Segmented Stator Groove Layout to Prevent Cooling Channel Blockage
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Solution Overview
Problem
Existing stator devices for electric machines face issues with flow channel blockage due to incorrectly positioned conductor elements, leading to increased pressure loss and reduced cooling efficiency.
Innovation Solution
A stator device with a laminated core arrangement featuring receiving grooves that have multiple groove geometry variants, allowing for alternating flow channel positions relative to conductor channels, preventing blockages by ensuring proper alignment and maintaining coolant flow efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conductor elements are directly cooled in receiving grooves, then cooling efficiency is improved, but flow channels may be blocked by incorrectly positioned conductor elements
Solution Approach 1:
The receiving grooves are designed with different groove geometry variants (different shapes, sizes, or positions) at different locations along the axial extent. This local variation in groove geometry provides different blocking characteristics at different positions, preventing conductor elements from tilting or slipping into flow channels while maintaining effective cooling contact.
Solution Approach 2:
The laminated core arrangement is divided into multiple laminated core units, each providing axial groove sections with different groove geometry variants. This segmentation allows the cooling system to be divided into zones with different geometric characteristics, enabling targeted prevention of flow channel blockage in different sections while maintaining overall cooling efficiency.
2Ease of manufacture
If uniform groove geometry is used throughout the laminated core arrangement, then manufacturing is simplified, but flow channels are more susceptible to blockage
Solution Approach 1:
The laminated core arrangement is segmented into multiple laminated core units, each with potentially different groove geometry variants. This segmentation allows standardization at the unit level (simplifying manufacturing of individual units) while achieving diversity at the system level (improving flow channel protection through varying geometries).
Solution Approach 2:
Multiple groove geometry variants are designed to serve the same basic function of receiving conductor elements, but with different geometric characteristics that provide varying levels of protection against flow channel blockage. This universality allows the system to maintain functional consistency while achieving protective diversity.
3Reliability
If multiple groove geometry variants are implemented, then flow channel blockage is prevented, but device complexity increases
Solution Approach 1:
The complexity of having multiple groove geometry variants is managed by segmenting the laminated core arrangement into modular laminated core units. Each unit can be manufactured independently with a specific groove geometry variant, and the variants are systematically distributed along the axial extent. This segmentation transforms system-level complexity into manageable module-level variations.
Solution Approach 2:
Different groove geometry variants are applied locally at different positions along the axial extent based on specific cooling or structural requirements. This localized application of geometry variants ensures that complexity is introduced only where necessary for flow channel protection, rather than uniformly throughout the entire structure.
Data Source
AI summary
A stator device for an electric machine, including a laminated core arrangement with a plurality of receiving grooves for receiving, in each receiving groove, at least one conductor element of a stator winding in a conductor channel, wherein the receiving grooves each provide at least one flow channel, wherein the laminated core arrangement includes a plurality of laminated core units which are lined up axially and which each provide axial groove sections of the receiving grooves, and wherein the groove sections associated with each of the plurality of laminated core units at least in part have a groove geometry variant taken from a group of at least two different groove geometry variants, such that the receiving grooves, over an axial extent along the laminated core arrangement, each have at least two different groove geometry variants.