Micro-channel Heat Exchanger for Stator Cooling
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Solution Overview
Problem
Conventional electric motors and generators face inefficiencies in heat dissipation due to the generation of heat through friction, resistive heating, and magnetic losses, which can lead to performance degradation and potential malfunction if not adequately addressed.
Innovation Solution
The integration of a micro-channel heat exchanger within the stator core of electric machines, where coolant flows through micro-channels and manifolds to efficiently dissipate heat, utilizing a counter-flow or parallel-flow heat exchanger configuration to enhance cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional cooling methods are used for stator core, then the structure is simple, but the heat dissipation efficiency is insufficient leading to performance degradation
Solution Approach 1:
The micro-channel heat exchanger is nested within the stator core structure itself. The cooling channels are formed by alternating patterns of first and second openings in adjacent laminations, creating an integrated cooling system that is embedded in the magnetic core rather than being a separate external component.
Solution Approach 2:
The cooling system is segmented into multiple micro-channels distributed throughout the stator core. The channels are formed by alternating patterns of openings in adjacent laminations, creating numerous parallel flow paths that collectively provide high heat dissipation efficiency while maintaining manageable system complexity.
2Area of stationary object
If micro-channel heat exchanger is integrated into stator core, then heat exchange surface area increases, but manufacturing complexity increases
Solution Approach 1:
The heat exchange surface is segmented into numerous micro-channels formed by alternating patterns of openings in adjacent laminations. This segmentation creates a large total heat exchange area while allowing each individual lamination to be manufactured using standard processes, with the complex 3D channel structure emerging from the assembly of simple 2D patterns.
Solution Approach 2:
The cooling channels extend in the axial dimension through alternating patterns in adjacent laminations, transforming the heat exchange from a 2D surface problem to a 3D volumetric solution. This dimensional transition enables large heat exchange area within the confined space of the stator core without requiring complex external cooling apparatus.
3Use of energy by moving object
If coolant flow pressure is reduced, then energy consumption decreases, but heat dissipation capability may be compromised
Solution Approach 1:
The coolant flow is segmented into numerous parallel micro-channels throughout the stator core. This segmentation reduces the flow velocity and pressure requirements in each individual channel while collectively maintaining high heat dissipation capability through the large total heat exchange area of all channels combined.
Solution Approach 2:
The channel dimensions are optimized to micro-scale proportions, with the ratio of surface area to volume dramatically increased. This parameter change enables efficient heat transfer at lower flow rates and pressures, as the thin channel walls provide excellent thermal coupling between the coolant and stator core while the small hydraulic diameter reduces pressure drops.
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 solution provides a highly efficient cooling mechanism that effectively reduces pressure requirements for coolant circulation, increases the heat exchange surface area, and mitigates hotspots, thereby improving the performance and reliability of electric machines by efficiently dissipating heat.
Implementation Method 1
The micro-channel heat exchanger is formed in the stator and routes a fluid through the stator to provide cooling
Implementation Method 2
routing fluid along internal surfaces of a stator core
Implementation Method 3
utilizing a counter-flow or parallel-flow heat exchanger configuration to enhance cooling efficiency
Data Source
AI summary
An electric machine has a stator that comprises a plurality of laminations with teeth and cooling apertures about a central opening. When the laminations are stacked to form the stator core, the teeth of adjacent laminations cooperate to form slots disposed circumferentially about the central opening that are configured to receive a plurality of stator windings, and the cooling apertures angularly spaced about the central opening cooperate to form cooling manifolds that extend along a length of the stator core. A portion of the laminations has their cooling apertures offset from other laminations in the stack in a manner to create a plurality of flow paths transverse to the manifolds. The transverse flow paths extend angularly between laminations and adjacent manifolds. A header assembly directs flow into and out of the stator core.