Electrical Rotor Machine Cooling via Radial Axial Channels
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Solution Overview
Problem
Conventional cooling methods for electrical rotor machines are inadequate in managing heat generated during starting or dynamic braking, leading to overheating issues due to insufficient heat flux paths and increased complexity and cost, with pressure losses reducing efficiency.
Innovation Solution
The electrical rotor machine incorporates a cooling system with radial and axial coolant paths, eliminating assembly supports in radial channels to minimize pressure losses and enhance efficiency, using a housing with locating features that do not obstruct coolant flow, and employing a novel manufacturing method to position and support subcores without conventional supports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional cooling methods are used with assembly supports in radial channels, then structural support is provided, but pressure losses increase and efficiency decreases
Solution Approach 1:
The patent removes assembly supports from the radial coolant channels, extracting the obstructing elements that caused pressure losses. The subcores are positioned using locating features on the housing instead, eliminating the supports that blocked coolant flow and reduced efficiency.
Solution Approach 2:
The patent introduces locating features on the housing as an intermediary mechanism to position subcores without requiring assembly supports in the coolant channels. This mediator enables both structural positioning and unobstructed coolant flow.
2Temperature
If conventional cooling methods with external fans are used, then cooling is achieved, but heat flow path is insufficient and overheating occurs
Solution Approach 1:
The patent transitions from external cooling (one-dimensional surface cooling) to internal cooling by routing coolant through radial and axial channels within the machine structure. This multi-dimensional approach creates extended heat flow paths through the core and housing, significantly improving heat dissipation capacity.
Solution Approach 2:
The patent employs a hydraulic cooling system by flowing coolant through defined radial and axial channels within the machine. This liquid cooling approach through internal passages provides superior heat transfer compared to external air cooling, effectively managing heat flux from the windings and core.
3Temperature
If cooling flow paths are formed through the machine, then cooling is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines the structural housing with the cooling system by integrating radial and axial coolant channels directly into the housing and core assembly. This merging of structural and thermal management functions eliminates the need for separate cooling components, simplifying manufacturing while maintaining effective cooling.
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 effectively reduces pressure losses and increases the power efficiency of the machine by allowing unobstructed coolant flow, improving heat transfer and reducing the complexity and cost of manufacturing.
Implementation Method 1
Cooling of electrical machines often involves transferring the heat generated by the machine to a cooling medium, such as air
Implementation Method 2
this heat flow path is not adequate to prevent overheating because the heat flux generated within the machine is too great to be removed via conduction through the cross-sectional area of the available heat flow path
Data Source
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AI summary
An electrical rotor machine and a method of manufacturing the same are disclosed. According to at least one aspect of the present disclosure, the method includes forming a stator core from two or more subcores and inserting the separate subcores into a housing before windings are wound through and around the subcores to form a stator. In such embodiments, the housing includes a locating feature structured to position and support the subcores such that a flow channel is formed between the subcores. The locating feature enables both radial and axial cooling of the stator core while reducing pressure losses within the cooling flow path.