Stator Slot Adhesive Segmentation for Refrigerant Cooling
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Solution Overview
Problem
Stators for rotary electric machines face a trade-off between high space factor for conductors, which leads to low copper loss and heat generation, and poor radiation performance due to the compact arrangement of flat wires, making it difficult for refrigerants to pass through the slots.
Innovation Solution
A stator design with rectangular conductors and through-holes formed by an adhesive material in each slot allows for the passage of refrigerants, balancing the space factor and radiation performance by enabling efficient cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If flat wires are used to form the stator winding, then the space factor in each slot is high and copper loss is reduced, but the radiation performance deteriorates because refrigerant cannot easily pass through the tightly packed conductors
Solution Approach 1:
The slot is segmented into multiple regions by dividing the adhesive material into first and second adhesive materials positioned at different locations. This segmentation creates distinct functional zones: one for conductor fixation and another for refrigerant flow, allowing both high space factor and good radiation performance to coexist
Solution Approach 2:
Different regions of the slot are assigned different properties: the first adhesive material provides strong bonding to secure conductors, while the second adhesive material creates a refrigerant passage channel. This local differentiation allows each region to optimize for its specific function, resolving the contradiction between conductor packing density and refrigerant accessibility
2Quantity of substance
If flat wires are used to form the stator winding, then the space factor in each slot is high, but the radiation performance deteriorates due to compact conductor arrangement
Solution Approach 1:
The adhesive material is divided into multiple segments (first and second adhesive materials) that perform different functions. The first adhesive material secures the conductors to maintain high space factor, while the second adhesive material creates dedicated channels for refrigerant flow, ensuring both high space factor and good radiation performance are achieved simultaneously
Solution Approach 2:
The adhesive material serves as an intermediary substance that performs dual functions: it bonds the conductors to the slot structure while simultaneously creating refrigerant passages. This intermediary role allows the adhesive material to facilitate both conductor fixation and heat dissipation, resolving the contradiction between space factor and radiation performance
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
The design enhances radiation performance while maintaining a high space factor for conductors, effectively managing heat generation and cooling efficiency in rotary electric machines.
Implementation Method 1
a fixing member (which fixes the in-slot portions to each of the slots, the fixing member being composed of an adhesive material charged into each of the slots such that a through-hole is left through each of the slots in the axial direction, refrigerant being allowed to pass through the through-hole
Implementation Method 2
refrigerant, such as air or cooling oil, can easily pass through the slot and thus the radiation performance is enhanced
Implementation Method 3
the conductors, which form the stator winding, generate heat on the basis of their electric resistance and thereby raise the temperature
Data Source
AI summary
In a stator, a stator winding is wound at a stator core. The stator winding has a section whose shape is rectangular and includes a plurality of conductors electrically connected to each other. Each of the conductors has in-slot portions being accommodated as being stacked in corresponding one of the slots when the winding is wound at the stator core. A fixing member fixes the in-slot portions to each of the slots. The fixing member is composed of an adhesive material charged into each of the slots such that a through-hole is left through each of the slots in the axial direction. Refrigerant is allowed to pass through the through-hole.