Rotor Cooling Channels for Low-Pumping Stator Cooling
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Solution Overview
Problem
Existing electric motor designs face inefficiencies due to high pumping capacity requirements for coolant distribution, which increases energy consumption and reduces longevity, as heat generated by the motor is not effectively managed, especially in separately excited synchronous machines.
Innovation Solution
The internal rotor design incorporates a rotor body with rotor teeth and displacement bodies featuring cooling channels that direct coolant from a first reinforcement ring inlet to a second reinforcement ring outlet, utilizing centrifugal force to distribute coolant radially onto the stator, reducing pumping capacity and enhancing cooling efficiency without additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a pump is used to provide coolant volume flow to cool both stator and rotor, then cooling effectiveness is improved, but energy consumption and system losses increase
Solution Approach 1:
The rotor itself serves as the coolant distribution mechanism through its rotating mass and centrifugal force, eliminating the need for an external pump. The rotor structure includes coolant channels and outlets that automatically distribute coolant to both the rotor and stator during rotation, making the system self-sufficient and reducing energy consumption.
Solution Approach 2:
The mechanical pump system is replaced by utilizing the natural centrifugal force generated by the rotating rotor. This substitution eliminates the mechanical pump component and its associated energy losses, while still achieving effective coolant distribution through the rotor's rotational motion.
2Quantity of substance
If high pumping capacity is used to distribute coolant, then coolant distribution is improved, but overall system efficiency decreases
Solution Approach 1:
The rotor structure automatically distributes coolant through its own rotation, with coolant channels and outlets positioned to utilize centrifugal force for even distribution across both rotor and stator surfaces, achieving effective coolant distribution without external pumping capacity.
Solution Approach 2:
The system changes the operational parameters of coolant distribution by utilizing rotational speed and centrifugal force instead of pump pressure. The coolant flow rate and distribution pattern are controlled by the rotor's rotational parameters rather than mechanical pumping capacity, improving overall system efficiency.
3Temperature
If coolant is directed through both stator and rotor, then heat management is improved, but device complexity increases
Solution Approach 1:
The cooling functions for both the rotor and stator are merged into a single integrated system. The rotor structure incorporates coolant channels and outlets that simultaneously cool the rotor itself and distribute coolant to the stator, eliminating the need for separate cooling systems and reducing overall device complexity.
Solution Approach 2:
The rotor serves multiple functions: it generates the magnetic field, rotates to produce mechanical output, and acts as the coolant distribution mechanism. This multi-functionality reduces the number of separate components needed, particularly eliminating the external pump, thereby reducing device complexity while maintaining effective heat management.
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 improves the cooling capacity of the stator, reduces the pumping capacity of the coolant pump, and minimizes energy losses, thereby enhancing the overall efficiency and longevity of the electric motor.
Implementation Method 1
The at least one coolant outlet is arranged and configured such that the escaping coolant experiences a movement via a component in a radial direction of the rotor
Implementation Method 2
a coolant, in particular a cooling oil, is used, which is directed through both the stator and the rotor and absorbs the heat generated in that location
Data Source
AI summary
An internal rotor for an electric motor, which is designed to rotate in a stator due to a magnetic field generated in the stator to drive a rotor shaft arranged on a rotor axis, the internal rotor including a rotor body having rotor teeth, rotor windings which are arranged on the rotor teeth, a displacement body is arranged in a circumferential direction of the rotor between adjacent rotor teeth. The at least one displacement body includes a cooling channel configured to enable transport of a coolant between a first reinforcement ring including a coolant inlet and a second reinforcement ring including a coolant outlet. The first reinforcement ring and the second reinforcement ring are arranged in an axial direction on opposite end faces of the rotor. The coolant outlet is configured such that the escaping coolant experiences a movement via a component in a radial direction of the rotor.