Single-Piece Motor Casing With Continuous Internal Cooling Coil
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rotating electric machine casings with cooling coils face challenges in manufacturing efficiency, thermal performance, and alignment issues due to the need for bipartite molds and interruptions in cooling coil channels for sand removal.
Innovation Solution
A single-piece casing design with integrated cooling coils and inspection caps that ensure integrity and impermeability, allowing for better thermal exchange and fluid flow while optimizing material use and manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-piece casing is used, then manufacturing complexity is reduced, but sand removal becomes difficult requiring large openings that interrupt cooling channels
Solution Approach 1:
The mold is divided into two separate pieces (first mold piece and second mold piece) that can be independently removed after casting. This segmentation allows the mold to be opened without requiring large openings in the casing, thus maintaining cooling channel continuity while simplifying the manufacturing process.
Solution Approach 2:
The mold pieces are designed to separate along a parting line that allows removal from different spatial dimensions. The first mold piece is removed from one side while the second mold piece is removed from the opposite side, enabling sand removal without compromising the integrity of the cooling channels.
2Ease of manufacture
If bipartite molds are used, then sand removal is facilitated, but manufacturing complexity increases due to multiple process steps
Solution Approach 1:
The mold is segmented into two pieces that can be separately removed after casting. This allows sand to be easily removed from both sides of the casing without requiring complex multi-step processes for mold opening and parting line management.
Solution Approach 2:
The mold pieces are designed in advance with parting lines and removal paths that facilitate automatic or semi-automatic sand removal. The preliminary design of the mold structure includes features that guide sand removal without requiring additional manual intervention or complex processing steps.
3Ease of manufacture
If large openings are added for sand removal, then sand can be completely removed, but cooling channel integrity is compromised
Solution Approach 1:
Instead of creating large openings in the casing for sand removal, the mold itself is segmented into two pieces. This allows sand to be removed through the mold gaps without requiring any openings in the final casing structure, thus maintaining the integrity and continuity of the cooling channels.
Solution Approach 2:
The mold pieces act as intermediaries that facilitate sand removal during the manufacturing process. The sand is removed through the mold structure itself rather than through openings in the casing, using the mold as a temporary medium that enables sand removal without compromising the final product's cooling system.
4Reliability
If cooling coils are integrated in single-piece casing, then thermal performance is improved, but manufacturing difficulty increases
Solution Approach 1:
The mold is segmented into two pieces that can be positioned around the cooling coil assembly during casting. This segmentation allows the cooling coil to be integrated into the casing without requiring the entire mold to be a complex single-piece structure, thus maintaining thermal performance while reducing manufacturing difficulty.
Solution Approach 2:
The cooling coil is nested within the mold structure during the casting process. The first and second mold pieces are positioned to enclose the cooling coil, allowing it to be integrated into the casing as a single-piece component. This nesting approach simplifies manufacturing by eliminating separate assembly steps while maintaining the thermal performance benefits of integrated cooling coils.
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 solution enables a continuous internal cooling coil with improved fluid flow and thermal performance, reducing manufacturing complexity and ensuring alignment between the casing and cooling coils.
Implementation Method 1
cooling coils for circulating cooling fluids... help in the removal of heat generated during the operation of the electric machine
Data Source
AI summary
The present invention relates to a single-piece casing for rotating electric machines. The casing includes at least one internal cooling coil, at least one inspection window including a through-opening, and at least one inspection cap. The single-piece casing and the internal cooling coil are formed in a single piece and protrusions of the inspection cap continue with the turns of the internal cooling coil in the region of the through-opening. The present invention further relates to a rotating electric machine.