Rotor Lamination Cooling via Segmented Flow Channels
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Solution Overview
Problem
Conventional cooling methods struggle to effectively manage heat generated by electric machine components, particularly magnets in interior permanent magnet electric machines, leading to potential demagnetization and reduced productivity and lifespan.
Innovation Solution
The electric machine module incorporates a rotor assembly with radially extending fins and circumferential flow channels, along with axial pathways and coolant apertures, to circulate coolant and enhance heat dissipation, utilizing centrifugal force to pressurize and disperse coolant for efficient cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cooling methods are used with a jacket filled with coolant, then the cooling system is simple in structure, but the cooling effectiveness is insufficient especially for magnets
Solution Approach 1:
The rotor assembly is segmented into multiple rotor laminations with different inner radii, creating multiple circumferential flow channels. This segmentation allows coolant to flow through multiple pathways, significantly improving cooling effectiveness for magnets and other rotor components without requiring a completely redesigned cooling system.
Solution Approach 2:
The cooling channels are nested within the rotor assembly structure itself. The circumferential flow channels are formed between the rotor laminations and rotor hub, effectively utilizing the existing rotor geometry to house the cooling pathways, thus improving cooling without adding external complexity.
2Area of stationary object
If rotor laminations with different inner radii are used to create multiple flow channels, then cooling surface area increases, but manufacturing complexity increases
Solution Approach 1:
The rotor is divided into multiple discrete laminations that can be manufactured separately using standard fabrication processes. Each lamination can be produced with a specific inner radius, and the modular nature allows for easier quality control and manufacturing compared to creating complex internal channels in a single-piece rotor.
Solution Approach 2:
Instead of creating complex three-dimensional internal channels within each lamination, the invention uses the radial dimension by stacking laminations with progressively different inner radii. This dimensional approach simplifies manufacturing while achieving increased cooling surface area through the cumulative effect of multiple channels.
3Productivity
If coolant apertures and axial pathways are added to connect flow channels, then coolant circulation efficiency improves, but device complexity increases
Solution Approach 1:
The rotor hub serves multiple functions: it provides structural support for the rotor laminations and simultaneously houses the coolant apertures and axial pathways. This multi-functionality improves coolant circulation efficiency without adding separate dedicated cooling components, thereby limiting the increase in device complexity.
Solution Approach 2:
The cooling system components (apertures and pathways) are merged with the rotor assembly structure. The axial pathways are integrated into the rotor hub, combining the structural and cooling functions into a single integrated component rather than separate elements.
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 provides uniform and enhanced cooling to both the rotor and stator assemblies, effectively preventing demagnetization and extending the electric machine's lifespan and performance by increasing the cooling surface area and circulation efficiency.
Implementation Method 1
utilizing centrifugal force to pressurize and disperse coolant for efficient cooling
Implementation Method 2
Conventional cooling methods can include removing the generated heat energy by forced convection to a jacket filled with a coolant
Data Source
AI summary
Some embodiments of the invention provide an electric machine module including a rotor assembly. The rotor assembly can include a rotor hub, a first set of rotor laminations which can include a portion having a first inner radius, and a second set of rotor laminations which can include a portion having a second inner radius larger than the first inner radius. At least one circumferential flow channel defined by the first set of rotor laminations, the second set of rotor laminations, and the rotor hub can at least partially circumscribe the rotor hub.