Rotor Winding End-Turn Cooling With Radial Coolant Conduits
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Solution Overview
Problem
Existing electric machine cooling systems, particularly in aircraft applications, face challenges in efficiently dissipating heat from rotor windings, leading to reduced efficiency and reliability due to inadequate thermal management.
Innovation Solution
A method and apparatus that utilize a liquid cooling system with strategically designed coolant conduits and end supports to direct coolant flow radially through the rotor winding end turns, enhancing thermal conduction and heat removal by redirecting coolant flow to effectively cool both rotor and stator windings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling systems are used for rotor windings, then the structure is simpler, but thermal management efficiency is inadequate
Solution Approach 1:
The coolant conduits are nested within the rotor assembly structure, with end supports positioned at axial ends that direct coolant flow through the rotor windings. The cooling system is integrated into the existing rotor architecture rather than being a separate external system, allowing efficient thermal management while maintaining structural compactness
Solution Approach 2:
Coolant serves as an intermediary substance that transfers heat from the rotor windings to the external cooling system. The end supports act as intermediaries to direct and channel the coolant flow radially through the rotor winding end turns, ensuring effective heat removal without requiring complex internal cooling channels within the windings themselves
2Power
If higher speed rotation is achieved, then power generation efficiency increases, but thermal losses increase
Solution Approach 1:
The cooling system enables continuous operation at high speeds by continuously removing heat as it is generated. The coolant flows continuously through the rotor windings, maintaining thermal management during sustained high-power operation, thus allowing the rotor to maintain higher speeds without thermal degradation
Solution Approach 2:
The system changes the thermal parameters of the rotor windings by actively cooling them, allowing the rotor to operate at higher speeds and power levels. The coolant temperature and flow rate can be adjusted to optimize thermal management under different operating conditions, enabling sustained high-performance operation
3Temperature
If generator size is increased to improve cooling, then thermal management improves, but device dimensions increase
Solution Approach 1:
The cooling system applies cooling specifically where it is most needed - at the rotor winding end turns and axial ends where heat generation is concentrated. The end supports are positioned strategically to direct coolant flow precisely to the hottest regions, providing localized efficient cooling without requiring a comprehensive increase in overall generator size
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 approach significantly improves thermal conduction, allowing for higher speed rotation and increased power generation efficiency without increasing generator size, while also enhancing reliability and reducing thermal losses.
Implementation Method 1
enhancing thermal conduction and heat removal by redirecting coolant flow to effectively cool both rotor and stator windings
Data Source
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AI summary
A method (200) and apparatus for a rotor assembly (96). The rotor assembly (96) includes a rotor core (100) having a rotatable shaft (40) and defining at least one rotor post (108), a winding (110) wound around the post (108) that defines an end turn (102, 104, 112), and at least one coolant conduit (150, 158) defined in part by an end support (120) and in a thermally conductive relationship with a portion of the winding (110).