Stator Coil Segment with Coolant Cutouts
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Solution Overview
Problem
Existing stator coil designs face challenges in achieving a compact and efficient cooling solution that saves installation space, particularly in high-power density electric machines, where air cooling is inefficient and fluid cooling systems increase stator volume.
Innovation Solution
A coil segment with a conductor bundle featuring a form-fit design and cutouts for coolant, allowing for efficient cooling while maintaining a compact stator design, utilizing stranded conductors and insulation to minimize heat losses and optimize filling factor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If fluid cooling systems are integrated into the stator using cylindrical jackets or pipes in stator sheet metal, then cooling efficiency is improved, but stator volume increases due to increased sheet metal cross section
Solution Approach 1:
The cooling function is merged with the existing conductor bundle structure by forming cutouts directly in the conductor bundle. This integration eliminates the need for separate cooling pipes or jackets, as the conductor bundle itself serves as the cooling fluid conduit, thereby improving cooling efficiency without increasing stator volume.
Solution Approach 2:
The conductor bundle is given multiple functions: it serves both as the electrical conductor and as the cooling fluid conduit. The cutouts in the conductor bundle allow cooling fluid to pass through, making the conductor bundle a multi-functional component that simultaneously performs electrical conduction and thermal management, thus avoiding additional volume for separate cooling systems.
2Volume of stationary object
If air cooling systems are used for stator cooling, then installation space is saved, but cooling efficiency is insufficient for high power density electric machines
Solution Approach 1:
The invention transitions from air cooling to fluid cooling by introducing cutouts in the conductor bundle that allow liquid cooling fluid to flow through. This hydraulic cooling system provides superior cooling efficiency for high power density machines while maintaining compact dimensions, as the cooling fluid can be conducted directly through the conductor bundle structure without requiring additional external cooling components.
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 efficient cooling of stators with reduced overall volume, allowing for high-power operation without exceeding material temperature limits, thus enhancing the performance of electric machines.
Implementation Method 1
the conductor bundle has at least one cutout for feeding coolant
Implementation Method 2
coolant is conducted in pipes which are provided in the stator sheet metal
Data Source
AI summary
A coil segment, in particular for a stator coil, wherein the coil segment has a conductor bundle, wherein the conductor bundle has a multiplicity of electrical conductors, wherein the conductor bundle has a form fit, wherein the conductor bundle has at least one cutout for feeding coolant. Furthermore, a method for manufacturing a stator coil, a stator coil having a coil segment according to the present invention, a machine having a stator coil according to the present invention, and a vehicle having a machine according to the present invention.