Stator Core Internal Cooling Passageways for Heat Dissipation
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Solution Overview
Problem
Existing electric machines face challenges in effectively managing heat generated during operation, as conventional thermal-management systems like spray cooling may not adequately distribute cooling fluids within the stator core to efficiently remove heat from the windings.
Innovation Solution
The electric machine incorporates a stator core with internal fluid passageways and laminations that define specific patterns of fluid openings, forming a fluid circuit that circulates cooling medium through the core and onto the windings, enhancing heat dissipation by utilizing a combination of inboard, outboard, and interconnecting passages, as well as annular chambers to facilitate fluid flow and heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If spray cooling system with external nozzles is used, then cooling coverage is provided, but heat removal efficiency from windings is insufficient
Solution Approach 1:
The cooling passageways are nested within the stator core structure itself. The fluid passageways are defined by the stacked laminations, with inboard passages, outboard passages, and interconnecting passages forming a nested network inside the core. This nesting approach integrates the cooling system within the existing stator structure, improving heat removal efficiency without adding external cooling components.
Solution Approach 2:
A cooling fluid acts as an intermediary medium to transfer heat from the windings to the stator core and then to the external environment. The fluid circulates through the internal passageways, absorbing heat at the inboard passages near the windings and carrying it to the outboard passages for dissipation. This intermediary fluid enables efficient heat transfer without direct thermal contact between the windings and external cooling systems.
2Ease of operation
If conventional spray cooling is used, then external cooling is provided, but fluid distribution within stator core is inadequate
Solution Approach 1:
The cooling system is segmented into multiple distinct passageways within the stator core: inboard passages, outboard passages, and interconnecting passages. This segmentation allows the cooling fluid to follow a controlled path that ensures adequate distribution throughout the core. The segmented structure enables the fluid to reach different regions of the stator core systematically, improving both fluid circulation efficiency and cooling effectiveness.
Solution Approach 2:
The cooling passageways extend in multiple dimensions within the stator core structure. The inboard passages extend radially inward, the outboard passages extend radially outward, and the interconnecting passages provide axial and radial connections. This multi-dimensional arrangement ensures comprehensive fluid distribution throughout the three-dimensional volume of the stator core, overcoming the limitations of conventional external spray cooling.
3Temperature
If internal fluid passageways are defined in stator core, then heat dissipation is enhanced, but manufacturing complexity increases
Solution Approach 1:
The stator core is constructed using laminations with defined fluid openings that create a porous-like structure for fluid flow. The stacked laminations form a network of passageways that allow cooling fluid to circulate through the core. This approach enables heat dissipation through the porous-like structure without requiring complex internal machining, as the passageways are formed by the lamination stacking process itself.
Solution Approach 2:
The stator core is segmented into multiple stacked laminations, each contributing to the formation of the cooling passageways. The fluid openings in individual laminations align when stacked to create continuous inboard, outboard, and interconnecting passages. This segmentation into manufacturable lamination units simplifies fabrication compared to creating monolithic internal passageways, while still achieving enhanced heat dissipation through the assembled structure.
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 effectively cools both the stator core and windings, preventing overheating by ensuring efficient fluid circulation and heat removal, thereby improving the thermal management of electric machines.
Implementation Method 1
The fluid passageways are defined in the stator core and configured to receive cooling fluid from an external source. The passageways circulate the cooling fluid through the core and onto the windings, thereby cooling the core and the windings.
Implementation Method 2
The passageways circulate the cooling fluid through the core and onto the windings, thereby cooling the core and the windings. This configuration effectively cools both the stator core and windings, preventing overheating by ensuring efficient fluid circulation and heat removal.
Data Source
AI summary
An electric machine includes a stator core having opposing first and second end faces, an outer surface between the end faces, and a plurality of fluid passageways defined within the stator core. Each fluid passageway includes an entrance hole defined in the outer surface and an inboard passage extending along a length of the core and in fluid communication with the entrance hole. Each fluid passageway further includes an outboard passage extending along a length of the core and having a first exit hole defined in the first end face and an interconnecting passage connecting the inboard passage in fluid communication with the outboard passage.