobbin with flange sections and grooves to increase coolant contact with the stator coil, enhancing both cooling and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a centralized winding type stator structure is adopted to achieve compact and high-output design, then the power density is improved, but the cooling efficiency deteriorates because the coolant cannot effectively contact the hot spots inside the coil
Solution Approach 1:
The patent divides the cooling approach into two distinct paths: one for the coil end surface (via coolant supply plate) and another for the inside of the coil (via cooling groove in bobbin). This segmentation allows each path to optimize its cooling function independently, with the cooling groove specifically targeting the hot spots that were previously inaccessible
Solution Approach 2:
The patent introduces a new cooling dimension by forming a cooling groove within the bobbin structure itself, creating an internal coolant passage that extends the cooling reach from the external coil surface into the internal coil region. This dimensional extension allows coolant to access previously unreachable hot spots
2Temperature
If a cooling groove is provided in the bobbin to cool the inside of the coil, then the cooling efficiency is improved, but the insulation between the coil and stator core deteriorates
Solution Approach 1:
The patent introduces resin blocks as intermediary elements that fill the gaps between the cooling groove and the stator core. These resin blocks serve as both thermal management components (maintaining the cooling groove structure) and electrical insulators, preventing direct contact between the conductive coolant path and the stator core
Solution Approach 2:
The patent uses resin blocks, which are inexpensive and easy to manufacture, to solve the insulation problem. These blocks are positioned strategically to provide electrical isolation without adding significant complexity or cost to the overall system
3Stability of the object's composition
If brims are provided on the bobbin to prevent coil winding collapse, then the coil shape stability is improved, but the cooling efficiency deteriorates because the brims reduce the coolant contact surface area
Solution Approach 1:
The patent separates the functions of coil support and cooling by using different structural elements: the bobbin flanges provide mechanical support and shape stability, while the cooling groove provides thermal management. This functional segmentation eliminates the conflict between support structure and cooling efficiency
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 design effectively increases the cooling surface area and maintains insulation, allowing for improved heat dissipation and efficient operation in compact, high-output rotating electrical machines.
Implementation Method 1
the rotating electrical machine is cooled by coolant
Implementation Method 2
the coolant is moved to trace each coil. This increases the heat dissipating effect
Data Source
AI summary
A rotating electrical machine includes: a stator that including a stator core and a teeth section, with a stator coil wound at the teeth section; a rotor arranged via a clearance at an inner periphery side of the stator and supported in a freely rotating manner; and a distribution unit supported by a resin holder, and including a conductor connected to the stator coil. The rotating electrical machine is cooled by coolant. The stator coil includes a coil end section projecting from an end of the stator in an axial direction. A gap is formed between an end of the stator core and a lower surface of the distribution unit by mounting the distribution unit on an upper part of the coil end section. The gap constitutes a path for the coolant.