Stator Slot Coil Layout for Aluminum Wire Heat Dissipation
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Solution Overview
Problem
In motors, particularly those used in compressors, there is a challenge in efficiently dissipating heat generated due to increased electrical resistance in aluminum wire coils, which leads to higher temperature rises when output and size reduction demands are met.
Innovation Solution
A stator design is implemented with a first coil made of aluminum and a second coil made of copper, where the aluminum coil is densely disposed in a region closer to the outer circumference of the stator core, enhancing heat transfer and dissipation through the stator core, while the copper coil is distributed in a region with lower occupancy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If an aluminum wire coil is used to reduce cost and weight, then the motor weight and cost are reduced, but the electrical resistivity increases causing excessive heat generation
Solution Approach 1:
The coil is segmented into multiple regions (first region, second region, third region) with different aluminum wire occupancy densities. The first region has higher occupancy density for better heat dissipation, while the second and third regions have lower occupancy density to reduce overall weight and cost, resolving the contradiction between weight reduction and heat generation.
Solution Approach 2:
Different regions of the coil are assigned different local qualities in terms of aluminum wire occupancy density. The first region (closer to stator core) has higher density for effective heat dissipation, while outer regions have lower density, creating a non-uniform structure that optimizes both heat management and weight reduction.
2Power
If the current flowing through the coil is increased to increase motor output, then the motor output is increased, but the heat generation in the coil increases
Solution Approach 1:
The coil structure uses non-uniform aluminum wire occupancy density across different regions to manage heat distribution. The first region with higher occupancy density near the stator core provides enhanced heat dissipation capability, enabling higher current flow and motor output without excessive overall heat generation.
3Volume of moving object
If the size of the motor is reduced, then the motor size is decreased, but the current required to obtain the same output increases causing more heat generation
Solution Approach 1:
The patent implements a non-uniform aluminum wire occupancy density distribution where the first region has higher density for heat dissipation and outer regions have lower density for size reduction. This allows compact motor design while managing heat generation through strategic material distribution.
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 effectively dissipates heat generated in the aluminum coil, suppressing temperature increases and enhancing the overall heat dissipation effect, allowing for increased motor output without significant temperature rises.
Implementation Method 1
Heat generation in the coil is due to an electrical resistance of the coil
Implementation Method 2
heat generated in the coil needs to be dissipated from the stator core
Data Source
AI summary
A first coil including a first metal, and a second coil including a second metal having a lower electrical resistivity than the first metal are disposed in a slot of a stator core. The slot includes a slot opening, a curved slot bottom portion connecting to a yoke, and first and second side portions disposed between the slot opening and the slot bottom portion. A first straight line connects borders between the slot bottom portion and either of the side portions. A first region is surrounded by the first straight line and the slot bottom portion. A second region is located between the slot opening and the first straight line in the radial direction. Areas S1 and S2 of the first and second regions, and total cross-sectional areas A1 and A2 of the first coil in the first and second regions satisfy (A1/S1)>(A2/S2).