Stator Frame Spiral Cooling Flow Path
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Solution Overview
Problem
Existing stator designs for rotary electrical machines face challenges in efficient cooling due to gaps between the stator frame and housing, leading to coolant leakage and reduced cooling efficiency.
Innovation Solution
A stator frame with a spirally formed flow path between its inner and outer surfaces, where the side wall portion has higher thermal conductivity than the inner and outer wall portions, eliminating the need for a separate housing and reducing coolant leakage by integrating the flow path directly into the stator frame, which is manufactured using additive layer manufacturing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate housing is fitted to the outside of the stator frame to form a cooling flow path, then the cooling function is provided, but manufacturing complexity increases and fitting precision is required to prevent coolant leakage
Solution Approach 1:
The flow path is integrated directly into the stator frame by forming it as a spiral groove within the stator frame body, eliminating the need for a separate housing component. This merging of the flow path function into the stator frame itself reduces structural complexity while maintaining cooling efficiency and eliminating leakage issues associated with separate fitted components
2Reliability
If a separate housing is fitted to the stator frame, then cooling function is achieved, but the number of components and assembly steps increases
Solution Approach 1:
The flow path is formed as an integral part of the stator frame through direct formation processes, reducing the total component count from two separate parts (stator frame and housing) to one integrated component. This eliminates assembly steps and reduces manufacturing complexity while maintaining the cooling function
3Reliability
If a spiral groove is formed in the stator frame outer surface, then cooling flow path is created, but the groove depth and structural strength may be compromised
Solution Approach 1:
The side wall portions of the spiral groove are formed with higher thermal conductivity material or properties compared to the inner and outer wall portions, optimizing heat transfer from the iron core while maintaining structural integrity. This local differentiation allows the groove to provide effective cooling without compromising overall frame strength
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 cooling efficiency, reduces manufacturing complexity, minimizes coolant leakage, and eliminates the need for additional components like sealing materials, thereby improving the overall performance and reliability of the stator and rotary electrical machine.
Implementation Method 1
a flow path which is formed spirally from one end side to the other end side in an axial direction of the stator frame between an inner circumferential surface and an outer circumferential surface... within which a coolant is circulated
Implementation Method 2
the side wall portion is formed of a material whose thermal conductivity is higher than the thermal conductivity of the inner wall portion or the outer wall portion
Data Source
AI summary
A stator frame includes a flow path which is formed spirally from one end side to the other end side in the axial direction of the stator frame between an inner circumferential surface and an outer circumferential surface while circling along a circumferential direction of the stator frame and within which a coolant is circulated, where a side wall portion which isolates the adjacent parts of the flow path, an inner wall portion which isolates the flow path from the inner circumferential surface of the stator frame and an outer wall portion which isolates the flow path from the outer circumferential surface of the stator frame are integrally formed.