Stator Casing with Segmented Cooling Ducts

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Solution Overview

Problem

Existing stator assemblies for electric machines face inefficiencies in cooling, particularly due to complex assembly processes and suboptimal heat transfer, leading to potential temperature-related integrity issues and reduced performance.

Innovation Solution

A containing casing for the stator with a radially inner and outer part forming a fluid-tight duct around the stator, featuring alternating sections that facilitate a serpentine cooling fluid path, enhancing heat dissipation by directing the cooling liquid close to the windings and using a stiff, low-thermal-conductivity metal like aluminum for the casing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a complex cooling system is used to improve heat dissipation, then cooling efficiency is improved, but assembly complexity increases

Engineering Contradiction:

Improvecooling efficiencyVSAvoidassembly complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The containing casing is divided into a first radially inner part and a second radially outer part that are coupled together to form the cooling duct. This segmentation allows the cooling system to be assembled in sections around the stator, simplifying the overall assembly process while maintaining effective heat dissipation through the coordinated structure of the two parts

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The containing casing serves multiple functions: it provides structural support for the stator, contains the cooling duct, and facilitates heat dissipation. By integrating these functions into a single assembly, the design reduces the number of separate components needed, thereby simplifying assembly while achieving effective cooling

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Temperature

If a fluid-tight duct is implemented to improve cooling, then heat transfer efficiency is improved, but risk of fluid leakage increases

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidfluid leakage risk

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The coupling between the radially inner part and radially outer part of the containing casing is designed to inherently prevent fluid leakage through proper sealing arrangements. By building the sealing capability into the basic coupling structure itself, the system provides built-in protection against leakage without requiring additional complex sealing components

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Temperature

If cooling fluid is directed close to windings to improve heat transfer, then cooling performance is improved, but assembly precision requirements increase

Engineering Contradiction:

Improvecooling performanceVSAvoidassembly precision

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The cooling duct is formed by coupling the radially inner part and radially outer part together, creating a segmented structure that naturally positions the cooling fluid path close to the windings. This segmentation allows each part to be manufactured and positioned independently, reducing the overall assembly precision requirements while still achieving effective heat transfer proximity

Inventive Principle:

Principle #1Segmentation

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 provides efficient cooling with reduced assembly complexity, minimizing fluid leakage risks and optimizing heat transfer through a three-dimensional fluid flow with turbulences, thus improving the operational integrity and performance of the electric machine.

Implementation Method 1

a serpentine cooling fluid path, enhancing heat dissipation by directing the cooling liquid close to the windings

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 2

using a stiff, low-thermal-conductivity metal like aluminum for the casing

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

optimizing heat transfer through a three-dimensional fluid flow with turbulences

Methodology Applied

Scientific EffectTurbulence: Turbulence

Data Source

PatentEP3048699B1Containing casing for a stator of an electric machine and stator assembly using said casing

Publication Date: 2018.01.03 LUCCHI R ELETTROMECCANICA

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AI summary

A containing casing (1) for a stator of an electric machine defines, around said axis (2), a compartment (3) to house the stator. A first radially inner part (10) and a second radially outer part (11) are coupled to one another and define together at least one duct (4) surrounding the axis (2) for the passage of a cooling fluid. Said duct (4) comprises, in turn, a plurality of first sections (40) and a plurality of second sections (41), which are distributed around the axis (2) alternated with one another. The first sections (40) are arranged around the axis (2) with an arrangement that supports the motion of the fluid around the axis (2). The second sections (41) are transverse to the first sections (40) and at least partially obtained inside respective protuberances (100) of the first radially inner part (10), which project towards the inside of the compartment (3). A space for the insertion of radially projecting portions of electric windings of the stator is defined between two consecutive protuberances (100) around the axis (2).