Stator Winding Cooling Channels With Integrated Turbulators
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Solution Overview
Problem
Electric machines generate heat during operation, which can negatively affect their efficiency and output, and existing cooling systems are not sufficient to effectively manage this heat.
Innovation Solution
Incorporating turbulators within the winding channels of electric machines to enhance heat transfer by creating turbulence in the cooling fluid flow, thereby improving the heat transfer coefficient and allowing for more efficient heat extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a cooling system is used to remove heat from the electric machine, then heat rejection is improved, but the heat transfer efficiency is insufficient
Solution Approach 1:
A turbulator is introduced as an intermediary component within the cooling fluid passage. The turbulator mediates between the heat-generating winding and the cooling fluid by creating turbulence that enhances heat transfer from the winding to the fluid, thereby improving overall heat rejection efficiency
Solution Approach 2:
The cooling fluid flow regime is changed from laminar to turbulent by introducing the turbulator. This parameter change in flow characteristics significantly increases the heat transfer coefficient, allowing more effective heat removal from the electric machine windings
2Temperature
If cooling fluid flows through the winding channel, then heat removal is improved, but the heat transfer coefficient is insufficient
Solution Approach 1:
The turbulator introduces mechanical disturbance and turbulence into the cooling fluid flow. This mechanical action disrupts the boundary layer between the fluid and channel walls, enhancing convective heat transfer and increasing the heat transfer coefficient for more reliable heat removal
3Power
If the electric machine operates at higher power, then output is improved, but heat generation increases
Solution Approach 1:
The turbulator serves as a mediator that enables higher power operation by improving the heat transfer pathway. It allows the electric machine to dissipate the increased heat generated at higher power levels, thereby sustaining high power output without excessive temperature rise
Solution Approach 2:
The enhanced cooling system with the turbulator ensures continuous and effective heat removal during high-power operation. The turbulence created by the turbulator maintains consistent heat transfer efficiency throughout the cooling process, enabling sustained high power output
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 implementation of turbulators within the winding channels of electric machines enhances thermal performance, reducing operating temperatures and enabling the machines to produce more electric power when functioning as generators or use power more efficiently when operating as motors.
Implementation Method 1
enhance heat transfer by creating turbulence in the cooling fluid flow
Implementation Method 2
cooling system operably coupled with the channel and is configured to move a cooling fluid through the channel
Data Source
AI summary
A stator core is provided that can define a plurality of core slots in a surface thereof. The core slots can extend between a first and a second end portion of the stator core. A winding can be housed in the core slots. The winding can define a channel through at least a portion thereof. A cooling system can be operably coupled with the channel and can be configured to move a cooling fluid through the channel. A turbulator can be positioned within the channel. The turbulator can be within a flowpath of the cooling fluid and can be integrally formed with the winding.