Stator Cooling Fin Layout for Heat Transfer and Strength
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Solution Overview
Problem
Existing cooling fin arrangements for rotating electrical machines are complex to manufacture, inefficient in material usage, and lack mechanical stability while compromising cooling efficiency.
Innovation Solution
A stator design with laminations featuring groups of cooling fins connected by peripheral members, where a fin in one lamination is interposed between two fins in another, creating a staggered arrangement that enhances heat transfer and mechanical stability, and optimizes material usage by forming fins from scrap material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling fins are provided on the stator core to increase heat transfer, then cooling efficiency is improved, but the stator requires more raw material and produces more scrap
Solution Approach 1:
The invention recovers and reuses the scrap material that would normally be discarded during lamination production. The scrap is formed into strip material and then shaped into cooling fins, transforming waste into a functional component that enhances heat transfer from the stator core.
2Temperature
If a staggered cooling fin arrangement is implemented to improve heat transfer, then cooling efficiency is enhanced, but manufacturing complexity increases
Solution Approach 1:
The staggered cooling fin arrangement is achieved by forming fins on alternating laminations in a segmented pattern. This segmentation allows each lamination to be manufactured independently with simpler tooling, while the alternating pattern creates the desired staggered configuration when laminations are stacked, improving heat transfer without requiring complex manufacturing processes.
Solution Approach 2:
The cooling fins are pre-formed as integral parts of the laminations during the lamination manufacturing process, rather than being added as separate components. This preliminary action simplifies assembly and reduces manufacturing complexity while achieving the staggered arrangement through the lamination stacking sequence.
3Temperature
If cooling fins extend radially into the airgap to maximize heat transfer, then thermal performance is improved, but mechanical stability of the stator is reduced
Solution Approach 1:
The cooling fins are provided only on alternating laminations rather than on every lamination. This local quality approach creates a staggered three-dimensional arrangement where fins on adjacent laminations are offset, allowing each fin to extend radially for effective heat transfer while the alternating pattern provides mechanical support and stability to the overall stator structure.
4Strength
If groups of cooling fins are connected by peripheral connecting members to improve mechanical stability, then structural strength is enhanced, but material usage efficiency decreases
Solution Approach 1:
Multiple cooling fins on the same lamination are connected by peripheral connecting members that extend circumferentially between them. This merging creates a rigid group structure that enhances mechanical stability and prevents fin deformation, while the connecting members are formed from the same scrap-derived strip material, maintaining overall material efficiency.
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 effective heat transfer, mechanical strength, and cost-effective manufacturing by utilizing material that would otherwise be discarded, while introducing turbulence for improved cooling efficiency.
Implementation Method 1
increase the transfer of heat from the stator core to the cooling air
Implementation Method 2
heat transfer from the stator to the cooling fluid passing over the stator
Implementation Method 3
introducing turbulence for improved cooling efficiency
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A stator for a rotating electrical machine is disclosed, the stator comprising a stack of stator laminations (20) forming a stator core (48; 60; 74; 80; 82). A lamination (20) comprises a plurality of cooling fins (28) arranged in at least one group of at least two fins. The cooling fins in a group are connected by a peripheral connecting member (30). The laminations are arranged in packs of at least one lamination. A group of fins (28) in one pack of laminations lies circumferentially between two adjacent groups of fins in an adjacent pack of laminations. A cooling fin (28) in one pack of laminations is interposed between two cooling fins in a group of cooling fins in another non-adjacent pack of laminations. This can allow a good thermal performance to be achieved while at the same time providing good mechanical strength and being cost effective to manufacture.