Electric Motor Rotor Cooling Channels Near Permanent Magnets
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Solution Overview
Problem
Existing electric motor rotors lack efficient cooling systems that effectively dissipate heat generated by magnetic field-inducing components such as permanent magnets or windings, leading to potential operational issues.
Innovation Solution
The rotor incorporates cooling channels adjacent to magnetic field-inducing components, with a manifold and drainage system, allowing for efficient coolant perfusion and drainage, and is manufactured using a reshaping process to form these channels between individual blades.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a central cooling channel is used in the rotor, then the cooling system is simple to manufacture, but the cooling efficiency is insufficient because the cooling channels are not adjacent to the magnetic field-inducing components
Solution Approach 1:
The rotor is divided into multiple individual blades that are joined together, with cooling channels formed between these blades. This segmentation allows the cooling channels to be positioned adjacent to the magnetic field-inducing components while maintaining manufacturing simplicity through modular assembly.
Solution Approach 2:
Cooling channels are specifically positioned in the regions adjacent to the magnetic field-inducing components (permanent magnets or windings) where heat generation is highest. This local placement of cooling functionality ensures efficient heat dissipation from the critical areas without requiring complex overall system redesign.
2Temperature
If cooling channels are arranged adjacent to magnetic field-inducing components, then cooling efficiency is improved, but the device complexity increases due to additional manifolds and drainage channels
Solution Approach 1:
Multiple cooling channels are merged into a unified cooling system with common supply and drainage manifolds. The drainage channels are integrated into the rotor shaft structure, combining multiple functions (cooling, structural support, drainage) into a single integrated system that reduces overall complexity despite the increased number of cooling channels.
Solution Approach 2:
The rotor shaft serves multiple functions: it provides structural support for the rotor blades, acts as a common drainage channel for all cooling channels, and provides mechanical connection to the rotor assembly. This multi-functionality reduces the need for separate dedicated components, thereby managing complexity.
3Temperature
If multiple cooling channels are formed between rotor shaft receptacle opening and rotor sheath, then cooling coverage is enhanced, but manufacturing precision requirements increase
Solution Approach 1:
The cooling channels are formed as passage openings in the individual rotor blades before the blades are assembled into the complete rotor. This preliminary formation of cooling channels in separate, manageable components allows for easier quality control and reduces the precision requirements compared to forming all channels in the assembled rotor structure.
Solution Approach 2:
A plastic compound is used as an intermediary material during the assembly process to seal and connect the passage openings in adjacent rotor blades, forming the complete cooling channels. This intermediary material facilitates the creation of precise cooling pathways without requiring extremely tight tolerances in the blade manufacturing itself.
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 enhances cooling efficiency by directly cooling the magnetic field-inducing components, ensuring safe and trouble-free operation of the electric motor.
Implementation Method 1
The cooling channels can be arranged in the immediate vicinity of the magnetic field-inducing components so that an effective cooling can take place
Implementation Method 2
a cooling medium... can be dissipated to ensure a safe and trouble-free operation of the electric motor
Data Source
AI summary
A rotor (1) of an electric motor (20) has a rotor body (21) with a rotor shaft receptacle opening (22) for receiving a rotor shaft (3), and a rotor sheath (23) is on the rotor body (21) outward of the rotor shaft receptacle opening (22). Magnetic field-inducing components (10) are arranged in the rotor body (21). The rotor body (21) further has first and second end faces (14, 18) facing away from one another. The rotor (1) also includes a cooling device (4) with a supply channel (5), a drainage channel (6) and cooling channels (11) formed in the rotor body (21) between the rotor shaft receptacle opening (22) and the rotor sheath (23). The cooling channels (11) are arranged adjacent to the magnetic field-inducing components (10). A method for manufacturing a rotor having a cooling device also is provided.