Stator Bobbin Cooling Structure for Compact E-Machine Windings
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Solution Overview
Problem
Existing e-machines in turbomachines suffer from inefficiencies due to electromagnetic losses and high operating temperatures, which affect performance, and are often bulky and difficult to manufacture and assemble.
Innovation Solution
A stator bobbin design for e-machines featuring winding supports with inner and outer radial portions and contoured flow surfaces that facilitate direct cooling, along with winding retainers to secure windings and direct coolant flow paths for efficient heat removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional e-machine designs are used, then the structure is simple, but the operating temperature becomes too high and efficiency decreases
Solution Approach 1:
The patent extracts the cooling function from a separate system and integrates it directly into the stator bobbin structure through contoured flow surfaces and coolant channels, allowing the bobbin to actively participate in heat removal rather than passively enduring thermal loads
Solution Approach 2:
The patent introduces fluid coolant as an intermediary substance that mediates heat transfer between the windings and the external cooling system, enabling efficient thermal management through the contoured flow surfaces that guide coolant movement
2Volume of moving object
If conventional e-machine designs are used, then manufacturing is simple, but the device becomes bulky and difficult to assemble
Solution Approach 1:
The patent merges multiple functions into the stator bobbin structure: structural support for windings, winding retention through integrated retainers, and thermal management through contoured flow surfaces, eliminating the need for separate components and reducing overall device volume
Solution Approach 2:
The stator bobbin is designed as a multi-functional component that simultaneously provides mechanical support, electrical insulation, winding retention, and thermal management functions, reducing the total part count and simplifying assembly
3Ease of operation
If conventional e-machine designs are used, then the part count is high, but the assembly becomes difficult and time-consuming
Solution Approach 1:
The patent combines winding support, retention, and cooling functions into a single integrated stator bobbin structure, reducing the number of discrete parts and simplifying the assembly process while improving ease of operation
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 design enhances e-machine efficiency through effective cooling, reduces size and weight, and simplifies manufacturing and assembly, while maintaining a low part count.
Implementation Method 1
a contoured flow surface at the second end. The contoured flow surface defines a nonlinear flow path for a fluid coolant of the e-machine
Data Source
AI summary
A stator bobbin includes a first winding support with an inner radial portion, an outer radial portion, and a winding space defined radially between the inner radial portion and the outer radial portion with respect to an axis of rotation. The winding space is configured to receive a plurality of windings of the e-machine. The inner radial portion and the outer radial portion extend along the axis between a first end of the stator bobbin and a second end of the stator bobbin. The stator bobbin further includes a winding retainer disposed at the first end and configured for receiving and retaining an end of the plurality of windings. Also, the stator bobbin includes a contoured flow surface disposed proximate the second end. The contoured flow surface defines a nonlinear flow path for a fluid coolant of the e-machine.