Integrated Stator Holder Refrigerant Guide for Rotary Machine Cooling

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Solution Overview

Problem

Conventional stator units of rotary electric machines have a high number of components and increased size due to the need for a bolt to fix the refrigerant guide portion to the stator core, which complicates cooling and efficiency.

Innovation Solution

The stator unit integrates the refrigerant guide portion with the stator holder, eliminating the need for a fixing member and reducing the radial size by forming a spiral refrigerant flow path and using drip holes for efficient refrigerant supply.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a bolt is used to fix the refrigerant guide portion to the stator core, then the refrigerant guide portion can be securely attached, but the number of components increases and the stator core size increases in the radial direction

Engineering Contradiction:

Improvefixing reliabilityVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The refrigerant guide portion is integrated into the stator holder as a single unified component, eliminating the need for separate bolts and fixing members. This merging approach maintains the functional reliability of securing the refrigerant guide while reducing the total component count and radial dimension.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The stator holder is designed to serve multiple functions: it provides structural support for the stator core and simultaneously integrates the refrigerant guide portion as part of its structure. This multi-functionality eliminates the need for dedicated fixing mechanisms, reducing both component count and radial size.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If a bolt is used to fix the refrigerant guide portion to the stator core, then the refrigerant guide portion can be securely attached, but the stator unit size increases in the radial direction

Engineering Contradiction:

Improvefixing reliabilityVSAvoidradial size

Core Design Contradiction:

ReliabilityVSLength of stationary object

Solution Approach 1:

By merging the refrigerant guide portion with the stator holder into a single integrated structure, the radial dimension is reduced because there is no need for additional protruding bolt lengths or separate fixing components extending radially outward.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The refrigerant guide portion is nested within or formed as part of the stator holder structure, allowing it to be contained within the existing radial boundaries of the stator holder without requiring additional radial space for separate fixing mechanisms.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Adaptability or versatility

If multiple separate components are used for the stator holder and refrigerant guide portion, then each component can be optimized independently, but the number of components increases and assembly complexity increases

Engineering Contradiction:

Improvecomponent optimization flexibilityVSAvoidnumber of components

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The stator holder and refrigerant guide portion are merged into a single integrated component, reducing the number of parts while maintaining design flexibility through integrated molding or forming processes that allow independent optimization of different functional zones within the unified structure.

Inventive Principle:

Principle #5Merging (Combining)

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 integration reduces the number of components, enhances cooling efficiency by promoting heat exchange, and effectively supplies refrigerant to the stator coil, maintaining performance despite increased temperatures.

Implementation Method 1

supplying a first refrigerant to the coil end portion

Methodology Applied

Scientific EffectHeat exchange: Convection

Implementation Method 2

measures such as cooling of the stator coil have been studied

Methodology Applied

Scientific EffectCooling: Cooling

Data Source

PatentUS11374445B2Stator unit of rotary electric machine

Publication Date: 2022.06.28 HONDA MOTOR CO LTD

AI summary

A stator unit of a rotary electric machine, which includes a stator including a stator core in which a plurality of slots are formed at predetermined intervals in a circumferential direction; and a stator coil inserted into the slots and having a coil end portion protruding from at least one end surface of the stator core; a stator holder disposed to surround an outer peripheral surface of the stator core and supporting the stator; and a refrigerant guide portion disposed above the coil end portion and configured to supply a first refrigerant to the coil end portion. The refrigerant guide portion protrudes from an end surface of the stator holder to above the coil end portion and is integrally formed with the stator holder.