Segmented Slot Liner With Phase Separator for Winding Cooling
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Solution Overview
Problem
Existing designs for electrical machines fail to efficiently address the challenges of heat dissipation, and the need to ensure effective cooling and securing of windings in electric machines, particularly in high-power applications, while minimizing size and weight without compromising performance.
Innovation Solution
A flexible, electrically non-conductive slot liner with a phase separator arm extending features extending adjacent the liner with a phase separator arm, the liner is designed to provide efficient cooling and securing of windings in electric machines, particularly in high-power applications, while minimizing size and weight without compromising performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If windings are tightly packed in slots to minimize machine size and weight, then space utilization is improved, but cooling efficiency deteriorates due to reduced coolant access and winding surface contact
Solution Approach 1:
The slot liner is segmented into multiple sections along its length, with each section having alternating first and second portions that project at different positions. This segmentation creates multiple coolant flow paths and increases the effective surface area for heat transfer, allowing efficient cooling even when windings are tightly packed in the slot.
2Power
If windings are tightly packed to maximize conductor density, then power density is improved, but the risk of arcing and short circuits between phases increases
Solution Approach 1:
The slot liner acts as an intermediary insulating barrier between adjacent phase windings in the slot. The alternating first and second portions provide continuous electrical insulation along the slot length, preventing arcing and short circuits between phases while allowing the windings to be tightly packed for high power density.
3Volume of moving object
If a thin insulating slot liner is used to minimize space occupation, then slot space is preserved, but winding securing capability deteriorates
Solution Approach 1:
The slot liner is divided into multiple sections with alternating portions that project at different positions within the slot. This segmentation creates multiple contact points and mechanical interlocking features along the slot length, providing effective winding securing capability while maintaining a thin overall profile that minimizes slot space occupation.
Data Source
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AI summary
A slot liner for an electric machine, arranged to be located and removably retained in a slot (2') of a machine to secure a winding (3') in the slot, whereby the slot liner comprises a flexible electrically non-conductive material defining a body (100) having a first surface to be located against a wall of the slot and an opposing surface (12) configured to receive a winding therearound, the slot liner further comprising a phase separator arm (23) extending adjacent but spaced from the opposing surface (12), the opposing surface and the phase separator arm (23) defining a space therebetween to accommodate a winding when mounted onto the slot liner (10), such that, in use, the separator arm (23) extends along the slot to separate a winding mounted on the slot liner from another winding secured in the slot by a slot liner on an adjacent tooth.