Stator Coil Bridging Wire Heat Dissipation
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Solution Overview
Problem
Rotating electric machines face inefficiencies due to high temperatures at the neutral point of the stator coil, which hampers cooling performance, especially in motor vehicles where heat management is critical.
Innovation Solution
The implementation of a stator coil design with intraphase and interphase bridging wires that are strategically arranged on the coil ends, allowing for direct or indirect contact and a wider angular range, along with a cooling liquid supplier to enhance heat dissipation and cooling performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling liquid is supplied to the coil ends of the stator coil, then the cooling performance is improved, but the heat dissipation area at the neutral point is insufficient
Solution Approach 1:
The patent extends the cooling approach from a single-point injection into a multi-dimensional heat dissipation network. By arranging bridging wires in a radial pattern across the coil end surface and providing multiple cooling liquid supply positions, the cooling system operates in both axial and radial dimensions, significantly increasing the effective heat dissipation area at the neutral point and throughout the coil end structure.
Solution Approach 2:
The bridging wires serve as thermal intermediaries that conduct heat from the high-temperature neutral point region to the cooling liquid supply positions. These wires act as heat transfer mediators, distributing thermal energy from concentrated hot spots across a broader area where cooling liquid can effectively remove the heat, thereby increasing the functional heat dissipation area.
2Device complexity
If the phase windings are star-connected to define a neutral point, then the electrical connection is simplified, but the temperature becomes highest at the neutral point
Solution Approach 1:
The patent extracts the neutral point region from the conventional star-connected structure by extending bridging wires radially outward from the neutral point area. This extraction separates the high-temperature neutral point zone from the standard winding configuration, allowing dedicated cooling liquid supply positions to be established in the extended regions, thereby addressing the overheating issue while preserving the simplified star-connection topology.
3Device complexity
If cooling air is supplied to flow through the stator and rotor, then the cooling system is simple, but the cooling performance at the coil ends is insufficient
Solution Approach 1:
The patent merges the advantages of both cooling methods by combining the simplicity of liquid cooling infrastructure with the targeted effectiveness of direct coil-end cooling. The cooling liquid supply system is integrated into the stator coil structure itself through the bridging wire extensions, creating a unified cooling solution that maintains system simplicity while achieving superior coil-end temperature control.
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
This configuration secures a large heat dissipation area for the bridging wires, effectively cooling the stator coil by ensuring efficient heat management and maintaining performance even under high current flow conditions.
Implementation Method 1
a cooling liquid supplier that supplies cooling liquid to at least one of the intraphase and interphase bridging wires
Implementation Method 2
In operation, electric current flows in the stator coil, causing the stator coil to generate heat
Data Source
AI summary
A rotating electric machine includes a rotor and a stator. The stator includes a stator core and a three-phase stator coil comprised of a plurality of star-connected phase windings. The phase windings are partially received in slots of the stator core to form a pair of coil ends which respectively protrude from opposite axial end faces of the stator core. Each of the phase windings is comprised of a plurality of winding segments. The stator coil also has a plurality of intraphase bridging wires electrically connecting the winding segments of the same phase and a plurality of interphase bridging wires electrically connecting neutral point-side ends of the phase windings. All of the intraphase and interphase bridging wires are arranged on one of the coil ends so that at least one of the intraphase bridging wires is in direct contact with at least one of the interphase bridging wires.