Stator Cooling and Power Integration for Compact Electric Drives
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Solution Overview
Problem
Existing electric machines face challenges with high heat generation due to Joule effect, leading to increased temperature and reduced efficiency, and require separate cooling systems that increase size and complexity, while power electronics occupy additional space and complicate assembly.
Innovation Solution
An integrated cooling system within the stator of an electric machine, using operating elements with internal ducts for refrigerant flow, shared power and cooling circuits, and electrically connected rings for efficient heat dissipation and reduced volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If separate cooling systems are used for the stator, then the stator temperature is reduced and efficiency is improved, but the overall volume and device complexity increase
Solution Approach 1:
The patent combines the cooling system with the stator structure by integrating cooling channels directly into the stator core. The cooling passages are formed within the stator teeth and yoke, merging the cooling function with the magnetic circuit structure, thereby reducing overall volume while maintaining effective cooling of the windings.
Solution Approach 2:
The stator structure serves dual functions: it provides the magnetic circuit for electromagnetic conversion and simultaneously houses the cooling channels for thermal management. This multi-functional design eliminates the need for separate cooling components, reducing volume and simplifying the overall device structure.
2Temperature
If separate cooling systems are used for the stator, then the stator temperature is reduced and efficiency is improved, but the device complexity and number of components increase
Solution Approach 1:
The cooling system is merged with the stator structure, eliminating separate cooling components. The cooling channels are integrated into the stator core, and the same structural elements serve both magnetic and thermal management functions, thereby reducing device complexity.
Solution Approach 2:
The stator structure performs multiple functions simultaneously: it provides the magnetic circuit for electromagnetic conversion and houses the cooling channels for thermal management. This multi-functionality reduces the number of separate components and simplifies the overall device architecture.
3Reliability
If power electronics are housed in dedicated spaces with separate connections, then electrical components are properly isolated and connected, but the overall volume and assembly complexity increase
Solution Approach 1:
The power electronics are integrated directly into the stator structure, with electronic components mounted on the stator core. The cooling channels, electrical connections, and magnetic circuit are merged into a single integrated structure, eliminating dedicated spaces for power electronics and reducing overall volume while maintaining proper electrical isolation.
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 integrated cooling system reduces fabrication costs, minimizes volume, enhances electrical compatibility, and simplifies assembly by combining power and cooling functions within the stator, improving efficiency and reducing mechanical and electrical connections.
Implementation Method 1
each one of said operating element being suitable to thermally interact with the two adjacent windings
Implementation Method 2
said duct being configured to allow a refrigerant to flow
Implementation Method 3
each operating element being in electrical contact with a respective one of the two adjacent windings; each operating element being configured to be traversed by a current suitable for supplying said respective one of the two adjacent windings
Implementation Method 4
The windings, due to the electrical current flowing through it, generates heat during operation. The heat causes an increase of the temperature of the conductors forming the windings
Data Source
Figure 1~2
Figure 3~4a
Figure 4b~5
AI summary
It is described a stator for an electric machine comprising: a hollow main body; a plurality of supporting teeth extending along an inner surface of said main body; a plurality of windings, each one engaged to a respective one of said supporting teeth; a plurality of operating elements, each one interposed between two successive windings; each one of said operating elements being suitable for thermally interacting with at least one of said windings to cool said at least one winding; each one of said operating elements being in electrical contact with a respective winding of competence being part of said plurality of windings, each operating element being configured to be traversed by a current suitable for supplying said winding of competence.