Single-Piece Motor Casing With Continuous Internal Cooling Channels
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Solution Overview
Problem
Existing rotating electric machine casings with internal cooling coils are challenging to manufacture in a single piece due to the need for multiple process steps and the difficulty in completely removing sand from the central core, which leads to interruptions and discontinuities in the cooling channels, impairing thermal performance.
Innovation Solution
A single-piece casing design with integrated inspection windows and caps that match the cooling coil geometry, ensuring alignment and sealing, allowing for continuous fluid flow without leaks, and manufactured using sand casting with specific protrusions and recesses for sealing and welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single-piece casing is used, then manufacturing complexity is reduced and productivity is improved, but sand removal from internal channels becomes difficult requiring large openings that interrupt cooling flow
Solution Approach 1:
The casing is divided into segments along its longitudinal axis that can be separated from each other. This segmentation allows sand to be removed from internal channels during manufacturing without requiring large openings that would interrupt the cooling flow path. The segments are designed to fit together with tight tolerances to maintain flow continuity while enabling sand extraction during the casting process.
Solution Approach 2:
The segmentation approach transforms the problem from a one-dimensional linear structure to a multi-dimensional solution where the casing can be disassembled in the longitudinal direction. This dimensional change enables access to internal channels for sand removal without creating interruptions in the cooling flow path, as the segments can be separated only during manufacturing and then reassembled to restore flow continuity.
2Ease of manufacture
If bipartite molds are used to facilitate sand removal, then sand extraction is improved, but the number of manufacturing steps and process complexity increases
Solution Approach 1:
Instead of using complex bipartite molds with multiple assembly steps, the casing itself is segmented into separable sections. This simplifies the manufacturing process by eliminating the need for complex mold assemblies while still enabling easy sand removal. The segmented casing design integrates the sand removal function directly into the product structure rather than requiring separate manufacturing processes.
Solution Approach 2:
The casing segments are designed with features that facilitate sand removal during the casting process itself, before final assembly. The segmentation is built into the design from the outset, allowing sand to be extracted during manufacturing without requiring additional post-processing steps or complex mold assemblies.
3Ease of manufacture
If inspection windows are added to remove sand, then sand extraction is enabled, but interruptions in cooling coil channels occur impairing thermal performance
Solution Approach 1:
The casing is segmented into sections that can be separated to allow sand removal, but the segmentation is designed to occur in locations that do not interrupt the cooling flow path. The segments are reassembled with tight tolerances to restore flow continuity, eliminating the need for large inspection windows that would create thermal performance issues.
Solution Approach 2:
The sand removal function is achieved by changing the dimensional approach from creating openings in the cooling channels to separating the casing along its longitudinal axis. This dimensional change allows sand extraction without creating interruptions in the cooling flow path, as the segments can be separated perpendicular to the flow direction and then reassembled to maintain flow continuity.
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
Ensures efficient thermal exchange and continuous cooling fluid flow by maintaining channel integrity, optimizing material use and manufacturing processes, while simplifying assembly and reducing material waste.
Implementation Method 1
The casing is a static element, generally cast in metal, responsible for integrating the structures of the rotating electric machine, which can also perform additional functions such as promoting cooling through, for example, turn-shaped channels or cooling coils through the which a fluid is pumped to help in the removal of heat generated during the operation of the electric machine.
Data Source
Figure 1~1a
Figure 2~4
Figure 5~6
AI summary
The present invention relates to a single-piece casing for rotating electric machines, comprising at least one internal cooling coil (200), at least one inspection window (300) comprising a through-opening (330) and at least one inspection cap (400), wherein the single-piece casing (100) and the internal cooling coil (200) are formed in a single piece and wherein protrusions (430, 431) of the inspection cap (400) continue with the turns (214) of the internal cooling coil (200) in the region of the through-opening (330). The present invention further relates to a rotating electric machine.