E-Machine Stator Cooling Channels With End Flow Redirection
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Solution Overview
Problem
Existing e-machines in turbomachines suffer from inefficiencies due to electromagnetic losses and high operating temperatures, leading to bulkiness, manufacturing difficulties, and assembly challenges, while requiring improved efficiency, compactness, and manufacturing ease.
Innovation Solution
A stator member with isolator barrier members and an end fluid deflector member for a fluid-cooled e-machine, featuring a bobbin with winding supports and contoured flow surfaces to redirect coolant flow for efficient cooling, reducing electromagnetic losses and enhancing manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional e-machines are used in turbomachines, then the turbomachine can operate, but the e-machine suffers from electromagnetic losses and high operating temperatures leading to inefficiency
Solution Approach 1:
The patent extracts the cooling function from a separate cooling system and integrates it directly into the e-machine structure through coolant flow channels formed by the isolator barrier members and end plates. This direct cooling approach removes heat at the source, reducing electromagnetic losses and improving efficiency without requiring external cooling equipment.
Solution Approach 2:
The isolator barrier members serve as intermediary components that perform multiple functions: they electrically isolate the windings, structurally support the winding supports, and define the coolant flow channels. This intermediary structure enables efficient heat removal while maintaining electrical integrity and mechanical strength.
2Temperature
If conventional e-machines are designed for adequate cooling, then operating temperature is reduced, but the e-machine becomes bulky and complex
Solution Approach 1:
The isolator barrier members and end plates perform multiple functions simultaneously: electrical insulation, structural support for windings, definition of coolant flow paths, and thermal management. This multi-functionality eliminates the need for separate components for each function, reducing overall structural complexity while maintaining effective cooling.
Solution Approach 2:
The patent merges the insulation barriers, structural supports, and cooling channel definitions into a single integrated structure formed by the isolator barrier members and end plates. This consolidation reduces the number of discrete parts and simplifies the overall e-machine construction while achieving adequate cooling.
3Temperature
If conventional e-machines are designed for adequate cooling, then operating temperature is reduced, but the e-machine becomes bulky
Solution Approach 1:
The coolant flow channels are formed in the axial dimension by the isolator barrier members extending between end plates, utilizing the available axial space efficiently. This approach provides effective cooling without requiring additional radial or circumferential space, keeping the e-machine compact.
4Reliability
If conventional e-machines are designed with multiple components for cooling and support, then functionality is adequate, but manufacturing and assembly become difficult
Solution Approach 1:
The isolator barrier members and end plates are designed to be formed as integrated components that simultaneously provide electrical insulation, structural support, and cooling channel definition. This merging of functions into fewer components simplifies manufacturing processes and reduces assembly steps while maintaining all required functionalities.
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 achieves high efficiency, compactness, and ease of manufacturing by effectively cooling the e-machine, thereby improving turbomachine performance and reducing part count.
Implementation Method 1
The first isolator barrier member, the inner radial portion, the second isolator barrier member, and the outer radial portion cooperatively define an axial flow channel extending through the bobbin between the first axial end and the second axial end
Implementation Method 2
an end fluid deflector member that is supported proximate the first axial end to define a redirection surface of the axial flow channel. The redirection surface is configured to redirect flow at the first axial end substantially from a first direction along the axis toward a second direction along the axis
Data Source
AI summary
A stator member for a directly-cooled e-machine includes a bobbin with a plurality of winding supports, a first isolator barrier member supported on a first angular side of a first winding support and a second isolator barrier member supported on a second angular side of the first winding support. The first and second isolator barrier members, the inner radial portion, and the outer radial portion cooperatively define an axial flow channel. The stator member further includes an end fluid deflector member that defines a redirection surface of the axial flow channel. The redirection surface is configured to redirect flow at the first axial end substantially from a first direction along the axis toward a second direction along the axis. The first direction is opposite the second direction.