Stator Cooling Channels for Electric Machine Heat Removal
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Solution Overview
Problem
Current electric machines face inefficiencies in heat removal from stator windings due to limitations in existing cooling methods, which can lead to reduced performance and increased operational temperatures.
Innovation Solution
The implementation of sealed longitudinal and radially extending cooling channels within the stator assembly, formed in resin and connected to a closed fluid system, to effectively circulate cooling fluid and remove heat from the stator winding, particularly at the rotor surface, while minimizing interference with magnetic flux and stator assembly design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling channels are provided in the stator winding to remove heat, then heat removal efficiency is improved, but device complexity increases
Solution Approach 1:
The cooling channels are integrated directly into the stator assembly structure itself, merging the cooling function with the stator body. The channels are formed within the resin material that bonds the stator teeth and windings, eliminating the need for separate cooling components and reducing overall device complexity while maintaining effective heat removal.
Solution Approach 2:
The stator assembly utilizes the resin material as a medium that can be formed into channel structures. The resin serves dual purposes: as the bonding material holding the stator components together and as the material through which cooling channels are formed, creating a porous-like structure that enables fluid flow for cooling without adding external complexity.
2Temperature
If cooling channels are integrated into the stator assembly, then heat removal efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The cooling channels are formed into the resin material before the final assembly and curing process. By preparing the channel structures in advance within the resin, the manufacturing process integrates cooling channel formation with the stator assembly fabrication itself, avoiding post-assembly modifications and simplifying the overall manufacturing workflow.
Solution Approach 2:
The manufacturing process utilizes changes in the resin material properties during curing and forming operations to create the cooling channels. By controlling the resin's physical state and flow characteristics during manufacturing, the channels are formed as an inherent part of the stator assembly without requiring separate machining or drilling operations after assembly.
3Temperature
If sealed cooling channels are used to circulate cooling fluid, then heat removal efficiency is improved, but device complexity increases
Solution Approach 1:
The sealing function is merged into the stator assembly structure itself. The resin material that forms the body of the stator also provides the sealing for the cooling channels, eliminating the need for separate seals or gaskets. This integration reduces the number of components and simplifies the cooling system while maintaining effective sealing for heat removal.
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 solution enhances heat removal efficiency, reduces operational temperatures, and increases power density by integrating cooling channels into the stator assembly without compromising magnetic flux or increasing the machine's size, thus improving overall performance.
Implementation Method 1
The cooling channels are configured to remove heat from the stator assembly proximate the surface of the rotor
Implementation Method 2
fluid can be directed through channels provided in the stator winding to remove heat; circulate cooling fluid to cool the stator assembly
Data Source
AI summary
An electric machine includes a housing, a rotor rotatably supported by the housing for rotation about a longitudinal axis and a stator assembly fixed secured to the housing spaced apart from a surface of the rotor and concentric with the rotor about the longitudinal axis. The stator assembly includes a stator winding comprising circumferentially spaced apart stator teeth about the longitudinal axis, the stator teeth having remote ends proximate the surface of the rotor. A plurality of sealed cooling channels extend parallel to the longitudinal axis and are disposed between remote ends of successive teeth. The cooling channels are formed in resin of the stator assembly, the cooling channels being fluidly connected to ports in a closed system to circulate cooling fluid to cool the stator assembly and configured to remove heat from the stator assembly proximate the rotor surface. Other aspects include methods of making such machines.