Stator Extended Insulator Radial Air Gaps Cooling
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Solution Overview
Problem
Existing rotating electrical machines face inefficiencies due to restricted airflow and thermal management issues caused by end windings with few air gaps and non-uniform resin distribution, which can lead to increased temperatures and reduced machine lifespan.
Innovation Solution
The implementation of radial air gaps between stator windings and the use of extended middle shoes or insulating components with U-shaped or wedge-shaped configurations to create pathways for airflow while maintaining electrical insulation, allowing air to flow radially and axially through the machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating paper is placed between the windings to provide electrical insulation, then electrical insulation between end windings of different phases is improved, but air flow through the windings is restricted and cooling efficiency is reduced
Solution Approach 1:
The insulating means are extended axially beyond the stator slots to form extended middle shoes, creating a three-dimensional structure that provides insulation in the axial direction while maintaining radial air gaps for cooling. This dimensional extension allows the insulating function to be separated from the airflow restriction problem.
Solution Approach 2:
The insulating means are divided into discrete extended middle shoes positioned at specific locations between coils of adjacent stator slots, rather than using continuous insulating material. This segmentation allows airflow to pass through gaps between the segmented insulating elements while maintaining electrical insulation where needed.
2Ease of manufacture
If end windings are tightly packed with few air gaps to improve manufacturing efficiency, then manufacturing precision and ease of manufacture are improved, but thermal management is worsened due to restricted airflow
Solution Approach 1:
The extended insulating means provide localized insulation functions at specific positions between coils of adjacent stator slots, allowing other regions to maintain open air gaps for cooling. This local differentiation of function allows tight packing in some areas while maintaining airflow channels in others.
3Stability of the object's composition
If lacing string or cording is used to hold the windings in place to improve mechanical stability, then stability of the object's composition is improved, but airflow gaps are further restricted and cooling efficiency is reduced
Solution Approach 1:
The airflow restriction function is extracted from the mechanical fastening function by using extended insulating means that provide both structural support for holding windings in place and maintained air gaps for cooling, eliminating the need for separate lacing elements that would block airflow.
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 airflow and thermal management, improving cooling efficiency and reducing the risk of arcing between windings, thereby increasing the machine's power density and lifespan.
Implementation Method 1
machines are arranged to have air flow through the machine, in order to cool the machine
Implementation Method 2
The extended middle shoes may assist with thermal management of the stator
Data Source
AI summary
A stator for a rotating electrical machine is disclosed, the stator comprising a plurality of stator slots (22) each of which accommodates a plurality of coils (40) of stator windings (18). Radial air gaps (46) are present between the coils of adjacent stator slots as the coils extend out of the stator slots. Insulating means (42, 54, 84) are provided between the coils of a stator slot as the coils extend out of the stator slot. The radial air gaps (46) are defined between the insulating means of the coils of adjacent stator slots. This can allow radial air passages to be formed through the windings, while ensuring sufficient electrical insulation between the coils of a stator slot.