Stator Slot Insulators With Cooling Channels for Low-Resistance Flow
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Solution Overview
Problem
Existing electric machines face high flow resistance and require powerful, heavy, and costly pumps for cooling liquid flow due to the passage of cooling liquid through stator slots, which also leads to increased installation space requirements.
Innovation Solution
A stator design with laminated stator core and fluidtight slot insulators featuring cooling channels spaced orthogonally to electric conductors, reducing flow resistance and allowing the use of smaller, lighter pumps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling liquid is introduced through stator slots along electric conductors, then cooling efficiency is improved, but flow resistance increases requiring powerful pumps
Solution Approach 1:
The cooling path is segmented into two separate regions: winding overhang regions where cooling liquid is introduced and removed, and stator slots where cooling channels are spaced apart from electric conductors. This segmentation avoids the high flow resistance problem of forcing cooling liquid through narrow stator slots while maintaining effective cooling of electric conductors through the distributed cooling channels.
Solution Approach 2:
Cooling channels act as intermediary structures within the stator slots, providing a dedicated cooling path that is spaced apart from electric conductors. These channels serve as mediators between the cooling liquid and the stator structure, enabling heat dissipation without requiring the cooling liquid to pass directly through the electric conductor paths, thus reducing flow resistance.
2Productivity
If powerful pumps are used to overcome high flow resistance, then cooling liquid flow is maintained, but pump weight and installation space increase
Solution Approach 1:
The cooling system is divided into separate functional zones: winding overhang regions for liquid introduction and removal, and stator slots with spaced cooling channels for heat dissipation. This segmentation creates more favorable flow conditions that reduce the power and weight requirements of pumps while maintaining effective cooling liquid flow through the system.
3Temperature
If cooling liquid flows through stator slots along electric conductors, then direct cooling is achieved, but flow resistance causes high costs and large installation space
Solution Approach 1:
The stator structure is segmented into functional regions with cooling channels positioned in stator slots but spaced apart from electric conductors. This segmentation allows effective cooling of electric conductors through the cooling channels while avoiding the high flow resistance and complexity associated with forcing cooling liquid directly through narrow stator slots along the conductors.
Solution Approach 2:
The cooling channels are positioned in a different spatial arrangement within the stator slots, spaced apart from electric conductors in the radial direction. This dimensional repositioning creates more favorable flow paths that reduce flow resistance and system complexity while maintaining cooling effectiveness through the distributed channel network.
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 achieves efficient cooling with minimal impairment to electromagnetic properties and pump efficiency, extending their service life while reducing weight and installation space.
Implementation Method 1
the slot insulators each have a cooling channel spaced apart from the electric conductors in a radial direction arranged orthogonally to the axial direction
Implementation Method 2
the cooling liquid flows further along the electric conductors, through stator slots of the stator, into a further winding overhang region. There, the cooling liquid can emerge from the stator, and the heat absorbed by the cooling liquid can be dissipated.
Data Source
AI summary
A stator for an electric machine includes a laminated stator core having stator slots arranged along an axial direction parallel to a stator axis, electric conductors arranged in the stator slots; and fluidtight slot insulators arranged in the stator slots between the electric conductors and the laminated stator core, wherein the slot insulators each have a cooling channel spaced apart from the electric conductors in a radial direction arranged orthogonally to the axial direction.