Rotor Cooling via Rib-Shaped Heat Exchanger Structures
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Solution Overview
Problem
Existing rotor designs with permanent magnets face irreversible demagnetization due to excessive temperatures, leading to manufacturing complexity and weight increases from additional cooling units like fans, which are not effectively addressed in current solutions.
Innovation Solution
A rotor design featuring an annular structure with permanent magnets on the outer radius and a conical hub structure on the inner radius, connected by rib-shaped or blade-shaped structures that function as a mechanical connection and heat exchanger, utilizing the existing mechanical rotating support structure to provide effective cooling without separate cooling units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If additional fans (axial or radial) are mounted concentrically on the rotor shaft for cooling, then the cooling effect for permanent magnets is improved, but the device complexity and weight increase
Solution Approach 1:
The patent combines the mechanical support structure (ribs or blades) with the cooling function by designing these structures to simultaneously provide mechanical connection and act as heat exchangers, eliminating the need for separate fan components
Solution Approach 2:
The rib-shaped or blade-shaped structures serve multiple functions: they provide mechanical connection between the annular and hub structures, act as heat exchangers for cooling permanent magnets, and function as structural support elements, thereby reducing overall device complexity
2Temperature
If additional fans are mounted on the rotor shaft for cooling, then the cooling effect is improved, but the weight of the rotor increases
Solution Approach 1:
The cooling function is merged into the existing mechanical support structures, eliminating the need for additional fan components that would increase rotor weight
Solution Approach 2:
The rib-shaped or blade-shaped structures perform multiple functions including mechanical support and heat exchange, thereby avoiding the weight penalty of adding dedicated cooling components
3Reliability
If additional separate cooling units are used, then the cooling reliability is improved, but the manufacturing complexity increases
Solution Approach 1:
The cooling function is integrated into the existing mechanical structures, reducing the number of separate components and simplifying the manufacturing process while maintaining reliable cooling
Solution Approach 2:
The multi-functional rib-shaped or blade-shaped structures reduce manufacturing complexity by eliminating the need to manufacture and assemble separate cooling units, while still providing reliable cooling through their heat exchange capability
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 simplifies manufacturing, reduces weight, and achieves reliable cooling for permanent magnets, enhancing ventilation and production aspects while maintaining a high cooling effect, thereby preventing demagnetization and increasing power density in electrical machines.
Implementation Method 1
an existing mechanical rotating support structure is used at the same time as a rotating heat exchanger
Implementation Method 2
Targeted air cooling of the rotor counteracts impermissible heating of the rotor magnets due to eddy current losses and heat input
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a weight-optimized, meridian-accelerated rotor (1) having permanent magnets (7) that are securely supplied with a required cooling during use. The invention further relates to a corresponding electrical machine, in which the problem of demagnetization of existing permanent magnets (7) due to rotor temperatures that are too high is avoided. The rotor (1) or the rotor (1) of an affected electrical machine has an annular structure (6) on the outside radius (5) for receiving the permanent magnets (7), furthermore has a conical hub structure (10) on an inside radius (9) and finally has a plurality of at least rib-shaped or blade-shaped structures (12) between the annular structure (6) and the conical hub structure (10) in order to form a mechanical connection of the annular structure (6) and conical hub structure (10).