Stator Cooling via Segmented Line Element
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current stator cooling methods for electrical machines in motor vehicles face challenges such as difficult thermal control and limited stator diameter due to jacket cooling, and corrosion risks with direct cooling, which increase costs and complexity.
Innovation Solution
A stator design incorporating a line element with separate cooling channels that extend within the laminated stator core and end cap, allowing for efficient heat dissipation without direct contact with the core, using a cooling medium like a water-glycol mixture, and featuring a robust, corrosion-resistant material for the line element to ensure effective sealing and corrosion protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If jacket cooling is used to cool the stator, then cooling is provided around the stator, but the stator diameter is limited and thermal control is difficult
Solution Approach 1:
The cooling system is segmented into multiple independent cooling channels formed within the stator core itself, rather than using a single jacket around the stator. This allows cooling to be distributed throughout the stator volume, improving thermal control while not limiting the stator diameter.
Solution Approach 2:
The cooling approach transitions from external jacket cooling (radial dimension) to internal cooling channels embedded within the stator core (axial and radial dimensions). This dimensional change allows the stator to achieve both large diameter and effective cooling throughout its volume.
2Temperature
If direct cooling with cooling medium contact is used, then efficient heat dissipation is achieved, but corrosion risks increase and specialized cooling mediums are required
Solution Approach 1:
A corrosion-resistant line element acts as an intermediary between the cooling medium and the stator core. The cooling medium flows through channels within this line element, which is in thermal contact with the stator core, providing efficient heat transfer while preventing direct contact between the cooling medium and the stator core, thus eliminating corrosion risks.
3Temperature
If direct cooling is implemented, then cooling efficiency improves, but complex sealing procedures and specialized materials are required
Solution Approach 1:
The line element serves as a self-contained sealing barrier that eliminates the need for complex external sealing procedures. The cooling channels are formed within the line element itself, which is designed to be corrosion-resistant and seal-tight, simplifying the overall cooling system implementation.
4Temperature
If separate cooling channels are formed within the stator core, then efficient internal cooling is achieved, but manufacturing complexity increases
Solution Approach 1:
The cooling channels are formed within the line element during its manufacturing process, before the line element is installed in the stator. This preliminary formation of cooling channels simplifies the overall manufacturing process, as the channels are created as an integral part of the line element rather than requiring post-assembly modifications to the stator core.
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 design enables efficient and cost-effective cooling of the stator, avoiding the limitations of jacket cooling and direct cooling, while maintaining a large stator diameter for increased power output and reducing the need for specialized cooling mediums and complex sealing procedures.
Implementation Method 1
The cooling medium is a cooling fluid, such as a liquid such as for example a water-glycol mixture, such that for example the stator is cooled as a result of a heat transfer from the stator to the cooling medium
Data Source
AI summary
A stator for an electrical machine, with at least one laminated stator core, and with at least one end cap following the laminated stator core in the axial direction of the stator, at least one line element, which is formed separately from the end cap and separately from the laminated stator core and has at least one first cooling channel, through which a cooling medium for cooling the stator may flow, being provided, having a first length region, extending in the laminated stator core, and a second length region, which extends in the end cap, which has at least one second cooling channel, through which the cooling medium may flow and which is fluidically connected to the first cooling channel.