Stator Cooling Manifold Layout for Uniform Heat Distribution
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Solution Overview
Problem
Existing electric machine stator cooling systems often lead to uneven heat distribution and potential thermal overheating due to centralized coolant inlets, which can reduce efficiency and lifespan.
Innovation Solution
The electric machine stator design features two manifolds attached to opposed axial ends with distribution channels that decrease in cross-sectional area, allowing for even pressure and flow velocity distribution of cooling fluid through cooling channels extending from one axial end to the other, and alternating connections for counterflow patterns to balance temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a centralized coolant inlet is used in the stator, then the cooling system structure is simple, but the heat distribution becomes uneven and thermal overheating occurs
Solution Approach 1:
The cooling system is segmented into multiple axial end inlets distributed around the stator perimeter, with each inlet serving a specific angular sector. This segmentation allows independent cooling control for different stator regions, achieving uniform heat distribution while maintaining relatively simple individual inlet structures.
Solution Approach 2:
Each axial end inlet is positioned to cool specific local regions of the stator core and windings. The inlet locations and flow distribution are optimized for local heat generation patterns, ensuring that each region receives appropriate cooling intensity matched to its thermal load characteristics.
2Loss of energy
If axial coolant channels are integrated into the stator teeth, then cooling efficiency improves, but the manufacturing complexity increases
Solution Approach 1:
The axial coolant channels are nested within the stator tooth structure itself, utilizing the existing magnetic core geometry. The channels are formed as hollow passages through the laminated stator teeth, integrating the cooling function directly into the structural component without requiring separate cooling assemblies.
Solution Approach 2:
The stator core utilizes a laminated construction with channels formed between or through the laminations, creating a porous-like flow path structure that allows coolant penetration and heat extraction while maintaining the magnetic properties of the stator core.
3Temperature
If cooling channels extend through the entire stator core, then heat removal from all regions improves, but the pressure drop across the cooling system increases
Solution Approach 1:
The cooling channels are segmented into multiple parallel axial paths, each serving a specific angular sector of the stator. This segmentation creates multiple flow routes that reduce the length and resistance of individual channel paths while collectively covering the entire stator perimeter, thereby reducing overall pressure drop.
Solution Approach 2:
The cooling system utilizes the circumferential dimension by distributing multiple axial channels around the stator perimeter. This dimensional distribution allows coolant to access different radial and axial positions through multiple parallel paths, reducing the effective flow path length and pressure requirements compared to a single centralized channel.
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 enhances heat removal efficiency by ensuring uniform temperature distribution along the stator core and reduces the risk of thermal overheating, thereby extending the lifespan of the electric machine.
Implementation Method 1
a plurality of cooling channels extending through the stator core, and two manifolds attached to opposed axial ends of the stator core for conveying a fluid into the cooling channels
Implementation Method 2
a flow cross-section of the distribution channel decreases along a main circumferential extension direction of the distribution channel
Data Source
AI summary
An electric machine stator including a stator core, a stator winding attached to the stator core, a plurality of cooling channels extending through the stator core, and two manifolds attached to opposed axial ends of the stator core for conveying a fluid into the cooling channels. Each of the two manifolds having a distribution channel hydraulically connected to a share of the cooling channels, wherein a flow cross-section of the distribution channel decreases along a circumferential main extension direction of the distribution channel.