Embedded Coolant Pipe Stator for Winding Heat Dissipation
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Solution Overview
Problem
Heat generated by electric machines in gas turbine engines interferes with their operation, leading to increased electrical resistance and decreased magnetic field generation, which affects efficiency and lifespan.
Innovation Solution
Incorporating liquid coolant pipes and thermally conductive potting material in the stator to dissipate heat from wires through convection and conduction, enhancing heat transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If liquid coolant pipes and thermally conductive potting material are incorporated in the stator, then heat dissipation efficiency is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple cooling functions into a single integrated stator structure. The coolant pipes are embedded within the stator core, and the thermally conductive potting material serves dual purposes: electrical insulation and thermal conduction. This merging of cooling, structural, and insulating functions into one component reduces overall system complexity despite adding thermal management capabilities.
Solution Approach 2:
The thermally conductive potting material acts as an intermediary substance between the coolant pipes and the wire windings. It facilitates heat transfer from the wires to the coolant pipes while providing electrical insulation, eliminating the need for separate insulating components and simplifying the overall structure.
2Temperature
If coolant pipes are disposed in slots with wires, then heat transfer from wires is enhanced, but manufacturing precision requirements increase
Solution Approach 1:
The patent changes the physical state of the potting material from liquid to solid through curing. The liquid potting material is injected into the slots to fill gaps and ensure complete contact between the coolant pipes and wire windings. After curing, it becomes a solid that maintains precise positioning and thermal contact, eliminating the need for high manufacturing precision during assembly.
3Temperature
If thermally conductive potting material is applied to secure wires and coolant pipes, then thermal conduction is improved, but manufacturing process complexity increases
Solution Approach 1:
The potting material serves multiple functions simultaneously: it secures the wires and coolant pipes in place, provides electrical insulation, and facilitates thermal conduction. This self-service approach eliminates the need for separate manufacturing steps for mounting, insulating, and thermal bonding, simplifying the overall manufacturing process despite the additional material step.
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
Improves the performance and longevity of electric machines by effectively dissipating heat, thereby maintaining efficient operation and reducing electrical resistance.
Implementation Method 1
Incorporating liquid coolant pipes and thermally conductive potting material in the stator to dissipate heat from wires through convection and conduction
Implementation Method 2
Incorporating liquid coolant pipes and thermally conductive potting material in the stator to dissipate heat from wires through convection and conduction
Data Source
AI summary
A stator for an electric machine includes a stator core defining a slot extending in an axial direction from a first end to a second end, a wire disposed in the slot, a coolant pipe disposed in the slot and extending in the axial direction from the first end to the second end, the coolant pipe extending from a pipe inlet to a pipe outlet, and a thermally conductive potting material disposed in the slot between the coolant pipe, the wire, and the stator core.