Rotor Magnetic Mass With Slot Cooling Separators
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Solution Overview
Problem
Existing cooling schemes for rotary electric machines are complex and time-consuming, involving the creation of bores in rotor conductors, stacking conductors to define cooling paths, and assembling space blocks between end windings, which complicates the cooling of rotor windings.
Innovation Solution
A magnetic mass with axial slots closed by wedges, each housing a radial separator that channels cooling fluid to cool concentric windings, with extraction and supply ducts configured to efficiently direct cooling fluid and prevent movement of windings and separators, using electric insulating materials for the separator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling medium flows through bores in rotor conductors or stacking conductors to define cooling paths, then cooling of rotor windings is achieved, but manufacturing complexity and assembly time increase
Solution Approach 1:
The invention extracts the cooling function from the conductor structure itself and relocates it to separate separator elements. Instead of drilling bores in conductors or stacking conductors to create cooling paths, the separators are inserted into slots to provide cooling channels, thereby simplifying conductor manufacturing while maintaining cooling efficiency.
Solution Approach 2:
The rotor winding structure is segmented into distinct functional components: conductors for electrical function, separators for cooling function, and slots for structural integration. This segmentation allows each component to be optimized independently - conductors can be manufactured without cooling considerations, while separators are specifically designed with cooling channels.
2Temperature
If space blocks are assembled between end windings to define cooling paths, then cooling of rotor windings is achieved, but assembly time and manufacturing complexity increase
Solution Approach 1:
The invention merges the cooling path definition function with the existing slot structure. Instead of adding separate space blocks between end windings, the separators are integrated directly into the slots where conductors are already placed, combining structural support and cooling functions in a single element positioned during normal winding assembly.
3Temperature
If complex cooling schemes with multiple assembly steps are implemented, then cooling of rotor windings is achieved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The separators are designed to be self-positioning elements that automatically define cooling paths through their geometric shape and placement in slots. The cooling channels are inherently formed by the separator geometry itself, eliminating the need for additional assembly steps to create or activate cooling paths - the cooling function is self-realized through simple insertion.
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 simplifies the cooling process, enhances cooling efficiency, and reduces assembly time by eliminating the need for drilling and complex assembly, while maintaining effective heat dissipation for rotary electric machines.
Implementation Method 1
the separator being configured to channel a cooling fluid in the said slot to cool the concentric windings
Implementation Method 2
cooling fluid flows axially from the ends of the rotor into corresponding bores in the rotor conductors toward the inside, issues radially into the air gap between stator and rotor after absorbing the rotor heat loss
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The magnetic mass (5) for rotor (3) which comprises slots (7) disposed on a diameter of the magnetic mass, extending along the magnetic mass in an axial direction and merging outwards in a radial direction, each slot being closed by a wedge (8). Each slot houses at least one separator (9) extending in the radial direction and two concentric windings (10, 11) separated by the separator in a circumferential direction, the separator being configured to channel a cooling fluid in the said slot to cool the concentric windings, the wedge being configured so that cooling fluid escapes the separator through the wedge and to prevent the concentric windings and the separator from moving in the slot.