Stator Insulation Recesses for Direct Conductor Cooling
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Solution Overview
Problem
Existing electric motor stators with rectangular conductors face inefficiencies in cooling due to a long cooling path, which affects the motor's performance and efficiency.
Innovation Solution
The insulation layer of the conductors is designed with recesses to form coolant channels, allowing direct cooling within the conductor bundle, with channels integrated between conductors and the stator slot base, enhancing heat transfer and cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If rectangular conductors are used to achieve higher copper fill factor, then conductor packing density is improved, but cooling efficiency deteriorates due to long cooling path
Solution Approach 1:
The insulation layer is segmented by creating recesses that divide it into regions forming coolant channels. This segmentation allows coolant to flow directly through the conductor bundle, reducing the cooling path length while maintaining the rectangular conductor geometry and high copper fill factor
Solution Approach 2:
The insulation layer recess acts as an intermediary structure that introduces coolant channels without requiring separate cooling components. The recesses in the insulation layer create pathways for coolant to directly contact the conductors, improving heat transfer while maintaining electrical insulation
2Temperature
If coolant channels are added to improve cooling, then cooling efficiency is improved, but device complexity increases
Solution Approach 1:
The cooling function is merged with the insulation layer by creating recesses within it. This integration allows the insulation layer to simultaneously provide electrical insulation and house coolant channels, eliminating the need for separate cooling structures and reducing overall device complexity
Solution Approach 2:
The insulation layer is designed to serve multiple functions: providing electrical insulation between conductors and stator, and simultaneously forming coolant channels through its recesses. This multi-functionality reduces the number of separate components needed in the motor 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 significantly improves cooling efficiency by allowing direct heat transfer from the conductors to the coolant, maintaining high conductor packing density and motor performance.
Implementation Method 1
allows direct heat transfer from the conductors to the coolant
Implementation Method 2
a fluid-tight coolant channel running along the stator, through which a coolant can be conducted
Data Source
AI summary
A stator for an electric motor, including a stator ring with slots arranged on the inner or the outer circumference, wherein each slot accommodates a plurality of conductors extending along the slot and having a rectangular cross-section, each of which is covered by an insulation layer, wherein to form a channel through which a coolant can flow, the insulation layer of at least one of the conductors has at least one recess extending along the conductor.