Rotor Cooling Channels With Integrated Centrifugal Pump
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Solution Overview
Problem
Electric motors powered by sustainable energy sources face challenges in thermal control, leading to inefficiencies and performance issues due to heat generation during operation.
Innovation Solution
Incorporating a centrifugal pump with a channel extending axially through the rotor body, utilizing end plates with inlets and outlets to flow fluid for thermal management, which can be clocked or non-clocked for efficient fluid direction, and using laminates to form channels adjacent or between magnets for thermal control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a centrifugal pump is incorporated into the rotor to flow fluid through channels, then thermal control effectiveness is improved, but device complexity increases
Solution Approach 1:
The centrifugal pump is integrated directly into the rotor structure, merging the pumping function with the rotor body. The end plates are formed as part of the rotor assembly, eliminating the need for separate pumping components and reducing overall device complexity while maintaining effective thermal control.
Solution Approach 2:
The rotor structure serves multiple functions: it generates electromagnetic torque while simultaneously acting as a centrifugal pump to move cooling fluid. The end plates perform both structural support and fluid pumping functions, demonstrating multi-functionality that reduces the number of separate components needed.
2Temperature
If channels are formed through magnet holes in the rotor body, then thermal management efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The rotor body is constructed from stacked laminates, each containing holes that align to form continuous channels. This segmentation allows channels to be formed in individual laminates during standard manufacturing processes, then assembled together, reducing the precision requirements compared to forming continuous channels in a solid rotor.
Solution Approach 2:
Channels are formed specifically in magnet holes and adjacent areas where thermal management is most needed, rather than uniformly throughout the entire rotor. This localized approach allows for optimized thermal control in critical regions while maintaining simpler manufacturing for other areas.
3Temperature
If end plates are clocked with each other to direct fluid flow, then thermal control effectiveness is improved, but ease of assembly decreases
Solution Approach 1:
The end plates are designed with asymmetric features including offset inlet/outlet ports and non-uniform rib patterns that create a specific clocking position. This asymmetric design ensures proper fluid flow direction while providing mechanical features that guide correct assembly orientation, reducing the complexity of assembly procedures.
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 solution effectively lowers rotor temperature during challenging operational cycles, enhancing the thermal control and efficiency of electric motors by utilizing fluid flow for heat absorption and dissipation.
Implementation Method 1
a centrifugal pump to flow a fluid in a channel extending axially through the rotor body from end to end
Implementation Method 2
The fluid flow for heat absorption and dissipation
Data Source
AI summary
An electric motor comprises: a stator; and a rotor comprising: a rotor body; and a centrifugal pump to flow a fluid in a channel extending axially through the rotor body from end to end. The channel can extend through a magnet hole in the rotor body. The channel can be formed in a hole of the rotor body that does not contain a magnet. The electric motor can include first and second end plates forming the centrifugal pump. The first and second end plates can be clocked with each other. The first and second end plates can be non-clocked with each other.