Two-Piece Stator Support Member Cooling Channel Design

Solution Overview

Problem

The existing stator support members with internal cooling channels in rotating electrical machines face manufacturing limitations and quality inspection challenges due to their one-piece casting structure, restricting the shape of cooling channel walls and hindering effective heat dissipation.

Innovation Solution

A two-piece stator support member design with a ring-shaped outer and inner part, each with specific cooling channel wall surfaces, is introduced, allowing for a hermetically sealed cooling channel formation by bonding these parts together, avoiding the limitations of traditional casting and enabling improved heat dissipation through enhanced design and manufacturing processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a one-piece casting structure with internal cooling channel is used, then the cooling channel is formed inside the stator support member, but the shape of cooling channel wall is restricted and quality inspection is difficult

Engineering Contradiction:

Improvecooling channel formationVSAvoidcooling channel wall shape

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The stator support member is divided into a first stator support member and a second stator support member that are coupled together. The cooling channel is formed between these two segmented parts, allowing the cooling channel wall to have an arbitrary shape without being restricted by casting limitations. This segmentation enables both easy manufacturing and high manufacturing precision.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cooling channel is extracted from the internal structure and repositioned to the external space between the first and second stator support members. This extraction allows the cooling channel to be formed with precise arbitrary shapes while enabling easy quality inspection from the outside, resolving both the manufacturing precision and inspection difficulty issues.

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of manufacture

If a one-piece casting structure with internal cooling channel is used, then the cooling channel is formed inside the stator support member, but quality inspection is restricted

Engineering Contradiction:

Improvecooling channel formationVSAvoidquality inspection

Core Design Contradiction:

Ease of manufactureVSDifficulty of detecting and measuring

Solution Approach 1:

The cooling channel is extracted from the internal structure and repositioned to the external space between the first and second stator support members. This extraction allows the cooling channel to be formed with precise arbitrary shapes while enabling easy quality inspection from the outside, resolving both the manufacturing precision and inspection difficulty issues.

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of manufacture

If traditional casting method is used, then manufacturing is simple, but casting defects occur and productivity is limited

Engineering Contradiction:

Improvemanufacturing processVSAvoidmanufacturing efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The stator support member is divided into a first stator support member and a second stator support member that are coupled together. The cooling channel is formed between these two segmented parts, allowing the cooling channel wall to have an arbitrary shape without being restricted by casting limitations. This segmentation enables both easy manufacturing and high manufacturing precision.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The manufacturing method changes from traditional casting to a coupling method using press-fitting or welding. This parameter change in the manufacturing process eliminates casting defects and improves productivity while maintaining ease of manufacture.

Inventive Principle:

Principle #35Parameter changes

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 design enhances cooling performance, improves manufacturing quality by avoiding casting defects, and simplifies inspection and assembly, leading to improved productivity and cooling efficiency for rotating electrical machines.

Implementation Method 1

a cooling fluid may flow along the cooling channel

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 2

cool a stator, which generates a large amount of heat when a motor is operated

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS10886798B2Stator support member of rotating electrical machine and method of manufacturing the same

Publication Date: 2021.01.05 HYUNDAI MOTOR CO LTD

AI summary

A stator support member of a rotating electrical machine is provided with a cooling channel formed in the stator support member to cool a stator. The stator support member is manufactured to have the cooling channel of a hermetically sealed structure so that a cooling fluid may flow along the cooling channel. In particular, the support member having the cooling channel is divided into a ring-shaped outer part and a ring-shaped inner part (two-piece type) and the separately manufactured ring-shaped outer part and inner part are combined together.