Concentrated Winding Stator With Liquid Cooling Manifold
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Solution Overview
Problem
Conventional stator winding designs in rotary electric machines face challenges such as complex end turns, reduced efficiency, acoustic noise due to tooth movement, and inefficient magnetic flux distribution, particularly in concentrated windings with separate teeth, as well as suboptimal cooling methods that limit power density and thermal performance.
Innovation Solution
A novel stator design incorporating a concentrated winding with edge form wound coils, pre-insulated wire, and a unique in-slot liquid cooling manifold using conductive fluids like ethylene glycol, which ensures metal-on-metal contact for secure tooth alignment and efficient heat management, reducing eddy current losses and enhancing power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate teeth are used to facilitate winding assembly, then ease of manufacture is improved, but structural stability deteriorates due to tooth movement causing acoustic noise
Solution Approach 1:
The stator is divided into separate teeth that can be independently assembled, allowing coils to be wound and attached before final assembly. This segmentation enables the ease of manufacture benefit while the pre-attachment of coils to teeth provides the structural stability needed to prevent movement and acoustic noise.
Solution Approach 2:
Coils are pre-attached to teeth before final stator assembly, creating a stable structural unit. This preliminary action ensures that when teeth are later joined to form the complete stator, the coils are already secured to their teeth, preventing movement and acoustic noise while maintaining the manufacturing advantage of separate tooth assembly.
2Device complexity
If conventional cooling methods are used, then device complexity is reduced, but thermal performance deteriorates limiting power density
Solution Approach 1:
The cooling manifold is integrated directly into the stator structure, merging the cooling function with the structural component. This eliminates the need for separate external cooling systems, maintaining low device complexity while achieving superior thermal performance through direct coolant contact with the stator core, enabling higher power density.
3Reliability
If rectangular wire with mica tape is used, then reliability is improved for high voltage machines, but manufacturing complexity increases due to labor-intensive winding
Solution Approach 1:
The patent uses pre-insulated round wire that eliminates the need for mica tape and complex layering procedures. The wire comes with sufficient insulation for the application, allowing a simpler, more automated winding process while maintaining adequate reliability for the specified voltage range, thus reducing manufacturing complexity.
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 design achieves higher current density, power density, and reliability with reduced acoustic noise and eddy current losses, while allowing for larger wire sizes and improved thermal performance, making it suitable for demanding applications.
Implementation Method 1
The machine described herein incorporates several novel construction methods in its stator. It uses a concentrated winding with a novel approach to secure its removable teeth. This method insures metal on metal contact with real manufacturing tolerances. The preload caused by deflected steel insures that this metal on metal contact maintains itself in all loading conditions.
Implementation Method 2
Another method that is commonly used is passing cooling through the stator laminations or into slots cut into the stator laminations. Either of these has similar disadvantages to the cooling jacket design.
Implementation Method 3
Rotary electric machines including electric motors, generators, and the like have employed various types of stator windings. The most common stator winding type is a distributed winding.
Implementation Method 4
A novel stator design incorporating a concentrated winding with edge form wound coils, pre-insulated wire, and a unique in-slot liquid cooling manifold using conductive fluids like ethylene glycol, which ensures metal-on-metal contact for secure tooth alignment and efficient heat management, reducing eddy current losses and enhancing power density.
Data Source
AI summary
A permanent magnet motor, generator or the like that is constructed with a concentrated winding using a separate tooth. This tooth is preloaded in such a way to achieve high structural rigidity and good magnetic performance.