Stator Cooling via Segmented Lamination Flow Channels

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Solution Overview

Problem

Existing rotary electric machine stators face inefficiencies in cooling due to limited fluid flow paths, which restrict heat dissipation and can affect magnetic uniformity and complexity in design.

Innovation Solution

A stator structure with a stack of laminations and subassemblies featuring extensions with flow channels, where the majority of the cooling fluid flows through channels and wide zones, rather than small radial gaps, enhancing heat dissipation without increasing complexity, and incorporating fins and peripheral connections for improved thermal exchange.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If cooling fluid flows through small radial gaps between extensions and jacket, then cooling is provided, but flow section is limited and heat dissipation efficiency is reduced

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidcooling fluid flow section

Core Design Contradiction:

TemperatureVSQuantity of substance

Solution Approach 1:

The stator is segmented into multiple subassemblies with extensions that create distinct flow paths. The cooling fluid flow section is divided into two main paths: channels within extensions (with fins) and wide zones between extensions, allowing optimized flow distribution and increased total flow capacity compared to a single gap path.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention transitions from purely radial flow through small gaps to a multi-dimensional flow path that includes axial components. The wide zones between extensions provide axial and radial flow paths, while channels within extensions add another dimensional aspect, creating a three-dimensional cooling flow network that significantly increases flow section.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Temperature

If extensions with flow channels are added to subassemblies, then heat dissipation is improved, but stator construction complexity increases

Engineering Contradiction:

Improvecooling effectivenessVSAvoidstator construction complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The stator is divided into a stack of laminations and a jacket as separate components that can be manufactured independently using standard processes. The extensions are integrated into the lamination stack, allowing modular assembly and simplifying construction compared to creating an entirely new monolithic structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The extensions serve multiple functions: they provide structural support for the lamination stack, create flow channels for cooling fluid, and support fins for enhanced heat dissipation. This multi-functionality reduces the need for separate cooling components, thereby reducing overall construction complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Temperature

If extensions project radially beyond laminations, then flow channels are created, but magnetic uniformity may be affected

Engineering Contradiction:

Improvecooling fluid flow capabilityVSAvoidmagnetic uniformity

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The extensions are positioned at specific locations on the laminations rather than uniformly across the entire stator. This localized approach allows cooling channels to be created where they are most effective for heat dissipation while minimizing disruption to the magnetic field distribution in critical areas, thereby preserving magnetic uniformity.

Inventive Principle:

Principle #3Local quality

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 configuration ensures over 60% of the cooling fluid flows through channels, improving heat dissipation while maintaining magnetic uniformity and simplifying fabrication, with a high effectiveness of heat exchange and minimal impact on the machine's magnetic characteristics.

Implementation Method 1

fluid flowing along the stack is subjected to a succession of passes within the channels and of passes through wide zones extending between the channels

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 2

the cooling fluid may be forced to flow through the channels and to be subjected to transitions between the channels and the wide zones, thereby encouraging good heat dissipation

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Data Source

PatentUS8427018B2Stator for a rotary electric machine having flow channels for passing a cooling fluid

Publication Date: 2013.04.23 MOTEURS LEROY SOMER

AI summary

A stator for a rotary electric machine, the stator including a jacket and a stack of stator laminations placed inside the jacket, subassemblies of laminations of the stack having extensions with flow channels for passing a cooling fluid therethrough, the subassemblies being disposed in such a manner that fluid flowing along the stack is subjected to a succession of passes within the channels and of passes through wide zones extending between the channels, the stack laminations being arranged in such a manner that for at least one extension, and better for the majority, or even all of the extensions of a subassembly, the flow section made available to the flow of cooling fluid within the extension is greater than the flow section defined by the space extending radially between the extensions and the jacket.