Rotor Cooling Ring and Fluid Line Layout for Uniform Heat Removal
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Solution Overview
Problem
Existing rotor cooling systems in electric drive machines, particularly in current-excited synchronous machines, are inefficient in effectively managing heat dissipation, leading to premature degradation and reduced performance.
Innovation Solution
A rotor device with a laminated rotor core and integrated cooling fluid lines that extend between pole limbs and windings, utilizing a collecting ring to collect and distribute cooling fluid, and a hollow shaft for additional cooling, along with adapters and outlet elements to ensure precise fluid flow and assembly stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling systems are used in rotors, then the structure is simpler, but the cooling efficiency is insufficient leading to rotor overheating and degradation
Solution Approach 1:
The rotor is divided into multiple segments including laminated rotor core with multiple pole limbs, and the cooling system is segmented into multiple cooling fluid lines positioned between adjacent pole limbs. This segmentation allows distributed cooling across the rotor structure, improving temperature control while maintaining manageable complexity through modular design
Solution Approach 2:
The cooling fluid lines are nested within the rotor structure, specifically positioned between adjacent pole limbs of the laminated rotor core. The collecting ring is nested on the rotor shaft, and adapters are nested within the collecting ring. This nesting approach integrates the cooling system into the existing rotor structure, improving cooling efficiency without proportionally increasing overall device complexity
2Reliability
If cooling fluid lines are added between pole limbs, then cooling efficiency improves, but manufacturing complexity increases
Solution Approach 1:
The cooling fluid lines are pre-positioned between adjacent pole limbs during the rotor assembly process, and the collecting ring is pre-assembled on the rotor shaft before final assembly. Adapters are pre-installed within the collecting ring to establish fluid connections. These preliminary actions simplify the overall manufacturing process by organizing complex components before final assembly, improving cooling effectiveness while managing manufacturing complexity
Solution Approach 2:
Adapters serve as intermediary components that connect the cooling fluid lines to the collecting ring. These adapters simplify the connection process by providing standardized interfaces between different components, making the assembly process easier while ensuring reliable cooling fluid distribution to improve cooling effectiveness
3Manufacturing precision
If the cooling fluid line extends along the entire length of the laminated rotor core, then uniform cooling is achieved, but the device complexity increases
Solution Approach 1:
The cooling system uses multiple separate cooling fluid lines, each extending between adjacent pole limbs along the length of the laminated rotor core. This segmentation into multiple shorter lines rather than one long line achieves uniform cooling distribution while simplifying manufacturing and assembly of each individual line
Solution Approach 2:
Multiple cooling fluid lines are merged into a single collecting ring that collects cooling fluid from all lines and directs it to the rotor shaft. This merging approach achieves uniform cooling along the entire rotor core length while managing complexity by consolidating multiple lines into a single collection point
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 provides extensive and uniform cooling of the rotor, preventing overheating and enhancing the operational efficiency and durability of electric machines.
Implementation Method 1
Heat can therefore be absorbed from the rotor via the cooling fluid flowing through the cooling fluid line, so as to cool the rotor
Implementation Method 2
the at least one collecting ring which is arranged on an end face of the rotor and which is designed to collect cooling fluid flowing along the end face
Data Source
AI summary
A rotor device for an electric machine, comprising: a rotor which comprises a rotor laminated core having a plurality of pole legs which project radially from a central axis of the rotor and can be wrapped around by respective rotor windings; at least one cooling fluid line, which extends in the circumferential direction between adjacent pole legs with its longitudinal extension direction parallel to the central axis of the rotor, and which is designed for a cooling fluid to flow through it for cooling of the rotor; and at least one collecting ring, which is provided on an end face of the rotor and is designed to collect cooling fluid flowing along the end face and to supply it to the at least one cooling fluid line.