Rotor End Turn Support and Cooling for High-Speed Windings
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Solution Overview
Problem
Conventional electric machines, such as generators, face challenges at high rotational speeds due to centrifugal and axial forces that can weaken or break rotor windings, and discontinuous end turn support structures lead to windage losses, reducing efficiency.
Innovation Solution
The proposed solution involves an improved rotor winding end turn support structure that includes a set of collars, a coupling disc, a support disc, and a coolant distribution ring, which collectively provide enhanced retention, balance, and cooling of the rotor windings, reducing windage losses and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If rotor windings are operated at high rotational speeds, then power output increases, but centrifugal and axial forces weaken or break rotor windings
Solution Approach 1:
The rotor winding end turn support structure is segmented into multiple collars (first collar, second collar) and a support disc, with each component providing localized support at different positions along the rotor winding length. This segmentation allows distributed force management, reducing stress concentration on any single winding section while maintaining overall structural integrity at high rotational speeds
Solution Approach 2:
The invention merges multiple functions into a unified support structure: the collars and support disc simultaneously provide mechanical retention, dynamic balancing, and windage loss reduction. The integrated structure combines the strengths of discrete components while eliminating gaps that would cause windage losses, allowing the rotor to operate at higher speeds without compromising winding strength
2Ease of manufacture
If discontinuous end turn support structures are used, then manufacturing is simpler, but windage losses increase reducing efficiency
Solution Approach 1:
The first collar, second collar, and support disc are positioned adjacent to each other with no gaps, merging previously discontinuous support elements into a continuous structure. This eliminates the air gaps that cause windage losses while maintaining manufacturing simplicity through modular assembly of standard components
Solution Approach 2:
The continuous support structure provided by the adjacently positioned collars and support disc ensures uninterrupted support along the rotor winding end turns. This continuity eliminates the periodic disruptions caused by gaps in discontinuous structures, reducing turbulent air flow and windage losses while maintaining ease of manufacture through simple component assembly
3Temperature
If conventional cooling methods are used, then thermal management is provided, but thermal conduction is insufficient for high power density applications
Solution Approach 1:
The support disc acts as a thermal intermediary between the rotor windings and the external cooling system. It provides a large thermal conduction pathway that efficiently transfers heat from the rotor winding end turns to the cooling fluid, enabling effective thermal management in high power density applications where conventional cooling methods are insufficient
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 effectively enhances the dynamic balance of the rotor core, reduces deflection and relative movement of the rotor winding end turns, and improves thermal conduction for better cooling, leading to increased power density and efficiency of the electric machine.
Implementation Method 1
improves thermal conduction for better cooling
Data Source
AI summary
A rotor assembly includes a rotor core having a rotatable shaft and defining at least one rotor post, and a winding wound around the post that defines a set of rotor winding end turns. A support assembly for the rotor winding end turns is rotatably coupled to the rotatable shaft and defines a cavity in fluid communication with a fluid coolant flow. The rotor winding end turns extend into the cavity.