Segment Coil Turn Geometry for Compact Stator End Cooling
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Solution Overview
Problem
The dynamo-electrical machine's segment coil turn portions, when closely spaced, experience heat dissipation issues due to limited cooling medium access, leading to increased electrical resistance and performance degradation, while increasing the turn portion length to enhance cooling bottlenecks miniaturization efforts.
Innovation Solution
The segment coil design features a first and second linear portion inserted into separate slots, with a turn portion extending radially from the stator core, forming a bent portion that tilts the top portion toward the stator core, creating a gap between turn portions for improved cooling medium access and contact area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the spatial distance between turn portions of adjacent segment coils is increased to improve cooling performance, then the contact area with cooling medium increases, but the length of the bent-side coil end increases which bottlenecks miniaturization
Solution Approach 1:
The patent introduces a tilted bent portion that angles the turn portion toward the end face of the stator core, utilizing the axial dimension to create cooling gaps without extending the radial length of the coil end. This dimensional reorientation allows cooling medium access while maintaining compact coil end dimensions.
Solution Approach 2:
The patent segments the coil structure by introducing a distinct bent portion between the linear portion and turn portion, creating a tilted configuration that separates the cooling function from the electrical function. This segmentation allows the turn portion to be angled for cooling purposes without affecting the electrical performance of the linear portion in the slots.
2Length of moving object
If the spatial distance between turn portions is small, then the coil end length is reduced for miniaturization, but heat dissipation is insufficient leading to increased electrical resistance
Solution Approach 1:
The tilted bent portion utilizes the axial dimension to create cooling pathways, allowing heat dissipation without increasing the radial coil end length. The tilt angle creates a three-dimensional cooling structure that maintains compact dimensions while improving thermal management.
Solution Approach 2:
The bent portion acts as an intermediary structure between the linear portion and turn portion, creating a tilted configuration that facilitates cooling medium flow. This intermediary structure enables heat dissipation functionality without compromising the electrical connectivity or increasing overall coil end length.
3Volume of moving object
If the turn portion is positioned close to adjacent coils, then mechanical interference is avoided and compact design is achieved, but cooling medium access is limited
Solution Approach 1:
The tilted bent portion creates axial spacing between adjacent turn portions, providing cooling medium access in the axial direction while maintaining radial compactness. This dimensional approach allows cooling flow paths without increasing the overall volume or compromising compact design.
Solution Approach 2:
The introduction of a separate bent portion segments the coil structure, creating a distinct tilted section that facilitates cooling medium access. This segmentation allows the turn portion to be positioned at an angle that provides cooling pathways while maintaining close spacing between adjacent coils for compact design.
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 configuration enhances cooling performance by increasing the contact area with the cooling medium and preventing mechanical interference, without increasing the coil end length, thus addressing heat dissipation and resistance issues.
Implementation Method 1
The bent portion tilts the top portion of the turn portion toward the end face of the stator core, creating a gap between turn portions for improved cooling medium access and contact area
Data Source
AI summary
A novel dynamo-electrical machine is provided that can inhibit an increase in the height of a coil end positioned toward a turn portion and improve the cooling performance around the turn portion of a segment coil. A segment coil 31 includes a first linear portion 34r, a second linear portion 34a, and a turn portion 33 including a top portion 33c. The first linear portion 34r is inserted into a specified slot 22. The second linear portion 34a is inserted into another particular slot 22 different from the specified slot 22. The turn portion 33 extends from one end face portion of a stator core 21 toward the outside of the axial direction of the stator core 21 and connects the first linear portion 34r and the second linear portion 34a. The linear portions 34r and 34a of the multiple segment coils 31 are inserted and placed in the slots 22 in a layering manner from the inner periphery to the outer periphery in the radial direction. A bent portion 37 is formed between each of the linear portions 34r and 34a and the turn portion of the segment coils 31 layered in the radial direction. The bent portion 37 tilts the top portion33c of the turn portion 33 toward the end face of the stator core 21.