Liquid-Cooled Hollow Rotor Shaft Using Self-Driven Coolant Flow
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Solution Overview
Problem
Existing liquid-cooled rotors for electromechanical energy converters face challenges such as complex mechanical seals, power losses due to mechanical oil pumps, and increased susceptibility to faults, which affect the efficiency and reliability of the drive.
Innovation Solution
A liquid-cooled rotor design featuring a rotor shaft with a hollow portion and an integrally bonded liquid-guiding device that extends through the rotor shaft, allowing for efficient liquid flow and cooling without the need for a mechanical oil pump, thereby reducing power losses and improving reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a water lance is used for rotor cooling, then cooling effectiveness is improved, but mechanical seal complexity increases
Solution Approach 1:
The patent replaces the mechanical water lance system with a liquid-guiding device that uses the rotor's rotational motion to drive liquid flow through centrifugal and pressure gradients. This eliminates the need for mechanical seals at the rotor inlet, solving the contradiction between cooling effectiveness and mechanical seal complexity.
Solution Approach 2:
The liquid-guiding device utilizes the rotor's own rotation to generate the driving force for liquid circulation. The rotating rotor creates pressure gradients that automatically propel cooling liquid through the hollow shaft and onto the rotor components, making the system self-driven without external pumps or seals.
2Quantity of substance
If a mechanical oil pump is used for rotor cooling, then cooling flow is improved, but power loss increases
Solution Approach 1:
The patent replaces the mechanical oil pump with a liquid-guiding device that exploits the rotor's rotational motion to generate liquid flow. The rotation creates centrifugal forces and pressure gradients that automatically circulate cooling liquid, eliminating the power-consuming pump while maintaining adequate cooling flow.
Solution Approach 2:
The system uses the rotor's rotational energy to drive its own cooling system. The rotating mass generates the necessary pressure differentials to move cooling liquid through the hollow shaft and onto rotor components, making the cooling system self-powered without external energy input.
3Ease of operation
If a mechanical oil pump with electrical control is used, then cooling flow control is improved, but system reliability decreases
Solution Approach 1:
The patent replaces the electrically-controlled mechanical pump system with a purely mechanical liquid-guiding device driven by rotor rotation. This eliminates electrical components and controls in the cooling system, removing potential failure points while maintaining passive flow control through the rotor's rotational characteristics.
Solution Approach 2:
The cooling system becomes self-regulating through the rotor's rotation. The rotational speed naturally determines the pressure gradients and flow rates, eliminating the need for external electrical control systems and associated reliability issues.
4Power
If active cooling is implemented to achieve high power density, then power density is improved, but device complexity increases
Solution Approach 1:
The patent merges the cooling system with the rotor structure itself. The liquid-guiding device is integrated into the hollow rotor shaft, and the rotor's rotation serves dual purposes: generating mechanical power and driving the cooling system. This integration reduces overall system complexity while maintaining high power density through 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
The proposed design enhances the operating characteristics of the liquid-cooled rotor by improving cooling efficiency, reducing power losses, and increasing system reliability, thus achieving higher power density and extended drive lifespan.
Implementation Method 1
The liquid-guiding device (3) is set up for guiding liquid (50) which is provided for controlling the temperature of the rotor (1). Liquid flows through the hollow rotor shaft, absorbing heat and transporting it away from the rotor components.
Implementation Method 2
a liquid-guiding device, wherein the liquid-guiding device is set up for guiding liquid which is provided for controlling the temperature of the rotor
Data Source
AI summary
A liquid-cooled rotor for an electromechanical energy converter has a rotor shaft designed, at least in portions, as a hollow shaft and having a first, open axial end, a liquid-guiding device extending through the first end into the rotor shaft, wherein an annular liquid space is between the liquid-guiding device and the rotor shaft in the radial direction, and the liquid-guiding device has an interior space for guiding liquid and a liquid inlet opening into the interior space and arranged at a first axial end of the liquid-guiding device, the liquid-guiding device, at a second axial end, is received in the rotor shaft and guiding relative to the rotor shaft, and has a liquid outlet opening fluidically connecting the interior space to the annular liquid space, and the liquid outlet opening is between the first and second ends of the liquid-guiding device in the axial direction.