Stator Cooling Channels for Compact High-Current Electric Motors
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Solution Overview
Problem
Traditional electric motors face limitations in heat dissipation due to internal thermal resistance from insulation and laminated steel, restricting electrical current and energy density, and conventional cooling methods like natural convection and liquid cooling undesirably increase motor volume.
Innovation Solution
Incorporating non-electrically conductive polymeric cooling channels within the stator core, configured to direct cooling fluid flow through tooth gaps and stator teeth, with inlet and outlet headers to enhance cooling efficiency and reduce volume addition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling methods (natural convection or liquid cooling jackets) are used, then heat dissipation from motor windings is improved, but motor volume increases due to addition of cooling jacket
Solution Approach 1:
The cooling channels are merged with the stator core structure itself, eliminating the need for a separate cooling jacket. The stator core serves dual functions: magnetic flux conduction and heat dissipation, thereby maintaining compact motor volume while achieving effective cooling of the windings through integrated thermal management pathways
Solution Approach 2:
The cooling channels are nested within the stator core structure, with channels positioned in the stator teeth and yoke. This nesting approach allows the cooling system to occupy space already allocated for magnetic structure, avoiding additional volume while providing direct thermal coupling between the cooling fluid and windings through the stator core
2Reliability
If insulation layers and laminated steel are used to separate windings, then electrical insulation is improved, but internal thermal resistance increases limiting heat dissipation
Solution Approach 1:
The cooling channels act as an intermediary thermal pathway between the windings and the external environment. By introducing cooling fluid through channels positioned in the stator teeth and yoke, heat is conducted from the windings through the stator core material to the cooling fluid, bypassing the thermal barrier created by insulation layers and laminated steel while maintaining electrical insulation integrity
Solution Approach 2:
A liquid cooling system is implemented using hydraulic principles, where cooling fluid is pumped through channels in the stator core. The fluid absorbs heat from the windings through thermal conduction via the stator core, and the heated fluid is circulated out for heat rejection, creating an efficient thermal management system that overcomes the limitations of natural convection and reduces thermal resistance
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 effectively cools stator windings, increasing electrical current capacity and energy density while minimizing volume expansion, thereby addressing heat dissipation limitations and enhancing motor performance.
Implementation Method 1
A plurality of non-electrically conductive cooling channels are located in the stator core. The plurality of cooling channels are configured to direct a cooling fluid flow therethrough to cool the plurality of stator windings.
Implementation Method 2
The plurality of cooling channels are configured to direct a cooling fluid flow therethrough to cool the plurality of stator windings
Data Source
AI summary
A stator of an electric motor includes a stator core including a rim and a plurality of stator teeth extending from the rim. The plurality of stator teeth define a plurality of tooth gaps between circumferentially adjacent stator teeth. A plurality of stator windings are wrapped along the plurality of stator teeth. The plurality of stator windings include a plurality of core segments extending along the plurality of tooth gaps, and a plurality of end turn segments connecting adjacent core segments. A plurality of non-electrically conductive cooling channels are located in the stator core. The plurality of cooling channels are configured to direct a cooling fluid flow therethrough to cool the plurality of stator windings.