Rotor End Support Cooling Structure for High-Speed Windings
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Solution Overview
Problem
Existing electric machine rotors face challenges in effectively supporting and cooling their axial ends, particularly in high-speed applications where thermal management and mechanical stability are critical, leading to issues like overheating and mechanical failure.
Innovation Solution
The design incorporates a cradle-like end support structure with radially-extending coolant openings and channels that direct coolant flow to efficiently cool the rotor windings, enhancing thermal conduction and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional end support structures are used for rotor axial ends, then mechanical support is provided, but thermal management is insufficient leading to overheating
Solution Approach 1:
The patent combines the mechanical support function and thermal management function into a single integrated end support structure. The cradle-like structure provides both mechanical support for the rotor axial ends and incorporates coolant flow paths for thermal management, eliminating the need for separate cooling systems and achieving both mechanical stability and effective heat dissipation simultaneously
Solution Approach 2:
The end support structure acts as an intermediary between the rotor windings and the coolant system. It incorporates coolant flow paths that direct cooling fluid across the axial ends of the rotor windings, facilitating efficient heat transfer from the windings to the coolant while maintaining mechanical support
2Temperature
If cooling systems are added to improve thermal management, then overheating is prevented, but device complexity increases
Solution Approach 1:
The cooling system is merged with the mechanical end support structure rather than being added as a separate system. The end support structure itself incorporates the coolant flow paths and cooling surfaces, eliminating additional components and reducing overall device complexity while achieving effective thermal management
Solution Approach 2:
The end support structure is designed to perform multiple functions simultaneously: providing mechanical support for the rotor axial ends, directing coolant flow for thermal management, and facilitating heat transfer. This multi-functionality eliminates the need for separate dedicated cooling components, reducing device complexity
3Productivity
If rotor speed is increased to improve power generation, then efficiency increases, but thermal management becomes insufficient
Solution Approach 1:
The coolant flow paths are designed to provide continuous cooling across the axial ends of the rotor windings during rotation. The cradle-like structure with integrated coolant channels ensures uninterrupted thermal management, allowing the rotor to operate at higher speeds for improved power generation efficiency without thermal limitations
Solution Approach 2:
The mechanical support and thermal management functions are merged into a single integrated structure that rotates with the rotor. This ensures that thermal management keeps pace with the increased rotational speed, maintaining effective heat dissipation even at higher operating speeds for improved productivity
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 solution improves thermal dissipation, preventing overheating and mechanical failures, allowing for higher speed rotations and increased power generation efficiency without increasing generator size, while maintaining reliability and stability.
Implementation Method 1
radially-extending coolant openings and channels that direct coolant flow to efficiently cool the rotor windings
Implementation Method 2
enhancing thermal conduction and mechanical stability
Data Source
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AI summary
A rotor for an electric machine includes a core (100) having circumferentially-spaced, axially-extending posts (102), and defining an axial passage, a winding (104) carried by each of the posts (102) and comprising an electrically-conductive wire repeatedly wound around the post (102) such that a portion of the winding (104) extends axially beyond the post (102) to define an overhang with upper and lower surfaces connected by an end, and a hollow shaft (40) defining a rotor inner surface and a rotor outer surface.