Rotor End-Winding Cooling Collar for Higher Power Density
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Heat generated in rotor windings of electric machines due to current flow and magnetic fields leads to temperature rise, posing a risk of damage and limiting power density.
Innovation Solution
A coil containment collar structure is integrated with the rotor assembly to facilitate efficient coolant distribution to rotor winding end turns, enhancing thermal conduction and heat removal through fluid channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If rotor windings are used in electric machines, then power generation capability is improved, but heat generation causes temperature rise that limits power density and risks damage
Solution Approach 1:
A coolant collar is introduced as an intermediary component between the rotor windings and the cooling system. The collar receives coolant through internal passages and directs it onto the rotor winding end turns, serving as a mediator that transfers heat from the windings to the coolant, thereby managing temperature rise while maintaining power generation capability
Solution Approach 2:
The patent employs a hydraulic cooling system where coolant flows through passages in the coolant collar and is directed onto the rotor windings. This hydraulic approach enables efficient heat removal through fluid circulation, allowing higher power density without excessive temperature rise
2Temperature
If cooling systems are added to remove heat from rotor, then temperature control is improved, but device complexity increases
Solution Approach 1:
The cooling function is merged with the structural support function by integrating the coolant collar with the rotor assembly. The collar serves dual purposes: providing structural support for the rotor windings and delivering coolant to them, thereby improving temperature control without proportionally increasing device complexity
Solution Approach 2:
The coolant collar is designed as a multi-functional component that simultaneously provides mechanical support for the rotor windings and serves as a coolant distribution system. This universality reduces the need for separate cooling components, thereby limiting the increase in device complexity while achieving effective temperature control
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 improves thermal conduction, allowing higher speed rotation and increased power generation efficiency without increasing generator size, while providing stability and reliability to the rotor end windings.
Implementation Method 1
improves thermal conduction, allowing higher speed rotation and increased power generation efficiency
Data Source
AI summary
A method of cooling rotor winding end turns extending from a rotor core includes coupling a collar to a rotatable shaft of the rotor core. The collar has a first wall confronting the rotor core, a second wall spaced from and opposing the first wall, a third wall between the first and second walls defining a set of apertures therethrough, a first cavity cooperatively defined by the first, second and third walls, having a first opening opposing the third wall, a fourth wall circumscribing the third wall, a second cavity cooperatively defined by the second, third and fourth walls, the second cavity defining a second opening opposing the second wall. The first and second cavities are in fluid communication, and the rotor winding end turns are receivable into the second cavity. The method includes directing a coolant into the first cavity, and delivering the coolant to the second cavity.