Stator Housing Accommodating Region for End Winding Cooling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electric machines suffer from poor cooling of end windings due to lack of direct thermal contact with the stator body, leading to high temperatures as they are exposed to air rather than a conductive material.
Innovation Solution
A housing with a protruding end region featuring a tightly accommodating geometry and an electrically insulating cladding material is used to surround and press the end windings, ensuring effective heat dissipation through thermal contact with the housing, which may include cooling channels and additional components like end plates or terminating rings for comprehensive cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the end windings are exposed to air in conventional electric machines, then the manufacturing process is simple, but the cooling efficiency of the end windings is poor
Solution Approach 1:
The housing is designed to integrate both structural support and cooling functions. The accommodating region of the housing directly contacts the end windings, merging the mechanical protection function with the thermal management function into a single integrated component, thereby improving cooling efficiency without proportionally increasing device complexity.
Solution Approach 2:
The accommodating region acts as an intermediary thermal path between the end windings and the external cooling system. It provides direct thermal contact with the end windings and conducts heat to the housing exterior, serving as a heat transfer mediator that enables efficient cooling of previously exposed windings.
2Loss of energy
If the housing is designed to tightly surround the end windings, then heat dissipation is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The accommodating region is designed with specific local geometric features that match the shape and dimensions of the end windings. This localized precision design ensures optimal thermal contact only where needed, improving heat dissipation while concentrating manufacturing precision requirements to specific critical areas rather than the entire housing structure.
3Temperature
If the end windings are pressed into the housing, then thermal contact is enhanced, but the risk of electrical short circuit increases
Solution Approach 1:
An electrically insulating layer is introduced as an intermediary between the conductive housing and the end windings. This thin insulating layer maintains thermal contact for heat dissipation while providing electrical insulation to prevent short circuits, thus resolving the contradiction between thermal efficiency and electrical reliability.
Solution Approach 2:
The housing structure incorporates composite material properties by combining thermal conductivity with electrical insulation. The accommodating region uses materials or coatings that provide both thermal contact for heat dissipation and electrical insulation, creating a composite structure that simultaneously addresses both thermal management and electrical safety requirements.
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 enhances thermal contact and heat dissipation from the end windings, improving cooling efficiency and reducing the risk of overheating while maintaining electrical insulation to prevent short circuits.
Implementation Method 1
the first accommodating region surrounding a first of the end windings so as to bear tightly against a first end face of the stator body
Implementation Method 2
the housing may include cooling channels
Data Source
AI summary
A stator (1) and a method for manufacturing such a stator for an electric machine. Windings of the stator (1) protrude in the longitudinal direction beyond a cylindrical stator body (3) in the form of end windings (17, 19) on end faces (13, 15) of the stator body (3). In this case, a complementarily designed accommodating region (31) is provided on a housing (21), with the result that, when the housing (21) is assembled with the stator body (3), the windings of the end winding (17) can be pressed. As a result, good thermal contact can be effected between the end winding (17) and the housing (21), which is cooled via a cooling apparatus (25), for example.